Petrochemicals An Overview (STUDENT) (1of3)

Chemical Engineering Guy
www.ChemicalEngineeringGuy.com
1. Introduction
2. Overview of the Petrochemical Industry
3. Naphtha & Gas Cracking
4. FCC & Steam Cracker Recovery
5. Basic Gases
6. C1 Group
7. C2 Group
8. C3 Group
9. C4 Group
10. C5 Group
11. Aromatics
12. Conclusion
▪ Refining →
▪ Petrochemical →
▪ Refining →
▪ Petrochemical →
▪ Give an overall Overview of the Industry & Petrochemical Plants
▪ Get to know the basic petrochemicals
▪ Understand processes
▪ Pathways for production
▪ Common terminology
▪ What is a Petrochemical?
▪ Petrochemical Types
▪ Paraffins, Oleffins, Napthenes, Aromatics
▪ Raw Material → Crude oil (Naphtha) & Gas

▪ Course “Arrangement” & Order
▪ Intermediates
▪ Main Products
▪ End Products
▪ Top Petro Companies
▪ List of Petro Reffineries
▪ Petrochemicals refers to all those compounds that can be derived from the
petroleum refinery products
▪ It can be seen that petrochemicals are produced from :
▪ simple compounds such as methane, ethylene and acetylene
▪ but not multicomponent products such as naphtha, gas oil etc.
▪ These are the chemicals that are made from petroleum and natural gas.
▪ Petroleum and natural gas are made up of hydrocarbon molecules, which comprises
of one or more carbon atoms, to which hydrogen atoms are attached.
▪ About 5 % of the oil and gas consumed each year is needed to make all the
petrochemical products.
▪ Petrochemicals play an important role on our food, clothing, shelter and leisure.
▪ Because of low cost and easy availability, oil and natural gas are considered to be
the main sources of raw materials for most petrochemicals.
▪ Light Petrochemicals:
▪ These are mainly uses:
▪ bottled fuel
▪ raw materials for other organic chemicals.
▪ The lightest of these
▪ methane, ethane and ethylene
▪ gaseous at room temperature.
▪ The next lightest fractions comprise:
▪ petroleum ether
▪ light naphtha
▪ boiling points between 80 and 190 degrees
Fahrenheit.
Petroleum ether is the petroleum fraction consisting of aliphatic

hydrocarbons and boiling in the range 35‒60 °C
▪ Medium Petrochemicals:
▪ Gasoline (AGO, Automotive Gas
Oil)
▪ Hydrocarbons with 6 – 12 carbon
atoms
▪ Used mainly in automobile fuels.
▪ Octane, with eight carbons, is a
particularly good automobile fuel,
and is considered to be of high
quality.
▪ Kerosene
▪ contains 12 to 15 carbons and is
used in aviation fuels, and also as
solvents for heating and lighting.
▪ Heavy Petrochemicals:
▪ They contain around 15 and 18 carbon atoms
▪ These can be generally categorized as:
▪ diesel oil
▪ heating oil
▪ lubricating oil for engines and machinery.
▪ Boiling points between 570 and 750 degrees
Fahrenheit.
▪ The heaviest fractions of all are called
"bitumens“
▪ Used to surface roads or for waterproofing.
▪ Bitumens can also be broken down into lighter
hydrocarbons using a process called "cracking."
▪ Paraffin → hydrocarbon chains (single-
bonded)
▪ Olefins → linear alkenes
▪ Naphthenic → classified as cyclic aliphatic
hydrocarbons (simply Cycloalkanes)
▪ Aromatic → contain conjugated planar ring
systems with delocalized pi electron clouds
instead of discrete alternating single
and double bonds
▪ Gaseous →
▪ Natural Gas, condensates, Refinery
Gases, Coal Bed Methane, Gas
hydrates
▪ Liquids →
▪ Naphtha, Solvent Extracts, Middle
Distillates
▪ Solids →
▪ Coal, Coke, Wax, Residues
▪ Biomass →
▪ Agriculture residue, Algae, etc..
▪ Order via Carbon Count (i.e. C-Groups)
▪ Via Types (Oxides, ethylene oxides, Propylene oxides)
▪ Methanol, Ethanol, Propanol
▪ Petrochemicals “from” X
▪ Methanol from syngas
▪ C1-Group Methane, CO – H2 synthesis, synthesis gas derivatives
▪ C2-Group Ethane, ethylene, ethylene derivatives, acetylene
▪ C3-Group Propane, propylene and propylene derivatives
▪ C4-Group Butadiene, Butanes, Butenes,
▪ C5-Group Pentane, Pentene, Isoprene, Cyclopentadiene
▪ Aromatics Group Benzene, Toluene , Xylenes Naphthalene, BTX derivatives
For full list, download

