Refining Technologies

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Distillation is an important process in many plants. It is used to separate mixtures into various components. In some plants, distillation may be the final step in processing a material so that it meets product specifications. The heart of a distillation process is a distillation column, or tower. Depending on the needs of the plant, a distillation process may include conventional, azeotropic, extractive, or vacuum columns.

Learning Objectives

Topic I: Introduction 

• Define the following terms: conventional distillation, thermal degradation, and azeotrope. 
• Identify three types of distillation processes that may be used instead of conventional distillation.
• Identify similarities of azeotropic, extractive, vacuum, and conventional distillation columns.

Topic II: Azeotropic Columns, Part 1

• Describe why azeotropes make conventional distillation impossible.
• Define the following terms: minimum boiling point azeotrope and maximum boiling point azeotrope.
• Identify the major parts of a typical azeotropic distillation system and describe the basic process of azeotropic distillation.
• Describe the basic process of azeotropic distillation in systems that do not use solvents.

Topic III: Azeotropic Columns, Part 2

• Identify process variables important to the operation of a typical azeotropic distillation system and describe how they can be monitored and controlled.

Topic IV: Extractive Columns, Part 1

• Compare and contrast the use and behavior of an extractive solvent and an azeotropic solvent.
• Identify the major parts of a typical extractive distillation system and describe the basic process of extractive distillation.

Topic V: Extractive Columns, Part 2

• Identify process variables important to the operation of a typical extractive distillation system and describe how they can be monitored and controlled.

Topic VI: Vacuum Columns, Part 1

• State advantages of distilling material at a reduced pressure in a vacuum column.
• Identify the major parts of a typical vacuum distillation system and describe the basic process of vacuum distillation.

Topic VII: Vacuum Columns, Part 2

• Identify process variables important to the operation of a typical vacuum distillation system and describe how they can be monitored and controlled.
• Identify abnormal conditions that can affect the operation of a vacuum distillation system and describe how these conditions may be dealt with.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Petroleum refinery products are blends of components from various process units plus additives. When the necessary blend components have been combined and any additives have been added, the result is a finished product, such as gasoline, jet fuel, or diesel fuel. In this course, you will explore some common products and the components used to blend them, different methods for blending products, and typical operator responsibilities throughout blending operations.

Learning Objectives

Topic I: Introduction to Blending Operations

• State the general purpose of blending operations.
• Identify operational requirements and variables that influence blending operations.
• Describe the basic concepts of batch blending and inline blending.
• Identify common operator responsibilities during blending operations

Topic II: Gasoline Components and Specifications

• Identify common grades of gasoline produced by gasoline blending.
• Identify typical gasoline blend components provided by process units.
• Describe specifications and tests for gasoline volatility, vapor/liquid ratio, and octane number.

Topic III: Gasoline Quality

• Describe the effect on product quality of blending gasoline blend components with different RON, MON, RVP, and sensitivity values.
• Define the following terms: oxygenate, octane pool, and blending octane numbers.
• Describe how blending bonuses and blending negatives affect the quality of blended gasolines.
• Identify some common gasoline additives and describe the relationship between oxygenates and octane number.

Topic IV: Gasoline Blending

• Define the following terms: octane giveaway, protofuel, target octane, trimming, and trim component.
• Describe a typical example of inline gasoline blending.

Topic V: Distillates Blending

• Identify common distillates and finished products produced by blending these distillates.
• Describe jet fuel components and specifications.
• Describe diesel fuel components and specifications.
• Describe furnace oil components and specifications. 
• Describe a typical example of batch blending distillates to produce diesel fuel.

Topic VI: Asphalt Blending and Residual Fuel Blending

• Describe the composition and specifications for various types of asphalt.
• Describe the composition and specifications for residual fuel.
• Describe a typical example of inline blending of cut-back asphalt.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Operators must properly monitor and control the distillation process in the crude unit so that the products leaving the unit meet process specifications. This course provides an overview of the operation of a crude distillation unit. The steps that crude oil goes through in the crude unit, process variables, and conditions that affect unit operation will also be examined. This course will also consider problems that might arise in the crude distillation unit and how to correct them.

