Processos de Refino

Objetivos do curso:

• Conhecer algumas caracter ísticas do petróleo e seus derivados

• Analisar o processamento de gás natural
• produtos
• esquemas de processamento
• Analisar o processamento de petróleo
• Produtos
• Esquemas de processamento em refinarias
• Principais unidades do refino
• Destilação atmosf érica e vá cuo
• Craqueamento catalítico
• Hidrotratamento de derivados

O Petróleo e o gás natural nas

Unidades de Processamento

1
 Escoamento do petróleo e do gás

• Transporte por oleodutos e gasodutos das áreas

de produção nacional
• Em terra (onshore)
• No mar (offshore)
• Transporte por petroleiros
• Petróleo importado
• Petróleo nacional

Offshore-Onshore Facilities
Tankers

Production

Gas/Oil Pipelines

Offshore Campos Basin

2
 Offshore Floating Platform

FPSO – Floating Production Storage Offloading

3
Offshore Facilities

FPSO Schematic

FPSO Schematic

4
General Production System

Natural Gas Processing

Offshore-Onshore Facilities

5
 Onshore facilities

UPGN

Slug-catcher

Slug-Catcher

UPGN

Mercury Removal

Gas from
Dehydration

Activated Carbon
Adsorption Bed

Gas to NGL
Recovery

- Protection of aluminium equipment below -39 C

- Environmental/personal protection

6
 Gas Sweetening

5m 6.0 m

Acid Gas to
Sweet Gas to
Sulphur
NGL Plant Recovery

21 m Absorber Regenerator 21 m

Flash
Gas
Feed Gas
Lean Amine

Rich Amine

Gas Drying

WET GAS

WATER
A B C BED C IS SHOWN IN
REGENERATION MODE

DRY GAS

- To avoid water hydrates

Gas Processing Overall Block Diagram

Mercury
Removal

7
 Gas Processing

Products from Natural Gas Processing

Natural Gas Processing
Components (Separation) Products

N2
H 2O .........RESIDUAL GAS
CO 2
N2 C1
CO 2 H 2S
C1 C2 .........ETHANE PETROCHEM
C2
C3
C3
C4 .........LIQUIFIED NATURAL
C4 PROCESSING
GAS (GLP)
C5
C6 C5
C7 C6
H 2O C7
C8
. C8 .........NATURAL GASOLINE
. .
. . (C5+)
.
Cn
Cn

Natural Gas
Typical Compositons

NATURAL GAS REFINERY NAPHTHA

COMPOSITION GAS GAS
ASSOCIATE NON RESIDUAL (REDUC) (COMGAS)
ASSOCIATE (PROCESSED)
C1 75 92 87 20 33
C2 12,5 4 9,5 15,5 -
C3 7 1 0,5 2 -
C4 3 0,5 - 1 -
C5+ 1 - - - -
CO - - - 3 3
CO2 0,5 0,5 2 3 21
O2 - - - - -
H2 - - - 45 43
N2 1 2 1 10 -
H2S 0,5

8
 Natural Gas
Production Regions
ESTATE PRODUCTION BURNED REINJECTED
% % %

BA 12,4 1,8 6,4

SP 2,5 0,0 0,0
RJ 44,8 83,8 9,5
ES 2,6 2,3 0,0
SE 5,0 1,0 7,3
AL 5,1 0,3 5,4
RN 8,8 4,6 7,6
CE 0,8 0,9 0,0
AM 18,0 5,3 63,8
TOTAL: 42 600 3 790 9 628

