Refinery Complex Research Articles

DNA methylation differences in exposed workers and nearby residents of the Ma Ta Phut industrial estate, Rayong, Thailand

Adverse biological effects from airborne pollutants are a primary environmental concern in highly industrialized areas. Recent studies linked air pollution exposures with altered blood Deoxyribo-nucleic acid (DNA) methylation, but effects from industrial sources and underlying biological mechanisms are still largely unexplored. The Ma Ta Phut industrial estate (MIE) in Rayong, Thailand hosts one of the largest steel, oil refinery and petrochemical complexes in south-eastern Asia. We measured a panel of blood DNA methylation markers previously associated with air pollution exposures, including repeated elements [long interspersed nuclear element-1 (LINE-1) and Alu] and genes [p53, hypermethylated-in-cancer-1 (HIC1), p16 and interleukin-6 (IL-6)], in 67 MIE workers, 65 Ma Ta Phut residents and 45 rural controls. To evaluate the role of DNA damage and oxidation, we correlated DNA methylation measures with bulky DNA and 3-(2-deoxy-β-D-erythro-pentafuranosyl)pyrimido[1,2-α]purin-10(3H)-one deoxyguanosine (M(1)dG) adducts. In covariate-adjusted models, MIE workers, compared with rural residents, showed lower LINE-1 (74.8% vs 78.0%; P < 0.001), p53 (8.0% vs 15.7%; P < 0.001) and IL-6 methylation (39.2% vs 45.0%; P = 0.027) and higher HIC1 methylation (22.2% vs 15.3%, P < 0.001). For all four markers, Ma Ta Phut residents exhibited methylation levels intermediate between MIE workers and rural controls (LINE-1, 75.7%, P < 0.001; p53, 9.0%, P < 0.001; IL-6, 39.8%, P = 0.041; HIC1, 17.8%, P = 0.05; all P-values vs rural controls). Bulky DNA adducts showed negative correlation with p53 methylation (P = 0.01). M(1)dG showed negative correlations with LINE-1 (P = 0.003) and IL-6 methylation (P = 0.05). Our findings indicate that industrial exposures may induce alterations of DNA methylation patterns detectable in blood leucocyte DNA. Correlation of DNA adducts with DNA hypomethylation suggests potential mediation by DNA damage.

Efficient biodegradation of naphthalene by a newly characterized indigenous Achromobacter sp. FBHYA2 isolated from Tehran Oil Refinery Complex

A bacterial strain, FBHYA2, capable of degrading naphthalene, was isolated from the American Petroleum Institute (API) separator of the Tehran Oil Refinery Complex (TORC). Strain FBHYA2 was identified as Achromobacter sp. based on physiological and biochemical characteristics and also phylogenetic similarity of 16S rRNA gene sequence. The optimal growth conditions for strain FBHYA2 were pH 6.0, 30 °C and 1.0% NaCl. Strain FBHYA2 can utilize naphthalene as the sole source of carbon and energy and was able to degrade naphthalene aerobically very fast, 48 h for 96% removal at 500 mg/L concentration. The physiological response of Achromobacter sp., FBHYA2 to several hydrophobic chemicals (aliphatic and aromatic hydrocarbons) was also investigated. No biosurfactant was detected during bacterial growth on any aliphatic/aromatic hydrocarbons. The results of hydrophobicity measurements showed no significant difference between naphthalene- and LB-grown cells. The capability of the strain FBHYA2 to degrade naphthalene completely and rapidly without the need to secrete biosurfactant may make it an ideal candidate to remediate polycyclic aromatic hydrocarbon (PAH)-contaminated sites.