INDEX Content
▪ Adhesives
▪ Polymers
▪ Fibre/Clothing
▪ Rubber
▪ Chemical intermediate
▪ Painting, Coating, Dyes
▪ Carpeting
▪ Detergents
▪ Agrochemicasl → Fertilizers, Pesticides
▪ Csometics → Perfume, Shampoo,
▪ Wax
https://www.moneycontrol.com/stocks/marketinfo/marketcap/bse/petrochemicals.html
www.ChemicalEngineeringGuy.com https://en.wikipedia.org/wiki/List_of_oil_refineries
▪ Jamnagar Refinery, India
www.ChemicalEngineeringGuy.com https://en.wikipedia.org/wiki/List_of_oil_refineries#Mexico
▪ Paraguana Refinery Complex (PDVSA)
▪ Port Arthur Reffinery, TX, USA
▪ Mexico
▪ Tula Refinery (Pemex)
▪ Tula, Hidalgo 300,000 bbl/d (48,000 m3/d)
▪ Minatitlan Refinery(Pemex)
▪ Minatitlan 167,000 bbl/d (26,600 m3/d)
▪ Cadereyta Refinery (Pemex)
▪ Cadereyta Jiménez, Nuevo León 217,000 bbl/d (34,500 m3/d)
▪ Salamanca Refinery (Pemex)
▪ Salamanca, Guanajuato 192,000 bbl/d (30,500 m3/d)
▪ Francisco I. Madero Refinery (Pemex)
▪ Ciudad Madero 152,000 bbl/d (24,200 m3/d)
▪ Salina Cruz Refinery (Pemex)
▪ Salina Cruz 227,000 bbl/d (36,100 m3/d)
▪ A) Check out this video:
▪ https://www.youtube.com/watch?v=oU-vDjhK_jQ
▪ B) Check out the refineries in your country/location
https://en.wikipedia.org/wiki/List_of_oil_refineries
▪ Reactors
▪ Reactors are the most important units in
petrochemical processes.
▪ Petrochemicals are manufactured by
following simple reactions using relatively
purer feedstocks.
▪ Therefore, reaction chemistry for
petrochemicals manufacture is very well
established from significant amount of
research in this field.
▪ Essentially all petrochemical processes need
to heavily depend upon chemical
transformation to first product the
purification.
▪ Separation
▪ With distillation being the most important unit operation to separate
the unreacted feed and generated petrochemical product, the
separation processes also play a major role in the process flow sheet.
▪ Where multiple series parallel reactions are involved, the separation
process assumes a distillation sequence to separate all products from
the feed.
▪ A characteristic feed recycle will be also existent in the process
topology.
▪ Apart from this, other separation technologies used in petrochemical
processing units include phase separators, gravity settling units and
absorption columns.
▪ Therefore, the underlying physical principle behind all these
separation technologies is well exploited to achieve the desired
separation.
▪ Definition of Battery Limit.
▪ A battery limit is a defined boundary between two areas of responsibility, which may be
physical (e.g. a flange on a pipe); or represented by a map coordinate; or some other
means (for example a point in time).
▪ ISBL = Inside Battery Limits
▪ OSBL = Outside Battery Limits
▪ ISBL (Inside Battery Limits) plant costs are the cost of procuring and installing all
process equipment.
▪ ISBL costs include purchasing and shipping costs of equipment, land costs, infrastructure,
piping, catalysts, and any other material needed for final plant operation, or construction
of the plant.
▪ ISBL costs also include any associated fees with construction such as permits, insurance, or
equipment rental; even if these items are not needed once the plant is operational.
▪ OSBL (Outside Battery Limits), or Off-Site Costs, are still an important component
of the plant cost but deals with calculating costs associated with off-site
developments that require the plant to run.
▪ For example, if water or electricity is being utilized from the main grid, and infrastructure
needs to be expanded to accommodate the chemical plant's addition to these systems,
these costs are considered OSBL because they are not directly associated with elements
between the input and output of the chemical plant.
▪ An Overview of the Refining Process by The American Petroleum Institute
▪ https://www.youtube.com/watch?v=GYRwWyG3Qqw
▪ Napthta → Cracker → Ethylene, Propylene, C4-Cut
▪ Naphtha → Reforming → BTX
▪ Natural Gas → Ethane, Propane → Cracking → Ethylene,

