The general ways of improvement the primary petroleum refining rigs have been described in this article. It has been proposed to consider the operational control of primary petroleum refining processes as the most perspective branch of petroleum industry due to its comparatively cheap implementation. Operational control has a significant influence on the safe operation of equipment, products quality and amount of harmful emissions. Electrical conductivity and relative permittivity have been defined as the specific parameters for effective operational control.Primary oil refining rigs are the most important part of any petroleum refinery. Despite the Nelson complexity index which is only 1,0 for refineries it should be considered that they have a strong impact on the secondary refining rigs. That’s why one of the most important task in the petroleum refining industry worldwide is improvement of primary oil refining rigs

Grigorov, Andrey

Ovsiannikova, Tatiana

Sater, Nabil Abdul

Sytnik, Alexey

Tulskaya, Alena

English

Electronic National Technical University &quot;Kharkiv Polytechnic Institute&quot; Institutional Repository (eNTUKhPIIR)

Petroleum and Coal                           Pet Coal (2019); 61(2) 390-394 ISSN 1337-7027 an open access journal Article                                                                Open Access   WAYS OF IMPROVING THE EQUIPMENT FOR PRIMARY PETROLEUM REFINING  Nabil Abdul Sater1, Andrey Grigorov1, Alena Tulskaya1*, Tatiana Ovsiannikova1, Alexey Sytnik2  1 National Technical university “Kharkiv Polytechnic Institute”, Kharkiv, Ukraine  2 Ukrainian State Coal-Chemistry Institute, Kharkiv, Ukraine  Received January 7, 2019; Accepted March 19, 2019   Abstract The general ways of improvement the primary petroleum refining rigs have been described in this article. It has been proposed to consider the operational control of primary petroleum refining processes as the most perspective branch of petroleum industry due to its comparatively cheap implementation. Operational control has a significant influence on the safe operation of equipment, products quality and amount of harmful emissions. Electrical conductivity and relative permittivity have been defined as the specific parameters for effective operational control.Primary oil refining rigs are the most important part of any petroleum refinery. Despite the Nelson complexity index which is only  1,0 for refineries it should be considered that they have a strong impact on the secondary refining rigs. That’s why one of the most important task in the petroleum refining industry worldwide is improvement of primary oil refining rigs. Keywords: primary petroleum refining processes; relative permittivity; electrical conductivity; control parameter; level of separation; fraction; emulsion; salts.  1. Introduction  Primary petroleum refining equipment, as a rule, include the following technological parts: raw material treatment (removing of salts, water and mechanical admixtures), gasoline frac-tion separation, distillation, vacuum treatment of fuel oil. All these parts are in strong connec-tion. So improvement of one or several parts affect the general equipment efficiency.   Fig.1. Structural model of improvement the pri-mary petroleum refining process  One of the most significant criterion of ef-ficiency for primary petroleum refining rigs evaluation is depth of separation of light fractions and refining of heavy fractions. Ac-cording to [1] fuel oil vapor contains about 5 % of diesel hydrocarbons and tar contains about 10 % of vacuum distillate fraction [2]. Very important performance measure of equipment is durability which is caused by corrosion protection and harmful emission decrease.  General directions of improvement the primary petroleum refining equipment, that can provide its long durability and decrease of harmful emissions, may be performed in Fig. 1. Each of these directions will be ob-served in details below.    Ways of improvement of primary petroleum refining rigs  Chemical reactants Equipment design change New construction materials Technological parameters adjustment Preliminary raw material treatment Operative process control Destruction of emulsion, corrosion protection, Intensification of process  Increase of fractions yield, Accident prevention,  Emission decrease Heat losses decrease, Corrosion protection, Eqiupment sealing Fractions separation, Decrease of capital costs   390Petroleum and Coal                          Pet Coal (2019); 61(2): 390-394 ISSN 1337-7027 an open access journal 2. Results and discussion Addition of various chemical demulsifiers is widely used in petroleum refining industry and mainly at electro desalting and electro dehydrating rigs. The following demulsifiers are most popular in Ukraine and Russia: - Dissolvan 4411 and Separol 25 (Germany); - NALCO EC, Basorol E2032 and L-1632 (USA); - R-11 and Х-2647 (Japan); - Servo 5348 (Holland);  - Kemelix 3448x (Great Britain) But search of the most effective and comparably cheap demulsifiers has not been finished yet. The examples of researches devoted to the current problem ale presented below.  