Environmental comparison of straight run diesel and cracked diesel

Abstract Diesel is produced conventionally by distilling crude oil which also results in lower value heavy distillates. Recently, complex refineries have higher value-added diesel from these heavy distillates. However, this requires additional energy. Hence, it is interesting to evaluate what effect the economic value addition has on the use of non-renewable resources and greenhouse gas emissions. This study was conducted to compare the gate-to-gate energy related impacts i.e. Global Warming Potential (GWP) and Abiotic resource Depletion Potential (ADP) between straight run diesel (S-HSD), produced by a simple refinery and cracked diesel (C-HSD), produced by a complex. The results showed that the C-HSD required more energy than the S-HSD because of the energy used by the additional processes. 1 L of the S-HSD generated 0.048 kg CO2 eq while that of the C-HSD generated 0.372 kg CO2 eq. In contrast, the C-HSD has a lower ADP than the S-HSD proving that the production of diesel from the heavy distillate indeed helps conserve natural resources. 1 L of the S-HSD generated 0.022 kg Sb eq. while that of the C-HSD generated 0.017 kg Sb eq. Producing the C-HSD helps conserve natural resources but has higher GWP than the S-HSD. However, there are possibilities to reduce GHG emissions from the C-HSD production by energy efficiency improvement.

Integrating Delayed Coking Process into Nigeria's Refinery Configuration

The large availability and economic cost of heavy crude both directly from oil wells and as by-products of crude oil processing calls for methods for its utilization. Delayed coking is one method used for processing and utilization of heavy crude; it is deployed as a unit in refineries. An evaluation of heavy residual oil processing units has been done for Nigerian refineries. Process flow schemes of three Nigerian refinery complexes were carefully analyzed and the yields of coke, gas and liquid products were predicted from the study. The study revealed that Nigeria's refineries were in need of such processes like Delayed coking which is seen to have a lot of advantages in technological, economical and environmental perspectives. The developmental trend in the conceptual planning of the existing refineries in Nigeria is light fuel orientation. The product slates of existing refineries are lacking in heavy products of secondary origin. The uses of Delayed Coking Plant (DCP) and its products in contemporary downstream processing had also been highlighted. Nigeria's emerging metallurgical and electrodes manufacturing industries stand to gain in DCP products, particularly petroleum coke, while the economy will be protected as cash flight through coke import shall be minimized with an introduction of DCP into Nigeria's refining configuration.

Composite catalysts of Pt/SO42−–ZrO2 and Pt/WO3–ZrO2 for producing high octane isomerizate by isomerization-cracking of long paraffins

Isomerization-cracking of long paraffins to produce octane enhancers for the gasoline pool is a complex refinery operation that needs simultaneous adjustment of the molecular size of the feed (cracking) and skeletal branching (isomerization). As both reactions are acid-catalyzed it is very difficult to adjust the acidity distribution of a single catalyst to have a proper balance. In this work the used catalyst is a mixture of an isomerization catalyst (Pt/WO3–ZrO2) (PtWZ) and a cracking catalyst (Pt/SO42−–ZrO2) (PtSZ), working at the same reaction conditions. The tests were performed using n-hexadecane as a model feedstock.The screening of pressure and temperature conditions indicates that the best match for both catalysts is 20atm and 225°C. Stable activity levels for both catalysts can only be achieved at a H2/n-C16 ratio of 10. An adequate space velocity for increasing the yield to iC5–9 and preventing consecutive cracking is 18.4h−1. At this process conditions mixtures (PtWZ+PtSZ) that contain 25% or 50% PtSZ have a better product distribution, with the maximum displaced to higher carbon numbers, with a reduced yield to isobutane and light gasses.Operation points lie on a monotonic curve of octane number gain (∆RON) as a function of the yield of light gasses (C1–4) that indicates that RON gains can only be obtained at the expense of the liquid yield.

Toxicity assays of marine sediments from western Venezuela

Refineries are one of the main sources of coastal marine pollution worldwide. In this study, the toxicity of sediments potentially impacted by the Paraguaná Refinery Complex on the west coast of Venezuela was evaluated using chronic toxicity assays. This toxicity was determined by exposing larvae of the shrimp Litopenaeus vannamei and the polychaete Scolelepis texana to bioassays during 28 and 10 days, respectively. Both bioassays indicated that the sediments surrounding the refinery are highly toxic, compared to sediments from the same region farther from the refinery and sediments from a control zone. The sediments surrounding the refinery had relatively high concentrations of total petroleum hydrocarbons (&gt;10,000 ppm); of heavy metals such as chrome, nickel, and zinc; and of polycyclic aromatic hydrocarbons (ΣPAHs &gt; 1000 ppb). This study forms part of the first environmental ecological risk assessment done in Venezuela. The high toxicity of the sediments close to one of the largest refinery complexes in the world should serve as a warning of the possible impacts on benthic and planktonic communities that live in the environs of refineries in coastal marine environments.