DATA: AGO/2002

Natural Gas Processing Units

PROCESSING CAPACITY NOMINAL PRODUCTION (m 3/ d )
UNIT
(103 m3/d) GLP C5+

URUCU I (AM) 600 178 11

URUCU II (AM) 6000 1990 113
LUBNOR (CE) 350 147 33
GUAMARÉ I (RN) 2000 545 89
GUAMARÉ II (RN) 2000 632 168
PILAR (AL)1 1800 290 30
ATALAIA (SE) 2000 580 250
CARMÓPOLIS (SE) 350 52 17
CATU (BA) 1400 330 150
CANDEIAS (BA) 2000 490 225
LAGOA PARDA (ES) 150 31 12
CABIÚNAS (RJ) 560 179 15
UPCGN CABIÚNAS (RJ) (m3/d de líq.) 1500 689 295
URGN CABIÚNAS (RJ) 3000 548 139
URL CABIÚNAS (RJ)2 (1a. Fase) 4500 0 0
REDUC I (RJ) 2400 564 94
REDUC II (RJ) 2000 576 51
UGN RPBC (SP)3 2300 0 1500
TOTAL (18 UNITS) 34910 7821 3192
1 2 3
Startup nov/2002 generate LGN (C2+) Condensate 60o API

Processing Units - Technology

• Refrigeration
• Refrigerated Absorption
• JT Expansion
• Turbo-expansion

9
NGL Cascade Refrigeration Plant

NGL Absorption Plant

NGL Joule-Thomson Plant

Compressor

10
 NGL Turbo-Expander/Compressor Plant

Turbo-Expander/Compressor

NGL Turbo-Expander/Compressor Plant

Process
Simulation

11
 Propane Recovery

28.5bara 2MW
-15° C 23bara
-65° C
23bara
-54° C

-16° C 1.3MW

17.2bara
50° C

Propane
47bara 2.8MW 2MW 29.7bara
44°C 44bara 103° C 5.8bara
-27° C 50° C
-32°C
-17°C 23.5bara Butane
6° C

23bara

Other Users
Sales Gas SEALINE Users 18.4bara
26bara 121° C
51bara

1.3MW 1.8MW 6.3bara

114° C Condensate

Target propane recovery is 95%.

Ethane Recovery

10.5bara
-110° C 7MW
11bara Ethane
-90° C
30bara
12° C
62bara 9.6MW
40°C 1.5MW 1.5MW
17.5bara
59.6bara 50° C
Sweetening -17°C
Dehydration Propane
Residue
11.0bara
11.0 bara -7° C

31.2bara
1.5MW 1.5MW
103° C
5.6bara Butane
50° C

19.0bara
121° C

17.0 MM Nm 3/d
62 bara Feed, 2 Expanders
7.1bara
115° C Condensate
90% Ethane Recovery

Turbo-Expander/Compressor/Dephlegmator

Cold box

12
Dephlegmator Cold box

Petroleum Processing
(Refinery)

Overall view of a Refinery

13
Fundo de
barril

Petroleum Processing
(Petrochemical)

Ethylene (typical)

Fornos de
craqueamento

Área de
separa çã o

Compressores

14
 Copesul-RS

Polietileno
(US$ 800 MM )
Polorio

Produzidos nas
refinarias e
plantas de gás
natural Downstream
Plants

CENTRAL DE MATERIAS PRIMAS

Petroleum Composition

15
Petroleum contains literally thousands of components

- Very few isolated as pure components

- methane to hexane
- Much petroleum is isolated as “fractions ” by distillation

The “fractions” are characterized by typical petroleum

industry distillation curves:
- ASTM distillation (Initial-Final)
- PEV (TBP-True Boiling Point) distillation
and
- Specific properties for quality control such as
- UOPK, API degree, Density, PINA (PIONA)
- Octane Number (Gasoline)
- Cetane Number (Diesel)
- Freezing point (Jet fuel-kerosene)
- and Sulfur, Nitrogen, Viscosity, etc.

Typical Distillation Curves

PEV

ASTM

Temperature FLASH

0 V (% vaporized) 100

Distillation Test Apparatus

PEV ASTM

16
 Distillation Test Apparatus

Petroleum qualification - API density

141 .5
API ? ? 131 .5
d15. 6 /15. 6

Density (API) Classification Price

US$/bbl

API > 40 Extra-light

40 > API > 33 Light

33 > API > 27 Medium

27 > API > 19 Heavy
10 > API > 15 Extra-heavy
API < 15 Asphaltic

Distillation
Range
on TBP
Curve

17
 Yield estimation

FBP

IBP

Typical Products Distillation Curves

18
19