Propylene
▪ Kerosene → Extractoin → N-paraifns for detergnets
▪ LPG → Cracking, Propylene, Butylene
▪ Gas Oil → Cracker → Ethylene, Propylene
▪ Chemical Routes
▪ Identify:
▪ Raw Materials
▪ C1, C2, C3, C4 Groups
▪ Intermediaters
▪ Final Products
▪ Identify:
▪ Raw Materials
▪ Final Products
▪ Relvant Processes
▪ Raw materials
▪ Intermediates
▪ Final Products
▪ Check out this file:
▪ http://www.ril.com/ar2016-17/product-flow-chart.html
▪ Identify:
▪ Raw Materials
▪ Intermediates
▪ Final Products
▪ “Basic” Petrochemicals
▪ Ensure you know what is the most common feedback for a petrochemical plant
▪ Common sub-products, intermediates and final products
▪ Final uses
▪ Common petrochemical plant structures and operations
▪ What is Naphtha?
▪ Steam Cracking
▪ Hot Section
▪ Cold Section
▪ Operating Variables
▪ Petroleum naphtha is an intermediate hydrocarbon
liquid stream derived from the refining of crude oil
with CAS-no 64742-48-9.
▪ It is most usually desulfurized
▪ It is typically catalytically reformed
▪ this re-arranges or re-structures
the hydrocarbon molecules in the naphtha as well as
breaking some of the molecules into smaller molecules
to produce a high octane component
of gasoline (or petrol).
▪ There are hundreds of different petroleum crude
oil sources worldwide and each crude oil has its
own unique composition or assay.
▪ There are also hundreds of petroleum refineries
worldwide and each of them is designed to process
either a specific crude oil or specific types of
crude oils.
▪ Naphtha is a general term as each refinery
produces its own naphthas with their own unique
initial and final boiling points and other physical
and compositional characteristics.
SOURCE:
https://en.wikipedia.org/wiki/Petroleum_naphtha
▪ The first unit operation in a petroleum refinery is the crude oil
distillation unit.
▪ The overhead liquid distillate from that unit is
called virgin or straight-run naphtha
▪ the distillate is the largest source of naphtha in most petroleum
refineries.
▪ It has:
▪ initial boiling point (IBP) of about 35 °C
▪ final boiling point (FBP) of about 200 °C
▪ it contains:
▪ paraffins, naphthenes (cyclic paraffins) and aromatic hydrocarbons ranging
▪ from those containing 4 carbon atoms to those containing about 10 or 11 carbon
atoms.
▪ The virgin naphtha is often further distilled into two
streams:
▪ a virgin light naphtha with an IBP of about 30 °C and a FBP of
about 145 °C containing most (but not all) of the
hydrocarbons with 6 or less carbon atoms
▪ a virgin heavy naphtha containing most (but not all) of the
hydrocarbons with more than 6 carbon atoms.
▪ The heavy naphtha has an IBP of about 140 °C and a FBP of
about 205 °C.
▪ The virgin heavy naphtha is usually processed in a catalytic
reformer
▪ light naphtha has molecules with 6 or fewer carbon atoms
▪ When reformed → crack into butane (C4) and lower

molecular weight hydrocarbons
▪ are not useful as high-octane gasoline blending components.
▪ Molecules with six carbon atoms (C6) tend to form

aromatics
▪ undesirable due to the environmental regulations of a number
of countries limit the amount of aromatics (most
particularly benzene) in gasoline.
▪ We use naphtha as main petrochemical source because of the high Demand for:
▪ Ethylene (C=C)
▪ Propylene (CC=C)
▪ Butenes (CC=CC, C=CC=C)
▪ Steam Cracker is used for this
▪ More on Steam Cracker
▪ Aka Naphta Cracker
▪ Main Unit
▪ Hot & Cold Sections
▪ Produces lots of olefins

▪ Typical feed stocks are Naphtha & LPG.
▪ Chemical Processes exist to convert “heavier” components into more “useful”
materials
▪ CxHy + H2O + O2 → C2H4 + C2H6 + C2H2 + H2 + CO + CO2 + CH4 + C3H6 + C3H8 + C4H10 + C4H8+ C6H6 + C +
Heavy oils
▪ Reaction temperature is about 700 – 800°C (Vapor phase reaction).
▪ The reaction is pretty complex as we produce about 10 to 12 compounds in one go.
▪ A view of the steam cracking unit at Wilton in the north-east of
England. The products from steam cracking include a mixture of
C1 - C4 hydrocarbons and are separated by fractional distillation.
Some of the columns are:
▪ 1 A debutaniser which separates the C4 hydrocarbons from the C1