The Hydrogen Network Optimization of a Complex Refinery

In this paper, the hydrogen distribution network of a complex refinery is optimized by the hydrogen surplus pinch method. By plotting the hydrogen purity profiles and hydrogen surplus diagrams, the hydrogen pinch with hydrogen purity of 87% is identified. The corresponding minimum hydrogen utility consumption is 17730.5 Nm3/h. Moreover, the optimal hydrogen distribution network with minimum utility consumption is designed. Compared with the current hydrogen network, the hydrogen utility consumption can be reduced by 10.45%.

Significance of Kaduna River to Kaduna Refining and Petrochemicals Complex: Some Checks and Balances

Kaduna Refinery and Petrochemicals Complex comprises of variousprocessing units. The plants produce various grades of petroleum andpetrochemical products. But in all of the plants and facilities, water isrequired in its various forms. The paper describes Desalter Process andRefinery Wastewater. The only major source of water is Kaduna River. TheChemical compositions of the raw and filtered water differ. The compositionsof the treated and &ldquo;imported&rdquo; bottled waters are the same and thus fit fordrinking. pH value is fairly constant and so also other elements. Purificationis by demineralization using ion-exchange resins. Demineralised watercontains a number of chemicals and compounds. The process waters aredischarged either as steam or drained out as affluent water. The Sour WaterStripper (SWS) is not functioning. Consequently, the polluted wastewater isdischarged directly to the environment. The Sour Water Stripper must beresuscitated and made to function. Government and KRPC would need toinform and educate members of the community about the effluent wastewaterand its consequences in the environment. Ultra Filtration Membrane Systemis recommended for treatment of desalter effluent.

Water network synthesis in refinery

Minimizing fresh raw water and wastewater effluent produced by industry has rigorously been studied over the past two to three decades. However, most studies have focused on rather theoretical illustration with little consideration of technical constraints in industry. Furthermore, use of massive industry data significantly increases the complexity of the problem, and no research paper has covered such a case study with practical solutions. This paper reviews the latest technology of water network synthesis and its applications, and provides a detailed guideline of the whole study procedure with a reference to case study based from refinery complex. Two main methodologies of water-pinch technology and a mathematical optimization programming are reviewed individually, and they are applied to a case study. Economic and operational constraints are embedded into optimization of water network synthesis in order to provide more reliable and achievable solutions for the minimization of fresh water consumption and reduction of waste water effluents. This generic approach can be similarly applied to other industries such as petroleum, steel, and paper manufacturing.

PETRONAS, SABIC HAVE BIG PLANS

MALAYSIAN STATE-OWNED oil refi ner Petronas plans to build a $20 billion oil refinery and petrochemical complex in the state of Johor. And Saudi Basic Industries Corp. (SABIC) is going ahead with a...

The energy efficiency of crude oil refining in Brazil: A Brazilian refinery plant case

This article evaluates energy efficiency in Brazilian crude oil refining in comparison with the crude oil refining in the United States between 1930 and 2008. It aims to show that increased refinery complexity reduces the energy consumption of products of high value added. Moreover, the article shows that improvements in energy efficiency result in higher quality products and increased processing of oil. A Brazilian refinery with a capacity of 157,000 barrels per day (kbpd) was modernized in 2008 at a cost of US $1.3 billion. As a result, its capacity increased by 17%, from 157 to 189 kbpd. Its complexity index also rose from 3.2 to 6.8, allowing an improvement in the EII (energy intensity index) from 110% to 93%. In relation to the crude oil processed before being modernized, energy consumption fell from 0.75 to 0.52 MBtu (million British thermal units) per barrel processed. These proceedings show that increases in complexity reduce the energy consumed in the production of final products with high value added, such as gasoline, diesel and jet fuel.