Learning Objectives

Topic I: Introduction to Crude Distillation

• Describe the general purpose of crude distillation.
• Describe the purposes of the two major steps in crude distillation.
• Identify equipment typically used in crude distillation.

Topic II: Heating and Desalting

• List and describe the basic steps of desalting.
• Explain how crude is heated both before and after desalting.
• Describe the operation of a typical desalter.
• Identify process variables and factors that affect desalter operation.

Topic III: Crude Distillation

• Describe the operation of a flash drum and a pre-fractionator.
• Describe the operation of an atmospheric distillation tower and its associated equipment.
• Describe the operation of a vacuum distillation tower and its associated equipment.

Topic IV: Process Variables

• Describe process variables that are important to the operation of a charge heater.
• Describe process variables that are important to the operation of an atmospheric tower.
• Describe process variables that are important to the operation of a vacuum tower.

Topic V: Maintaining Process Specifications

• Define the following terms: cut point, initial boiling point, final boiling point, boiling point percentage, and target temperature range.
• Describe how adjustments can be made to maintain process specifications.

Topic VI: Abnormal Conditions

• Describe the following abnormal conditions: flooding, dry trays, and upset trays; and explain how they can be detected and corrected.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

A typical petroleum refinery includes many different units that are associated with a variety of processes. One of the important units in a refinery is a fluid catalytic cracking unit, or “cat cracker.” This course describes the basics of fluid catalytic cracking operations, with emphasis on the equipment that is used, the process variables that are involved, and operator responsibilities.

Learning Objectives

Topic I: Introduction to Fluid Catalytic Cracking

• Describe the purpose and basic operation of a fluid catalytic cracking unit.
• Define the following terms: conversion, yield, and catalyst.
• Identify and describe the functions of the major pieces of equipment in a typical fluid catalytic cracking unit.
• Explain how the principle of heat balance applies to cat cracker operation.

Topic II: Catalysts and the Cracking Reaction

• Explain the role of the catalyst in fluid catalytic cracking operations.
• Define the terms “selectivity” and “activity” in relation to catalysts.
• Describe the cracking reaction and explain how it can be controlled.
• Define the terms “over-cracking” and “severity.”

Topic III: Fluid Catalytic Cracking Reactors

• Identify and describe the function of risers in a typical fluid catalytic cracking unit.
• Describe the design and function of a typical fluid catalytic cracking unit reactor.
• Explain the process of recovering spent catalyst from a reactor and describe the equipment that is typically used.

Topic IV: Catalyst Regeneration

• Identify the major parts of a typical fluid catalytic cracking unit regenerator and describe the function of each part.
• Describe a typical process for handling the flue gas from cat cracking operations.
• Define the following terms: dense phase, dilute phase, afterburning, and snowballing.
• Explain what the color of a regenerated catalyst sample typically indicates.

Topic V: Fractionation

• Identify the major pieces of equipment in a typical fractionation system and describe the basic operation of the system.
• List the products typically obtained from a fluid catalytic cracking unit’s fractionation system.

Topic VI: Catalyst Circulation

• Explain how catalyst circulation may be controlled.
• Describe two conditions that may result from improper catalyst circulation.

Topic VII: Process Variables

• Define the term “catalyst-to-oil ratio.”
• Describe how yield, conversion, severity, catalyst-to-oil ratio, and charge rate are related.
• Describe how a change in product yield can affect other process variables.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

A refinery uses a number of processing units to transform crude oil into a wide variety of products that are marketed to customers. This course examines the basics of crude oil and how it is processed in a refinery.

Learning Objectives

Topic I: What Is Crude Oil?

• Define the following terms: crude oil, specific gravity, API gravity, paraffinic crude, and asphaltic crude.
• Explain the difference between a sweet crude and a sour crude.