- C3 hydrocarbons
▪ 2 A depropaniser which separates out the C3 hydrocarbons
▪ 3 A deethaniser which separates out the C2 hydrocarbons
▪ 4 A demethaniser which separates out the methane
▪ 5 A C3 splitter which separates propene from propane
▪ 6 A C2 splitter which separates ethene from ethane
▪ Pyrolisis Furnace
▪ Quencher
▪ Scrubber
▪ Drying
▪ Compression
▪ Cooling
▪ Demethanizer
▪ Deethanizer
▪ Depropanizer
▪ Debutanizer
▪ HOT Section
▪ COLD Section
▪ Naphtha/LPG saturates is mixed with
superheated steam
▪ They are fed to a furnace fuel gas
▪ Fuel oil as fuels to generate heat.
▪ The superheated steam is generated from
the furnace itself using heat recovery
boiler concept.
▪ The C2-C4 saturates (recycled) are fed to
a separate furnace fed with fuel gas +
fuel oil as fuels to generate heat.
▪ In the furnace, apart from the steam
cracking, steam is also generated.
▪ After pyrolysis reaction, the products
from the furnace are sent to another
heat recovery steam boiler to cool the
product streams (from about 700 –
800°C) and generate steam from water.
▪ After this operation, the product vapours
enter a scrubber that is fed with gas oil
as absorbent.
▪ The gas oil removes solids and heavy
hydrocarbons.
▪ Separate set of waste heat recovery
boiler and scrubbers are used for the
LPG furnace and Naphtha steam cracking
furnaces.
▪ After scrubbing, both product gases from
the scrubbers are mixed and fed to a
compressor.
▪ The compressor increases the system
pressure to 35 atms.
▪ The compressed vapour is fed to a phase
separation that separates the feed into
two stream namely:
▪ vapour phase stream (C1-C3)
▪ liquid phase stream (C3-C4+)
▪ The vapour phase stream consists of H2,

CO, CO2 C1-C3+ components in excess.
▪ The liquid phase stream consists of
C3 and C4 compounds in excess.
▪ Subsequently, the vapour phase and
liquid phase streams are subjected to
separate processing.
▪ CO2 in the vapour phase stream is
removed using NaOH scrubber.
▪ Subsequently gas is dried to consist of
only H2, CO, C1-C3 components only.
▪ This stream is then sent to a
demethanizer:
▪ separates tail gas (CO + H2 + CH4)
▪ From a mixture of C1-C3components.
▪ The C2-C3 + components enter a
dethanizer:
▪ separates C2 from C3 components.
▪ Here C2 components refer to all kinds of

C2
▪ Ethane (C2H6)
▪ Ethylene (C2H4)
▪ Acetylene (C2H2)
▪ Similarly, C3:
▪ Propylene (C3H6)
▪ Propane (C3H8)
▪ The C2 components then enter a
C2 splitter:
▪ Separates ethane (C2H6)
▪ From ethylene and acetylene (C2H4, C2H2)
▪ Ethanes are recycled to the furnace
▪ The ethylene and acetylene (C2H4,
C2H6) gas mixture is fed to absorption
unit
▪ It is fed with an extracting solvent
▪ Typical solvent: N-methylpyrrolidinone
▪ Acetylene is extracted
▪ The extractant then goes to a stripper
that generates acetylene (C2H2) by
stripping.
▪ The regenerated solvent is fed back to
the absorber.
▪ The ethylene (C2H4) stream is fed to a
topping and tailing still to obtain high
purity ethylene
▪ A mixture of ethylene and acetylene are
obtained as top and bottom products.
▪ The mixture of ethylene and acetylene
(C2H4+C2H6) is sent back to the
C2 splitter unit
▪ Its composition matches to that of the
C2splitter feed.
▪ The liquid stream consists of:
▪ C3,C4, aromatics and other heavy oil
components
▪ These is fed to a NaOH scrubber to
remove CO2
▪ Eventually it is fed to a pre-fractionator.
▪ The pre-fractionator separates:
▪ lighter components from the heavy
components.
▪ C1-C3
▪ C3-C4
▪ The lighter components are mixed with
the vapour phase stream
▪ The stream is now sent to the NaOH
vapour phase scrubber unit.
▪ The pre-fractionator bottom product is
mixed with the deethanizer bottom
product.
▪ Eventually the liquid mixture enters a
debutanizer which separates
▪ C3, C4 components
▪ from aromatics and fuel oil mixture.
▪ The bottom product eventually enters a
distillation tower that separates aromatics
and fuel oil as top and bottom products
respectively.
▪ The top product then enters a
depropanizer that separates
▪ C3s from C4 components.
▪ The C3 components enter a C3 splitter
that separates:
▪ from propane + butane (C3H8, C4H10)
mixture.
▪ The saturates mixture is recycled to the
saturates cracking furnace as a feed
stream.
▪ The C4 components then enter an
extractive distillation unit that
separates:
▪ butane + butylenes
▪ from butadiene.
▪ The extractive distillation unit consists of