Size distribution and chemical composition of metalliferous stack emissions in the San Roque petroleum refinery complex, southern Spain

We demonstrate that there is great variation in the size range and chemical composition of metalliferous particulate matter (PM) present within petrochemical complex chimney stacks. Cascade impactor PM samples from seven size ranges (17, 14, 5, 2.5, 1.3, 0.67, and 0.33 μm) were collected from inside stacks within the San Roque complex which includes the largest oil refinery in Spain. SEM analysis demonstrates the PM to be mostly carbonaceous and aluminous fly ash and abundant fine metalliferous particles. The metals with the most extreme concentrations averaged over all size ranges were Ni (up to 3295 μg m −3), Cr (962 μg m −3), V (638 μg m −3), Zn (225 μg m −3), Mo (91 μg m −3), La (865 μg m −3), and Co (94 μg m −3). Most metal PM are strongly concentrated into the finest fraction (<0.33 μm), although emissions from some processes, such as purified terephthallic acid (PTA) production, show coarser size ranges. The fluid catalytic cracking stack shows high concentrations of La (>200 μg m −3 in PM 0.67–1.3), Cr and Ni in a relatively coarse PM size range (0.7–14 μm). Our unique database, directly sampled from chimney stacks, confirms that oil refinery complexes such as San Roque are a potent source of a variety of fine, deeply inhalable metalliferous atmospheric PM emissions.

Screening and batch treatment of wastewater containing floating oil using oil-degrading bacteria

Oil pollution is one of the important environmental problems in the world. In order to degrade floating crude oil in the wastewater, two soil samples were taken from the oil-contaminated soils in Ahwaz (Iran) and an oil refinery complex in Tehran (Iran). Fourteen strains of bacteria iso¬lated from these samples. Among these bacteria a strain marked as A-14 could treat 91% of total petroleum hydrocarbons and 83% of aromatic compounds in the floating crude oil after 10 d. Also the optimum time to reach the maximum removal percent (90%) was found to be 7 d. A-14 was identified to be Pseudomonas aeruginosa. All isolated bacteria in this study were able to produce biosurfactant. A-12 resulted in the best emulsification index that was about 36%. However, this strain could remove only 46% and 37% of the total petroleum hydrocarbons and aromatic compound, respectively. Most of the isolated microorganisms in this study had higher efficiency for the degradation of total petroleum hydrocarbons (TPH) than aromatic co...

Pollution in estuarine and bay sediments at a refinery complex located on the Mexican Pacific Ocean

The study was designed to determine potential environmental impacts to aquatic biota that may be linked to heavy metals and polycyclic aromatic hydrocarbons (PAHs) resulting from effluents of the oil refinery and industrial activities in the estuarine system, inner port and Bay of Salina Cruz, Mexico. The data indicate that the studied area is chronically polluted.

Catalytic cracking in today’s deep-conversion refinery

A trend in the development of catalytic cracking, one of the most important high-production-volume refinery processes, is integration into deep-conversion refinery complexes. We address studies on variation in the diesel/gasoline ratio and the processing of vacuum tower bottoms, renewable biomass, and polymer-containing wastes in complex facilities involving catalytic cracking and hydroconversion on nanosized heterogeneous catalysts.

Integrated design of diesel hydrotreating processes

This work presents an integrated approach for the design of diesel hydrotreating processes employing a simulated annealing optimisation algorithm. The modelling of reactor, separation and heat recovery system for diesel hydrotreating processes is discussed, and a novel optimisation framework is developed for the design of complex refinery processes. A comparison with conventional approach to process design, i.e. sequential evolution of design, is given to illustrate the ability of proposed approach to obtain overall hydrotreating process designs with minimum total annualised costs. The proposed integrated approach takes into account the trade-offs between capital and operating costs, as well as interactions between the hydrotreater, distillation column, and the associated heat exchanger network.