Topic II: Hydrocarbons

• Define the term “hydrocarbon.”
• Given the name of a hydrocarbon, state the number and the arrangement of carbon atoms. 
• Define the following terms: paraffin, olefin, naphthene, and aromatic.

Topic III: Crude Oil Distillation

• Explain the function of a crude oil distillation unit.
• List, from lightest to heaviest, typical fractions from a crude oil distillation unit.

Topic IV: Gases, SR Gasoline, Naphtha, and Kerosene Processing 

• Explain how gases, SR gasoline, naphtha, and kerosene from the crude unit are typically processed in a refinery.
• List typical products from a gas plant, a catalytic reformer, and the processing of kerosene.

Topic V: Gas Oils Processing

• Explain how gas oils are typically processed in a refinery.
• List typical products from a fluid catalytic cracker unit, an isomerization unit, and an alkylation unit.

Topic VI: Residuum Processing

• Explain how residuum is typically processed in a refinery.
• List typical products from a vacuum unit, a deasphalting unit, and a coking unit.

Topic VII: Motor Fuel Blending

• Define, in general terms, the concept of octane rating.
• Describe how motor fuels are blended.
• Explain the effects of vapor pressure on motor fuel blending.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video

High-octane gasoline is one of the most important and profitable refinery products, and the main function of many refinery units is to make products for gasoline blending. In the final blend, one of the cleanest burning components, and the component with the highest octane, is often alkylate; the end product of an alkylation unit.

Learning Objectives

Topic I: Introduction

• Explain what alkylation is.
• Identify the major chemical reactions that occur during alkylation.
• Identify the main sections of a typical alkylation unit.
• Identify the major process variables that are controlled in an alkylation unit.

Topic II: Feed Preparation

• Identify and describe the feed streams to an alkylation unit.
• Describe the equipment and basic operating principles involved in the removal of sulfur from the alkylation feed streams. •
• Describe the equipment and basic operating principles involved in the removal of water from the alkylation feed streams.
• Explain why and how the feed stream is cooled.

Topic III: Reaction Equipment

• Identify and describe the major components of the reaction section of a typical alkylation unit.
• Describe the basic operating principles for the following types of alkylation reactors: jet-type and impeller.

Topic IV: Acid Handling

• Describe how acid can be handled in a sulfuric acid alkylation unit.
• Describe how acid can be handled in a hydrofluoric acid alkylation unit.

Topic V: Fractionation

• Identify and describe the major components in the fractionation section of a typical alkylation unit.
• Identify the product streams produced in the fractionation section of a typical alkylation unit.

Topic VI: Process Variables

• Identify process variables that are monitored and controlled during alkylation.
• Explain why these process variables are important to alkylation.
• Describe considerations in responding to a decrease in the isobutane-to-olefin ratio in an alkylation unit.

Topic VII: Safety Considerations

• Identify safety hazards related to alkylation.
• Describe protective gear and safety equipment used to minimize alkylation hazards.
• Describe safety procedures that should be followed to minimize alkylation hazards.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video

Refineries produce many different types of products for a variety of uses. Although no single refinery produces all types of products, many refineries produce more than one type of product. This training unit examines the functions of refinery systems and equipment and describes the role of operators in refinery operations.

Learning Objectives

Topic I: Refineries

• Define the following terms: refinery, system, unit, finished products.
• Describe the flow path of materials through a refinery.
• Describe how refinery systems work together to produce finished products.

Topic II: Refinery Equipment

• Identify equipment used in a typical process system.
• Describe the basic functions of equipment used in a typical process system.

Topic III: Furnace And Distillation Process Systems

• Identify the components of a simple furnace system.
• Describe the basic operation of a furnace and a furnace system.
• Identify two types of distillation systems.
• Identify the components of a simple distillation system.
• Describe the basic operation of a pressure column distillation system.
• Describe the basic operation of a vacuum column distillation system.