a distillation column coupled to a solvent
stripper.
▪ The solvent stripper produces butadiene
and pure solvent which is sent to the
distillation column.
▪ Feedstock:
▪ Naphtha
▪ Steam
▪ Products
▪ Light gases (Hydrogen, CO, CO2)
▪ Hydrocarbons (CH4, C2H6, C3H8, C4H8)*
▪ Ethylene (C2H4)
▪ Acetylene (C2H2)
▪ Butylene (C4H8)
▪ Butadiene (C4H6)
www.ChemicalEngineeringGuy.com Recycled: C2H6, C3H8, C4H8)

▪ It consists of:
▪ convection zone
▪ radiant zone.
▪ In the convection zone:

▪ hydrocarbon feed stock is preheated and mixed with
steam and heated to high temperature.
▪ the rapid rise in temperature takes place and
pyrolysis reaction takes place.
▪ The addition of dilution steam enhances ethylene
yield and reduces the coking tendency in the
furnace coils.
▪ The production of the pyrolysis reaction consists
of a wide range of saturated and unsaturated
hydrocarbons.
▪ To avoid subsequent reaction the effluent are
fixed in their kinetic development by sudden
quench:
▪ first by indirect quench by water to 400 – 450 oC
in transfer line exchanger or quench boiler.
▪ This is a large heat exchanger that is a bundle
of metal tubes through which the gases pass
and around which is circulated water under
pressure.
▪ The hot water produced is used to generate
steam for use in the plant.
▪ In the next step the quench is done by heavy
product of pyrolysis.
▪ Convection Zone
▪ Feed stock is pyrolised and the effluent conditioned
▪ Radiation Zone
▪ The product formed are separated and purified
▪ Quench
▪ To avoid subsequent reaction the effluents are fixed in
their kinetics development by sudden quench.
▪ I Indirect - Indirect quench by water to 400-500 °C
generation of high pressure steam
▪ II Direct - Direct quench by heavy residue by-product of
pyrolysis
▪ Primary Fractionation Column
▪ Separation of light products of pyrolysis as top and
bottom as pyrolysis product
▪ Compression
▪ Compression of light products
▪ Caustic Scrubbing and Drying