For dehydration of crude oil from Basra, Iraq there have been applied demulsifiers based on industrial foundry oil. There has been compared the efficiency of two types of demulsifies: industrial RP/6000 and ammonium sulphonate from castor oil. The best results for the sepa-ration of emulsion (15 % of water, 3 % of NaCl) were obtained at the highest pH rate and highest concentration of ACS demulsifier [3]. Authors of [4] have described the research devoted to the application of different water-soluble and low-soluble demulsifiers for oil and water separation. Etoxylate of fatty alcohol, triethanolamine have been considered as the most effective from the water-soluble group and Basorol E2032, Basorol PDB 9935 and TOMAC from low-soluble group. It has been found out that increase of demulsifier concentration, salt content and tempe-rature up to 350 K encourages the separation degree at pH 5-9.  It has been also found out that the most effective composition that provides almost 90 % separation of oil and water, consists of triethanolamine – 16%, etoxylate of fatty alcohol – 20%, Basorol E2032 – 6 %, Basorol PDB 9935 – 8 %, TOMAC – 12 % and aromatic dissolvent – 39 %. Besides this new composition was more effective than industrial demulsifiers (VZB 1413 provides 65 % separation and VZB 1414 – 72 % separation). Moreover, addition of light hydrocarbon dissolvent encourages the destruction of oil-water emulsion and reduces the vis-cosity [5]. Authors of [6] proposed the new composition of demulsifiers that contain 25 – 48 % of surfactant “Sinterol” («Синтерол»), 3-8 % of modifying additives and dissolvent (methanol – aldehyde fraction). Level of oil dehydration with the proposed demulsifier can be raised up to 96 %. To protect the industrial equipment from corrosion destruction there has been pro-posed to add the following chemical reactants: amides, aliphatic amines and, in particular, nitrogen-containing inhibitor – polyhexamethylenguanidine – hydrate (5 – 20 g per 1 ton of raw material). Current inhibitor provides the 95-98 % protection [9]. To prevent the corrosion of equipment at oil and gas fields, pipelines and refining systems there should be applied an inhibitor of metal corrosion that contains 70 – 99,9 % of synthetic oil (as a by-product of benzene hydration and further oxidation of cyclohexane by air and dehydration of cyclohexanol) and 0,1 -30 % of carbamide [10].  Chemical reactants are widely used for preparation of crude oil and gas condensate for transporting. Authors of [11] recommend to perform the preparation of sulfur-containing crude oil through its low-pressure separation or in additional separation column at 300 – 350 K and 0.1 – 0.5 MPa. The aim of proposed method is to reduce the acidity and corrosion activity of crude oil. In [12] there has been described numerous compounds that may be applied as the corrosion inhibitors for steel in acidic solutions. It has been shown that acetylene alcohol is the most active component for corrosion protection.  Design change for refining equipment is one of the most complicated direction for improve-ment the primary petroleum refining rigs which demands considerable investments. At the same time, there are two determining factors of effective separation of petroleum fractions – design of contact devices and constant temperature gradient in distillation column. Bubble-cap trays and valve collars are the most widely used devices in atmospheric distillation col-umns [13]. Replacement of bubble-cap trays with ejection trays provides the increase of tray efficiency up to 20 % [20]. Replacement of grooved tray with ejection valve trays encourages 391Petroleum and Coal                          Pet Coal (2019); 61(2): 390-394 ISSN 1337-7027 an open access journal the decrease of distillate fractions content in fuel oil by 7 % in average [15]. According to [16] the regular structured nozzles by “Sulzer” are the most effective comparing to tray contact devices. Replacement of trays with stationary valves with regular structured nozzle “Sulzer” provides the increase of equipment productivity and decrease the content of C7 –hydrocarbons in low-boiling fraction 350 K down to 0.43 %. In [17] authors describe the varying of sections diameter in packed columns. This approach allows to decrease energy costs for separation in distillate columns.  Methods of pretreatment of raw material aim the increase the yieldt of light fractions, en-courages the destruction of oil-water emulsions and can be implemented for the preparation of oil before the electrodesalter and electrodehydrator. In [18] there have been presented the results of activation of viscous crude oil by rotary pulsating apparatus by waves from infra-sound to ultrasound. As a result – the content of gasoline fraction raised up to 10 % comparing to unprocessed crude oil.  In [19] there has been described a research devoted to desalting and dehydration of crude oil with pretreatment in electromagnetic field at 0,1375 Tl and linear flow speed 1 m/s which has shown the increase of dehydration level by 5-30 % and 2 times decrease of emulsifier consumption comparing to traditional technologies.  Implementation of technological refining of crude oil includes the exploitation of equipment under extremely hard conditions, i.e. wide temperature and pressure rate, corrosion destruc-tion etc. Thus, construction materials of pipes, heaters, coils, valves and pumps play the cru-cial role. There are widely used different types of steel that contain Сr, Mo, Mn, Si, Ti, Ni etc. These components improve strength and hardenability and corrosion resistance of steel. Now-adays the most popular types of steel are produced by JFE Steel Company [21]. Also there are widely used metal and non-metal matrices with the specific location of hardeners. One of the most promising construction sealants in petroleum refining industry is expanded graphite [22]. Due to its high adsorption capacity expanded graphite can be applied for removing of fuel oil, heavy metals and other organic substances from water. The main benefit of expanded graphite is its self-regeneration. 