Challenges and technological opportunities for the oil refining industry: A Brazilian refinery case

The worldwide oil refining industry currently faces strong challenges related to uncertainties about future feedstock and characteristics of oil products. These challenges favor two main strategies for the sector: the first strategy is increasing refinery complexity and versatility; the second is integrating the refining and petrochemical industries, adding value to the crude oil while guaranteeing market share to premium oil products. Both strategies aim at increasing production of highly specified oil products, simultaneously reducing the environmental impacts of the refining industry. This paper analyses the case of a Brazilian refinery, Gabriel Passos Refinery (REGAP), by proposing additional investments to alter and/or expand its current production scheme. All the proposed options present relatively low investment rates of return. However, investments in a hydrocracking based configuration with a gasification unit providing hydrogen and power can further improve the operational profitability, due to reduced natural gas consumption.

Robust planning of multisite refinery networks: Optimization under uncertainty

This paper considers the problem of multisite integration and coordination strategies within a network of petroleum refineries under uncertainty and using robust optimization techniques. The framework of simultaneous analysis of process network integration, originally proposed by Al-Qahtani & Elkamel [Al-Qahtani, K., & Elkamel, A. (2008). Multisite facility network integration design and coordination: An application to the refining industry. Computers & Chemical Engineering, 32, 2198], is extended to account for uncertainty in model parameters. Robustness is analyzed based on both model robustness and solution robustness, where each measure is assigned a scaling factor to analyze the sensitivity of the refinery plan and integration network due to variations. Parameters uncertainty considered include coefficients of the objective function and right-hand-side parameters in the inequality constraints. The proposed method makes use of the sample average approximation (SAA) method with statistical bounding techniques. The proposed model was tested on two industrial-scale studies of a single refinery and a network of complex refineries. Modeling uncertainty in the process parameters provided a practical perspective of this type of problems in the chemical industry where benefits not only appear in terms of economic considerations, but also in terms of process flexibility.

Simultaneous optimization of energy and materials based on heat exchanger network simulation for diesel hydrotreating units

A multi-period nonlinear programming (NLP) formulation is presented in this paper. This is intended to optimize energy and materials simultaneously for diesel hydrotreating units in order to minimize the total costs which include product income, material cost, energy cost, and other fixed operating costs. The heat exchanger network (HEN) is integrated into the model to address the energy consumption changes with the stream flow and temperature of different production modes. Some process models are regressed from production data or are supplied by refinery engineers, similar to the models for steam turbines and compressors, and distillation towers. An iterative algorithm is developed to solve the complex mathematical model based on HEN simulation. An industrial diesel hydrotreating unit is provided by the Chinese Refinery Complex and is used to demonstrate the performance of the formulated model and algorithm. It is found that the optimized results from the simultaneous consideration of the energy and materials are more profitable than those obtained from other methods that individually optimized the energy or materials.

CO 2 capture for refineries, a practical approach

This paper evaluates the opportunities and associated costs for post-combustion capture at a world-scale complex refinery. It is concluded that it is technically feasible to apply post-combustion capture at such a refinery. The costs for capture and sequestration from a gasifier are calculated to be lowest at about 30 Euro per ton; this process currently already produces a concentrated CO 2 stream. Next, the CO 2 source most suited for capture appears to be a combined stack, but there are a number of other sources that may be targeted at comparable costs. In total these sources may form about 40% of the overall refinery emissions. Our evaluations show the costs of capture from such sources based on available amine technology will be in the range of 90–120 Euro per ton, which is about 3–4 times higher than the current carbon trading values. The capture of CO 2 from a large amount of smaller CO 2 sources will bring along even much higher costs. A high-level study of the CO 2 emissions profile of a number of Shell refineries shows that, typically, up to 50% of the emitted CO 2 may be captured at similar costs. About 10–20% of concentrated CO 2 associated with hydrogen manufacturing may be captured at lower costs. The remainder of emitted dilute CO 2 will bring along significantly higher costs. Based on this study, it is concluded for the justification of the implementation of post-combustion capture at refineries, either a significant increase in carbon trading values, mandatory regulations, or a major technological break-through is required.