Topic IV: Reactor Process Systems

• Describe the basic functions of reactor process systems.
• Identify two types of reactor process systems.
• Describe the general operation of two types of reactor process systems.

Topic V: Refinery Instrumentation

• Identify process variables that are commonly controlled in refineries.
• Describe the basic functions of sensing devices, indicators, recorders, and alarms.
• Describe how a process control system can automatically control the value of a process variable.

Topic VI: Refinery Operations

• Describe some general tasks performed by refinery operators inside and outside the control room.
• Identify some general types of safety equipment and practices that are used in refineries.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video

Refineries develop and improve products such as high-octane, low-knock gasoline; aviation fuel; and petrochemical feedstocks. The major role of hydrotreating and catalytic reforming units is to work together to produce these fuels and petrochemical feedstocks. This course examines the reactions and equipment that are involved in hydrotreating and catalytic reforming and identifies the process variables that have to be monitored and controlled.

Learning Objectives

Topic I: Introduction

• Explain what hydrotreating and catalytic reforming are.
• Identify the major sections of typical hydrotreating and catalytic reforming units.

Topic II: Process Reactions

• Describe the major chemical reactions that occur during hydrotreating.
• Describe the major chemical reactions that occur during catalytic reforming.
• Explain how a reforming catalyst promotes reforming reactions. 
• Explain how recycling hydrogen protects a reforming catalyst.

Topic III: Hydrotreating Equipment

• Identify the major components of a typical hydrotreating unit. •
• Describe the functions of the major components of a typical hydrotreating unit.

Topic IV: Catalytic Reforming Equipment 

• Identify the major components of a typical catalytic reforming unit.
• Describe the functions of the major components of a typical catalytic reforming unit.

Topic V: Hydrotreating Process Variables

• Identify process variables that are monitored and controlled during hydrotreating.
• Explain why these process variables are important to hydrotreating.

Topic VI: Catalytic Reforming Process Variables, Part 1

• Explain the relationship between octane number and yield. 
• Identify process variables that are monitored and controlled in the reaction section of a catalytic reforming unit.
• Explain why these process variables are important to catalytic reforming.

Topic VII: Catalytic Reforming Process Variables, Part 2

• Identify process variables that are monitored and controlled in the separation section of a catalytic reforming unit.
• Explain why these process variables are important to catalytic reforming.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video

Crude oil contains valuable and desirable hydrocarbon molecules. In addition, however, raw crude and distilled fractions contain impurities. The type and amount of impurities in raw crude and distilled fractions may vary, depending on several factors, including the origins of the crude and the boiling ranges of the fractions. This course covers some treating processes that are used to remove or convert sulfur compounds.

Learning Objectives

Topic I: Introduction to Treating and Sulfur Recovery

• State the purpose of treating and sulfur recovery.
• Identify two types of sulfur compounds contained in crude fractions and explain how they can be removed or converted.
• Describe a basic caustic wash process.
• Identify hazards associated with caustic use.

Topic II: Amine Treating, Part 1

• Identify typical amines used for treating fractions to remove Hydrogen sulfide (H2S).
• Describe the equipment and operation of a typical amine treatment unit.

Topic III: Amine Treating, Part 2

• Describe process variables and conditions associated with a typical amine treating process.
• Explain why foaming is a problem and how it can be minimized.

Topic IV: Mercaptan Extraction

• Describe the equipment and operation of a typical mercaptan extraction process.
• Identify process variables and conditions associated with mercaptan extraction.

Topic V: Mercaptan Conversion

• Describe the operation of a liquid-liquid mercaptan conversion system.
• Describe the operation of a fixed bed mercaptan conversion system.
• Identify process variables and conditions associated with liquid-liquid and fixed bed mercaptan conversion systems.

Topic VI: Sulfur Recovery

• Explain the major process reactions involved in Claus type sulfur recovery.
• Identify the equipment in a Claus type sulfur recovery unit and describe the unit’s operation.
• Describe process variables and conditions associated with sulfur recovery unit operations.