1 gram of expanded graphite can adsorb up to 80 grams of organic substances [23]. Carbon materials can be applied for production of complicated high-temper-ature heaters including flexible pipes, high-temperature heat shields etc. [24] Technological parameters of primary oil refining such as temperature, pressure and infinite reflux can be considered as the powerful tools to improve the production efficiency [25].  Each type of raw material, that is supposed to be processed at refinery, has a considerable level of technological parameters. For example, boiling point is the crucial factor for construction ma-terials choose. Heat balance of equipment depends on the temperature of raw materials and refining products. Pressure has the huge influence on boiling point of liquids and on separation of liquid and gas fractions in separators. Infinite reflux is an important factor that defines temperature range of column. Also temperature and pressure have an influence on construc-tion materials, design of refining equipment and environmental safety.  Operational control of refining processes is the developing branch of petroleum industry. Nowadays the operational control at most of the refineries in Ukraine and Russia is based on laboratory analysis of samples, taken from the definite key points of rig. In this case there should be defined around 3-5 quality parameters which are supposed to be defined as soon as possible. Ideally there should be a specific integral parameter to characterize the compo-sition and structure of raw material and products. Specific conductivity (δ) and relative per-mittivity (ε) have been proposed as the specific integral parameter [26-27]. Choose of param-eter should be based on origin of analyzed material. Thus, primary oil refining field can be divided into two areas (Fig. 2). Preparation area includes the separation of water, salts and mechanical admixtures from crude oil. Refining area includes stabilization of oil and fractional separation in distillate column.  392Petroleum and Coal                          Pet Coal (2019); 61(2): 390-394 ISSN 1337-7027 an open access journal  Fig 2. Structural scheme of primary petroleum refining:  I – crude oil, II – fresh water, III – waste water, IV – insufficiently prepared crude oil,  V – prepared oil,  VI – final product, VII – substandard product Considering the fact that crude oil and products of it refining are non-polar dielectrics, it is quietly reasonable to control these substances by permittivity ε. For this purposes on I, V and VI fields there have been located the sensors S(ε0), S(ε1), S(ε2) to measure this parameter. Also, parameter ε may be used for determination of water in prepared crude oil.  Since the increase of boiling point of petroleum fractions leads to increase of relative permittivity, sensor S (ε2) may be used to get the reliable information about the level of fractions separation.  Considering the electric conductivity it should mentioned that its value always depends on the amount of conductive components that are removed with water in preparation area (flow III). In this case salts and mechanical admixtures are conductive components that have been removed from crude oil. In the preparation area the proportion δ1>δ0 is always constant so to control the removal of salts and admixtures in II and III flow there have been set spec ial sensors S(δ0), S(δ1). Based on sensors S(ε1) and S(δ1) readings if the prepared oil is unfit for further refining and refining, it should be taken back to preparation area. Similarly, for refining area – if the high level of separation has not been reached, the products should be mixed with crude oil for repeated refining.  3. Conclusion  The general ways of improvement of primary petroleum refining rigs were presented. In our opinion, one of the most perspective directions is operative process control. T his system is based on primary diagnostic information received from sensors that have been set at the general material flows of the rigs. The operating principle of sensor is based on the measuring of electrical conductivity and relative permittivity in different areas. The presented scheme provides the realibility of equipment exploitation, reduces the harmful emission and minimize the time for correction of technological parameters. References [1] Akhmetov SA. Tehnologiya glubokoy pererabotki nefti i gaza, Moscow, 2002, 217 p.  [2] Kapitonova OV. Nalozhenie neftyanyih fraktsiy pri razdelenii mazuta pod vakuumom. Vestnik tehnologicheskogo universiteta. 2015. Vol.18, №20: 88-90. [3] Ali HAAR. Preparation and evaluation of demulsifiers agents for Basra crude oil. 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To whom correspondence should be addressed: Professor Alena Tulskaya, National Technical University “Kharkiv Polytechnic Institute”, Kharkiv, Ukraine  394

Ways of improving the equipment for primary petroleum refining

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Ways of improving the equipment for primary petroleum refining

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Ways of improving the equipment for primary petroleum refining

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Electronic National Technical University &quot;Kharkiv Polytechnic Institute&quot; Institutional Repository (eNTUKhPIIR)

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