▪ Scrubbing with caustic followed by molecular sieve
adsorption to remove sulphur compounds, mercaptan,
etc.
▪ After compression, caustic scrubbing and drying the
light effluents enter the cold section of the unit
which performs the separation of:
▪ (I) hydrogen to various concentration
▪ (ii) ethylene containing 99.4 percent
▪ (iii) 95 percent propylene
▪ (iv) A C4 cut containing 25-50 percent butadiene
▪ (v) pyrolysis gasoline which is rich in aromatic
hydrocarbons.
▪ The complexity of the separation section of a
cracker increases markedly as the feed changes from
ethane.
▪ Typical Cooling Scheme
▪ Note:
▪ Low temperatures
▪ Pressures
▪ Flows
▪ No. of Trays
▪ Demethaniser
▪ Methane condensed at top
▪ around – 100°C
▪ pressure 32Pa
▪ Deethaniser
▪ Separation of C2 cut (Ethane and ethylene)
▪ Acetylene eliminated
▪ selective hydrogenation Catalyst: Palladium
or Nickel 40-80°C, 3000 Pa
▪ Separation of Ethylene
▪ Ethylene is fractionated and unreacted
ethane recycled
▪ Depropaniser
▪ C3+ cut from bottom of deethaniser is
fractionated.
▪ C3 cut from top of depropaniser is selectively
hydrogenated to remove methyl acetylene and
propadience.
▪ Propylene content 95%.
▪ Separation in supplementary column for more
pure propylene.
▪ Removal of propane from propylene
▪ Separation in supplementary column for more
pure propylene
▪ Debutaniser
▪ Separation of C4 stream from C5+ stream
▪ Do the same for this diagram!
▪ Identify
▪ HOT/COLD Sections
▪ Demethanizer
▪ Deethanizer
▪ Depropanizer
▪ Feedstock/Products
▪ Cleaning of gases
17
1 19
▪ Do the same for this diagram! 10
▪ Identify
15
7
8
▪ HOT/COLD Sections
11
▪ Demethanizer
0
▪ Deethanizer 3
▪ Depropanizer
18
▪ Feedstock/Products
13
9
▪ Cleaning of gases
4 12
5
14
6
16
2
▪ Where are we?
C2
C3
C4
C6+
▪ Where are we?
▪ Feedstock Composition
▪ Furnace Run Length
▪ Pyrolysis temperature
▪ Residence Time
▪ Partial Pressure of Hydrocarbon
▪ Steam to Naphtha Ratio
▪ Severity and Selectivity Concept
▪ What is FCC?
▪ Recovery
▪ Off-Gases
▪ C3: Propylene
▪ C4-C5 Upgrade
▪ Gasolines
Prop Catalytic Cracking Thermal Cracking Steam Cracking
Formula C16H34 --> C8H16 + C8H8 C16H34 --> C8H16 + C8H8 C6H12 --> C3H6 + C3H8
Cracks Long Chains Long Chains Medium Chains
Length Medium Chains Medium Chains Small Chains
Temp Low Moderate High
Pressure Low High Moderate
Catlayst SiO2 (Silica) None None
Mechanism Heterolytic fisison, ionic carbocaiton
homolytic, intermediates
free radical homolytic, free radical
▪ FCC (Fluid Catalytic Cracking) has developed into a
major upgrading process in the petroleum refinery
industry for the conversion of:
▪ heavy fuel oil → more valuable products
▪ ranging from light olefins to naphtha and middle
distillate.
▪ Large amounts of:
▪ Ethylene
▪ C4 compounds
▪ C5 compounds
▪ Gasoline in FCC.
▪ Reactor
▪ Regenerator
▪ Main Column (Distillation)
▪ Increasing in demand of C4/5:
▪ upgrading of C4 and C5 is required
▪ Steam Crackers and Catalytic Cracker are important in
improving the economic performance of the above
processes.
▪ C4 & C5 streams are an important source of feedstock
for synthetic rubber and many chemicals
▪ It also provides a rich resource of reactive molecules,
which forms the backbone of the synthetic rubber
industry.
▪ FCC units are versatile and can be operated in
three main modes:
▪ middle distillate
▪ Gasoline
▪ olefins
▪ FCC is the second largest source of propylene

supplied for petrochemical application.
68,000 BPD
▪ Product distribution from FCC depends
▪ Reactor temp
▪ Feed preheat temperature
▪ Catalyst activity
▪ Catalyst circulation rate
▪ Recycle rate
▪ catalyst type
▪ catalyst to oil ratio
▪ rise of outlet temperature
▪ recycle of fractionators bottom.
▪ Watch this video → https://www.youtube.com/watch?v=u1tKTd3meUY
▪ FCC Graphic Animation
▪ Watch this video → https://www.youtube.com/watch?v=X5SitOqlm5M
▪ FCC Plant Setup
▪ Watch this video → https://www.youtube.com/watch?v=ezmAEWUag4E
▪ FCC Catalyst Animation
▪ Off-gases
▪ C3 → propylene
▪ C4/C5
▪ Propylene from FCC may be as high as 25% with
new FCC based propylene technologies.
▪ Increased production of olefins from FCC units has
been achieved through changes in:
▪ operations
▪ base cracking catalyst
▪ additive catalysts
▪ hardware designs
For Propylene → Check out its lecture!
▪ This is an overview…
▪ Check out C4-Group and C5-Group for more
specific data on petrochemicals
For C4/C5 → Check out C4 and C5 Groups
▪ C4 streams from Cracker and FCC
▪ Typical composition of
▪ C4 stream is given here:
For C4 → Check out C4-Group
▪ Typical C5 cuts from steam cracking
contains and FCC
For C5 → Check out C5-Group
▪ Several oxygenated fuel components have figured prominently in refinery
reformulated gasoline planning.
▪ Methyl tertiary butyl ether (MTBE)
▪ Tertiary amyl methyl ether (TAME)
▪ Ethyl tertiary butyl ether (ETBE).
▪ All oxygenated fuels reduce hydrocarbons in the automobile exhaust.

