CHAPTER 1

PROJECT SCOPE

1.1. Problem Statement

The procedure in which more unstable substances in a mixture are divided from less

unstable substance is called crude distillation. This procedure is to separate the crude

physically into different groups of hydrocarbons, also called as fractions, depending on

their boiling points. Refinery plants are naturally a dangerous and risk zones because of

accidents that can happen during the processes involving equipment. This can be enhanced

through designing better processes and it can also help to have higher efficient plant.

One of the most problem in crude oil refining units is corrosion (Bhowmik et al,

2012). Corrosion has a big factor on refinery plants since it can have an effect to the

reliability of the equipment which can cause loss of products, decreasing of efficiency. This

can also cause safety issues, health issues, affects cleanliness due to contamination and

releasing of hazardous substances. This will eventually lead to poor product’s condition

and even shutdowns of refinery operations (Wood et al., 2013).

1.2 Client Identification and Recognition of Need

Crude oil can be turned into finished petroleum products made up of a mixture of

hydrocarbons being subjected to distillation process to separate the crude oil into broad

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categories of its component hydrocarbons. It is heated and then put into a distillation

column, where different products boil off and are recovered at different temperatures.

Since crude oil is a global commodity, its price is determined by supply and demand

factors on a worldwide basis. The price reflects the interactions of buyers and sellers. Oil

is the world economy’s most important source of energy and is therefore critical to

economic growth. Its value is driven by demand for refined petroleum products specially

in the transportation sector. Consumers settle for a low-cost domestic oil since the demand

of gasoline in transport sector today has been depleting due to more fuel-efficient vehicles

and renewable fuel standards. However, oil is not only used in transportation but also in

major factors in consumers lifestyle such as in plastics, clothing, insulation and food. This

means that there are still many sectors of economy which will be adversely by the increase

or decrease of oil prices.

1.2.1 Economics of Products

In many businesses, profits or losses results primarily from the difference between

the cost of inputs and the price of outputs. To have a competitive edge, a business must

make higher-value products using lower-cost inputs than competitors. In the oil refining

business, the cost of inputs (crude oil) and the price of outputs (refined products) are both

highly volatile, influenced by global, regional, and local supply and demand changes.

Refineries must find the sweet spot against a backdrop of changing environmental

regulation, changing demand patterns and increased global competition among refiners in

order to be profitable.

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 Planning, designing, permitting and building a new medium-sized refinery is a 5-7-year

process and costs $7-10 billion, excluding the acquiring of the land. The cost varies

depending on the location (which determines land and construction costs); the type of

crude to be processed and the range of outputs (both affect the configuration and

complexity of the refinery) and the size of the plant and local environmental regulations

After the refinery is built, it is expensive to operate. Fixed costs include personnel,

maintenance, insurance, administration and depreciation. Variable costs include crude

feedstock, chemicals and additives, catalysts, maintenance, utilities and purchased energy

(such as natural gas and electricity). To be economically viable, the refinery must keep

operating costs such as energy, labor and maintenance to a minimum. Like most other

commodity processors (such as food, lumber and metals), oil refiners are price takers: in

setting their individual prices, they adapt to market prices.

1.3 Project Goals and Objectives

1.3.1 Main Objectives

In line with problem statement and needs of client, this project aims to control

the corrosion in the crude distillation process and to produce quality products for

the consumers.

1.3.2 Specific Objectives

To meet the objectives, this project will design a process controlling its sulfur

and hydrogen content. Moreover, the equipment will also be considered for

corrosion control.
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1.4 Contemporary Issues Relevant to the Project

In crude oil refining units, corrosion is a typical issue worldwide and the most

critical consumption is what they called overhead corrosion. Because of the variety of

process liquid substance piece and the procedure parameter like the pressure, temperature,

weight, pH and dampness and so on, the level of destructive parts is different in the refining

process framework.

