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Electrical power
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Process water
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Desalted crude
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Unrefined crude Heater Emulsifier
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FIGURE 32 An electrostatic desalting unit
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332 Distillation Distillation was the first method by which petroleum was refined In the early stages of refinery development, when illuminating and lubricating oils were the main products, distillation was the major and often only refinery process At that time gasoline was a minor, but more often unwanted, product As the demand for gasoline increased, conversion processes were developed because distillation could no longer supply the necessary quantities of this volatile product It is possible to obtain fuels ranging from gaseous materials taken off at the top of the distillation column to a nonvolatile residue or reduced crude (bottoms), with correspondingly lighter materials at intermediate points The reduced crude may then be processed by vacuum or steam distillation in order to separate the high-boiling lubricating oil fractions without the danger of decomposition, which occurs at high (>350 C, >662 F) temperatures Atmospheric distillation may be terminated with a lower boiling fraction (cut) if it is felt that vacuum or steam distillation will yield a better-quality product, or if the process appears to be economically more favorable Not all crude oils yield the same distillation products and the nature of the crude oil dictates the processes that may be required for refining Atmospheric Distillation The distillation unit is a collection of distillation units but, in contrast to the early battery units, a tower is used in the modern-day refinery (Fig 33) and brings about an efficient degree of fractionation (separation) The feed to a distillation tower is heated by flow through pipes arranged within a large furnace The heating unit is known as a pipe still heater or pipe still furnace, and the heating unit and the fractional distillation tower make up the essential parts of a distillation unit or pipe still The pipe still furnace heats the feed to a predetermined temperature usually a
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FUELS FROM PETROLEUM AND HEAVY OIL
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Gas (butane and lighter) + Gasoline (light naphtha)
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Atmospheric fractionation
Gas separator Gasoline
Heavy naphtha Kerosene Light gas oil Heavy gas oil
Desalter Furnace Crude oil Pump
FIGURE 33 An atmospheric distillation unit
Residuum
temperature at which a predetermined portion of the feed will change into vapor The vapor is held under pressure in the pipe in the furnace until it discharges as a foaming stream into the fractional distillation tower Here the unvaporized or liquid portion of the feed descends to the bottom of the tower to be pumped away as a bottom nonvolatile product, while the vapors pass up the tower to be fractionated into gas oils, kerosene, and naphtha Pipe still furnaces vary greatly and, in contrast to the early units where capacity was usually 200 to 500 bbl/day, can accommodate 25,000 bbl, or more of crude petroleum per day The walls and ceiling are insulated with firebrick and the interior of the furnace is partially divided into two sections: a smaller convection section where the oil first enters the furnace and a larger section (fitted with heaters) and where the oil reaches its highest temperature All of the primary fractions from a distillation unit are equilibrium mixtures and contain some proportion of the lighter constituent s characteristic of a lower boiling fraction The primary fractions are stripped of these constituents (stabilized) before storage or further processing Vacuum Distillation Vacuum distillation as applied to the petroleum-refining industry evolved because of the need to separate the less volatile products, such as lubricating oils, from the petroleum without subjecting these high-boiling products to cracking conditions The boiling point of the heaviest cut obtainable at atmospheric pressure is limited by the temperature (ca 350 C; ca 662 F) at which the residue starts to decompose (crack) When the feedstock is required for the manufacture of lubricating oils, further fractionation without cracking is desirable and this can be achieved by distillation under vacuum conditions Operating conditions for vacuum distillation (Fig 34) are usually 50 to 100 mmHg (atmospheric pressure = 760 mmHg) In order to minimize large fluctuations in pressure in the
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