▪ MTBE was considered one of the most important oxygenates used in the production
of lead free gasoline and was used produced on a large scale throughout the world.
▪ There has been because of environmental problem.
▪ The oxygenated MTBE and ETBE are produced by the reaction of methanol/ethanol
and isobutylene.
www.ChemicalEngineeringGuy.com For C4/C5 → Check out C4 and C5 Groups

▪ Syngas:
▪ Hydrogen Gas
▪ Syngas (H2, CO, CO2)
▪ Ammonia, NH3
▪ N2
▪ NH3
▪ Urea, Nitric Acid, etc…
▪ Hydrogen gas is very versatile
▪ Fuel
▪ Hydrogenation
▪ Ammonia production
▪ Following methods:
▪ Treatment of gas mixture → manufacture of coke, olefins by steam cracking and catalytic
reforming
▪ Decomposition of hydrocarbons -→into carbon and hydrogen, from partial oxidation or
steam treatment
▪ Water decomposition → electrolysis, thermochemical cycles
▪ Most commonly:
▪ Partial Oxidation (heavy, non-valuable hydrocarbons)
▪ Raw Materials:
▪ Oxygen / Air
▪ Fuel oil
▪ Product Gases
▪ ‘Synthesis gas’ is commonly used to describe two basic gas mixtures:
▪ synthesis gas containing CO, hydrogen (CO+H2)
▪ synthesis gas containing hydrogen and nitrogen for the production of ammonia (N2+H2)
▪ Methane and synthesis gas are important petrochemical feedstock for manufacture
of a large number of chemicals
▪ which are used directly or as intermediates
▪ Many of these products are number of which

are finding use in:
▪ Plastic
▪ synthetic fiber
▪ Rubber
▪ pharmaceutical and other industries.
▪ Petrochemical derivatives based on synthesis gas
and carbon monoxide have experienced steady
growth due to large scale utilization of methanol
▪ It is an excellent basis for the synthesis of some
valuable petrochemicals such as
▪ ammonia, methyl alcohol, formic acid, acetic acid,
formaldehyde, phosgene and others.
▪ Recent market studies show that there will be a
dramatic increase in demand of CO and syngas
derivatives.
▪ Methanol is the largest consumer of
synthesis gas.
▪ The reformed gas is to meet certain
requirements with regard to its
composition.
▪ It is characterized by the stoichiometric
conversion factor, which differs from case
to case
▪ Various raw materials for synthesis gas production
are:
▪ natural gas, refinery gases, naphtha, fuel
oil/residual heavy hydrocarbons and coal.
▪ Although coal was earlier used for production of
synthesis gas, it has now been replaced by
petroleum fractions and natural gas.
▪ Petrocoke is the emerging source for Synthesis
gas.
▪ Coal is again getting importance alone are with
combination of petroleum coke.
▪ SYNGAS production technologies:
▪ steam methane reforming
▪ naphtha reforming
▪ auto-thermal reforming
▪ oxygen secondary reforming
▪ partial oxidation of heavy
hydrocarbons, petroleum coke and
coal.
▪ Various steps involved in synthesis gas production through steam reforming are:
▪ Desulphurization of gas
▪ Steam reforming and compression
▪ Separation of CO2
▪ Various available synthesis gas generation schemes are:

▪ Conventional steam reforming
▪ Partial oxidation
▪ Combined reforming
▪ Parallel reforming
▪ Gas heated reforming
▪ Partial oxidation:
▪ O2, N2, H2, CO, CO2, H2S
▪ The basis for the manufacture of synthesis gas at
the beginning of the nineteenth century was:
▪ The interaction of coal with water vapor at high
temperatures
▪ C + H O → CO + H
2 2
▪ Another method to prepare synthesis gas from
natural gas is called the partial oxidation of
methane as follows (Steam Reforming)
▪ CH 4 + H 2O → CO + 3H 2
▪ This method is called steam reforming in which

▪ Nickel is used as a catalyst
▪ Temperatures ranging from 800 to 850°C
▪ Pressure ranging between 25 and 40 atmospheres
▪ Another method to prepare synthesis gas from natural gas
is called the partial oxidation of methane as follows:
▪ CH 4 + 1
2 O2 → CO + 2 H 2
▪ At temperatures of more than 1500°C
▪ Pressure range between 130 and 140 atmospheres.
▪ A) Naphtha has to be gasified before reaction, which means
additional equipment, energy and financial costs.
▪ B) The sulfur content in naphtha is high and its removal is
more difficult than the removal of hydrogen sulfide in natural
gas
▪ for example, naphtha has to be treated carefully and costly to
remove sulfur before use.
▪ C) A larger quantity of carbon dioxide is formed when using
naphtha, and disposal costs are greater:
▪
▪ Naptha ( CH 2.1 ) + 2 H 2O → CO2 + 3.05H 2
CH 4 + H 2O → CO + 3H 2
▪ Nitrogen gas is found at 79% in air
▪ Typically , it will be distilled via cryogenics
▪ Nitrogen is an inert gas
▪ Nitrogen is used for “nitogenation” of materials