The corrosion issue in refining activities can be partitioned into three different

categories - corrosion from segments exhibit in the unrefined petroleum, corrosion from

chemicals utilized as a part of refinery forms and natural corrosion that is in the

environment.

The most widely recognized material of development for refinery hardware is

carbon steel and it is consumed in light of the fact that of the nearness of water and oxygen

for the most part in the surface. This consumption can be decreasing by disposing of the

water from the surface of the metal by methods for a defensive hindrance or covering.

Different sorts of barometrical consumption are: consumption under protection or

insulating, erosion of pipeline, consumption of structures and cooling water consumption.

1.5 Potential Impact of Project on Society (global, national, local)

The essential uses for naphtha and gas oil are the creation of powers, fuel for

naphtha, and diesel for gas oil. An optional use for naphtha is as a feedstock for steam

breaking to create petrochemicals and the generation of sweet-smelling petrochemical

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 items (benzene, toluene, and xylenes). Gas oil is utilized as a compound feedstock for

steam splitting, albeit by and large less favored than naphtha and flammable gas fluids.

Naphtha and gas oil refinery yields rely upon the creation of nourish unrefined oil used

and thus the raw petroleum local source. Raw petroleum extricated from Middle Eastern

fields has diverse properties from that separated in Alaska. Unrefined oils with an API

gravity of at least 30° deliver bigger measures of items, for example, naphtha, lamp fuel,

and light gas oils than those with an API gravity of under 30°. Likewise, naphthenic

unrefined oils tend to deliver generally more noteworthy amounts of naphtha than the

paraffinic crudes of a similar particular gravity, which create higher relative measures of

gas oils.

Figure 1. World Consumption of Naptha as of 2016.

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 Light naphtha utilization will increment quickly around the world, with the

exception of in North America, driven fundamentally by steam wafer feedstock request.

The vast majority of the request development will be in Southeast Asia, India, and the

Center East. Utilization of light naphtha is additionally expanding in North America,

specifically Canada, as a diluent for substantial unrefined mixing, and to some degree for

coordinate mixing into fuel and isomerization for octane improvement. In 2016, steam

breaking represented the greater part of the world utilization, trailed by coordinate mixing

into engine fuel and isomerization.

Overwhelming naphtha utilization is conjecture to increment at 1.6% yearly amid

2016– 21. Aromatics and gas generation are the main drivers for development. As more

overwhelming naphtha winds up accessible from refineries, the fares development rate will

decrease. In 2016, the larger part of overwhelming naphtha is utilized as reformer

encourage for creation of aromatics and high-octane gas. Joined with coordinate mixing

into engine gas, the rate increments much more.

Most substantial naphtha is utilized as reformer fuel, split between transforming for

gas and improving for aromatics. On the off chance that one additionally thinks about direct

mixing of engine fuel, the proportion is skewed significantly more toward for gas

generation. Toluene, xylenes, and substantial aromatics that are created in compound

reformers in abundance of what is expected to meet downstream synthetic and dissolvable

request is mixed into the gas pool as high-octane fuel parts.

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 The transportation segment represented very nearly 70% of gas oil utilization,

represented fundamentally by residential transportation (engine vehicle utilization of

diesel) and global fortifications (basically marine fuel). Mechanical (and business)

utilization is the second-biggest application for gas oil, with development conjecture at

1.2% every year amid 2016– 21. Mechanical is ordinarily light warming oil for modern

and business employments. Change is the third-biggest application, with utilization gauge

to decrease at 1.0% every year amid 2016– 21. Change forms incorporate transformation

of essential types of vitality to auxiliary and further change to deliver power or warmth.

Vitality represented 1.5% of gas oil utilization, and is figure to develop at 0.5% every year

amid 2016– 21. Vitality incorporates utilize and misfortunes by the vitality business itself

amid the refinery procedure. General gas oil utilization is figure to increment at 1.4% every

year amid 2016– 21.