▪ Ammonia is one of the main products
▪ Nitric acid is produced from Ammonia
▪ Ammonia is a light gas
▪ Polar
▪ MM = 17 g/mol
▪ Several ways to synthetize
▪ Applications:
▪ manufacture of nitrogen fertilizers
▪ Preparation of a large number of intermediates
and final petrochemicals.
▪ The production of ammonia ranged:
▪ between 600-800 metric tons per day
▪ Nitrogen required for the production of
ammonia is drawn from the air:
▪ N2+3H2 → 2NH3
▪ The resulting ammonia is condensed by cooling

at -33°C.
▪ The manufacturing companies retain secrets of
the catalysts used that make the efficient
conversion possible in the production of
ammonia and steam reforming.
▪ Steps:
▪ Air distillation
▪ Partial Oxidation of hydrocarbons
▪ Removal of carbon & Recovery of heat
▪ Removal of H2S
▪ Catalytic conversion of CO
▪ CO2 removal
▪ CO removal by liquid nitrogen
▪ N2+H2 mix will be the final product
▪ Partial Oxidation
▪ Partial Oxidation
▪ Two processes
▪ A → via oxidation
▪ Raw material:
▪ Fuel Oil
▪ Steam
▪ Air
▪ Byproducts
▪ Ash/soot
▪ H2S/Sulfur
▪ CO2
▪ B → via reforming
▪ Two processes
▪ Raw material:
▪ Fuel Oil
▪ Steam
▪ Air
▪ Byproducts
▪ Ash/soot
▪ H2S/Sulfur
▪ CO2
▪ Two processes
▪ Raw Materials:
▪ Natural Gas/Naphthta
▪ Steam
▪ Air
▪ Byproducts
▪ CO2

Petrochemicals An Overview (STUDENT) (1of3)

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Chemical Engineering Guy

▪ Raw Material → Crude oil (Naphtha) & Gas

Petroleum ether is the petroleum fraction consisting of aliphatic

For full list, download

▪ B) Check out the refineries in your country/location

▪ Naphtha → Reforming → BTX

▪ Natural Gas → Ethane, Propane → Cracking → Ethylene,

▪ LPG → Cracking, Propylene, Butylene

▪ Gas Oil → Cracker → Ethylene, Propylene

▪ When reformed → crack into butane (C4) and lower

▪ Molecules with six carbon atoms (C6) tend to form

▪ Steam Cracker is used for this

▪ Produces lots of olefins

▪ The reaction is pretty complex as we produce about 10 to 12 compounds in one go.

▪ 1 A debutaniser which separates the C4 hydrocarbons from the C1

▪ 2 A depropaniser which separates out the C3 hydrocarbons

▪ 3 A deethaniser which separates out the C2 hydrocarbons

▪ 4 A demethaniser which separates out the methane

▪ 5 A C3 splitter which separates propene from propane

▪ 6 A C2 splitter which separates ethene from ethane

▪ The vapour phase stream consists of H2,

▪ Here C2 components refer to all kinds of

▪ Ethanes are recycled to the furnace

▪ The extractive distillation unit consists of

www.ChemicalEngineeringGuy.com Recycled: C2H6, C3H8, C4H8)

▪ In the convection zone:

▪ Caustic Scrubbing and Drying

▪ FCC is the second largest source of propylene

For Propylene → Check out its lecture!

For C4/C5 → Check out C4 and C5 Groups

For C4 → Check out C4-Group

For C5 → Check out C5-Group

▪ All oxygenated fuels reduce hydrocarbons in the automobile exhaust.

www.ChemicalEngineeringGuy.com For C4/C5 → Check out C4 and C5 Groups

▪ Many of these products are number of which

▪ Various available synthesis gas generation schemes are:

▪ This method is called steam reforming in which

▪ Nitrogen is used for “nitogenation” of materials

▪ The resulting ammonia is condensed by cooling

▪ N2+H2 mix will be the final product

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