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Refinery

Refinery

Overview
A refinery is a production
Production, costs, and pricing
The following outline is provided as an overview of and topical guide to industrial organization:Industrial organization – describes the behavior of firms in the marketplace with regard to production, pricing, employment and other decisions...

 facility composed of a group of chemical engineering
Chemical engineering
Chemical engineering is the branch of engineering that deals with physical science , and life sciences with mathematics and economics, to the process of converting raw materials or chemicals into more useful or valuable forms...

 unit processes and unit operation
Unit operation
In chemical engineering and related fields, a unit operation is a basic step in a process.Unit operation involves bringing a physical change such as separation, crystallization, evaporation, filtration etc.. For example in milk processing, homogenization, pasteurization, chilling, and packaging are...

s refining
Refining
Refining is the process of purification of a substance or a form. The term is usually used of a natural resource that is almost in a usable form, but which is more useful in its pure form. For instance, most types of natural petroleum will burn straight from the ground, but it will burn poorly...

 certain materials or converting raw material into products of value.

Different types of refineries are as follows:
  • oil refinery
    Oil refinery
    An oil refinery or petroleum refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas...

    , which converts crude oil into high-octane
    Octane rating
    Octane rating or octane number is a standard measure of the anti-knock properties of a motor or aviation fuel. The higher the octane number, the more compression the fuel can withstand before detonating...

     motor fuel (gasoline
    Gasoline
    Gasoline , or petrol , is a toxic, translucent, petroleum-derived liquid that is primarily used as a fuel in internal combustion engines. It consists mostly of organic compounds obtained by the fractional distillation of petroleum, enhanced with a variety of additives. Some gasolines also contain...

    /petrol), diesel oil, liquefied petroleum gases (LPG), jet aircraft fuel, kerosene
    Kerosene
    Kerosene, sometimes spelled kerosine in scientific and industrial usage, also known as paraffin or paraffin oil in the United Kingdom, Hong Kong, Ireland and South Africa, is a combustible hydrocarbon liquid. The name is derived from Greek keros...

    , heating fuel oil
    Fuel oil
    Fuel oil is a fraction obtained from petroleum distillation, either as a distillate or a residue. Broadly speaking, fuel oil is any liquid petroleum product that is burned in a furnace or boiler for the generation of heat or used in an engine for the generation of power, except oils having a flash...

    s, lubricating oils, asphalt
    Asphalt
    Asphalt or , also known as bitumen, is a sticky, black and highly viscous liquid or semi-solid that is present in most crude petroleums and in some natural deposits, it is a substance classed as a pitch...

     and petroleum coke
    Petroleum coke
    Petroleum coke is a carbonaceous solid derived from oil refinery coker units or other cracking processes. Other coke has traditionally been derived from coal....

    ;
  • sugar refinery
    Sugarcane
    Sugarcane refers to any of six to 37 species of tall perennial grasses of the genus Saccharum . Native to the warm temperate to tropical regions of South Asia, they have stout, jointed, fibrous stalks that are rich in sugar, and measure two to six metres tall...

    , which converts sugar
    Sugar
    Sugar is a class of edible crystalline carbohydrates, mainly sucrose, lactose, and fructose, characterized by a sweet flavor.Sucrose in its refined form primarily comes from sugar cane and sugar beet...

     cane and sugar beets into crystallized sugar and sugar syrups;
  • natural gas processing
    Natural gas processing
    Natural-gas processing is a complex industrial process designed to clean raw natural gas by separating impurities and various non-methane hydrocarbons and fluids to produce what is known as pipeline quality dry natural gas.-Background:...

     plant, which purifies and converts raw natural gas into residential, commercial and industrial fuel gas, and also recovers natural gas liquids (NGL) such as ethane
    Ethane
    Ethane is a chemical compound with chemical formula C2H6. It is the only two-carbon alkane that is an aliphatic hydrocarbon. At standard temperature and pressure, ethane is a colorless, odorless gas....

    , propane
    Propane
    Propane is a three-carbon alkane with the molecular formula , normally a gas, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used as a fuel for engines, oxy-gas torches, barbecues, portable stoves, and residential central...

    , butane
    Butane
    Butane is a gas with the formula C4H10 that is an alkane with four carbon atoms. The term may refer to any of two structural isomers, or to a mixture of them: in the IUPAC nomenclature, however, butane refers only to the unbranched n-butane isomer; the other one being called "methylpropane" or...

    s and pentane
    Pentane
    Pentane is an organic compound with the formula C5H12 — that is, an alkane with five carbon atoms. The term may refer to any of three structural isomers, or to a mixture of them: in the IUPAC nomenclature, however, pentane means exclusively the n-pentane isomer; the other two being called...

    s;
  • salt refinery, which cleans common salt (NaCl
    Sodium chloride
    Sodium chloride, also known as salt, common salt, table salt or halite, is an inorganic compound with the formula NaCl. Sodium chloride is the salt most responsible for the salinity of the ocean and of the extracellular fluid of many multicellular organisms...

    ), produced by the solar evaporation of sea water, followed by washing and re-crystallization
    Crystallization
    Crystallization is the process of formation of solid crystals precipitating from a solution, melt or more rarely deposited directly from a gas. Crystallization is also a chemical solid–liquid separation technique, in which mass transfer of a solute from the liquid solution to a pure solid...

    ;
  • metal refineries refining metals such as alumina, copper
    Copper
    Copper is a chemical element with the symbol Cu and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is soft and malleable; an exposed surface has a reddish-orange tarnish...

    , gold
    Gold
    Gold is a chemical element with the symbol Au and an atomic number of 79. Gold is a dense, soft, shiny, malleable and ductile metal. Pure gold has a bright yellow color and luster traditionally considered attractive, which it maintains without oxidizing in air or water. Chemically, gold is a...

    , lead
    Lead
    Lead is a main-group element in the carbon group with the symbol Pb and atomic number 82. Lead is a soft, malleable poor metal. It is also counted as one of the heavy metals. Metallic lead has a bluish-white color after being freshly cut, but it soon tarnishes to a dull grayish color when exposed...

    , nickel
    Nickel
    Nickel is a chemical element with the chemical symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel belongs to the transition metals and is hard and ductile...

    , silver
    Silver
    Silver is a metallic chemical element with the chemical symbol Ag and atomic number 47. A soft, white, lustrous transition metal, it has the highest electrical conductivity of any element and the highest thermal conductivity of any metal...

    , uranium
    Uranium
    Uranium is a silvery-white metallic chemical element in the actinide series of the periodic table, with atomic number 92. It is assigned the chemical symbol U. A uranium atom has 92 protons and 92 electrons, of which 6 are valence electrons...

    , and zinc
    Zinc
    Zinc , or spelter , is a metallic chemical element; it has the symbol Zn and atomic number 30. It is the first element in group 12 of the periodic table. Zinc is, in some respects, chemically similar to magnesium, because its ion is of similar size and its only common oxidation state is +2...

    ;
  • vegetable oil refinery



The image below is a schematic flow diagram
Process Flow diagram
A process flow diagram is a diagram commonly used in engineering to indicate the general flow of plant processes and equipment.The PFD displays the relationship between major equipment of a plant facility and does not show minor details such as piping details and designations...

 of a typical oil refinery depicting various unit processes and the flow of intermediate products between the inlet crude oil feedstock and the final products.
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Encyclopedia
A refinery is a production
Production, costs, and pricing
The following outline is provided as an overview of and topical guide to industrial organization:Industrial organization – describes the behavior of firms in the marketplace with regard to production, pricing, employment and other decisions...

 facility composed of a group of chemical engineering
Chemical engineering
Chemical engineering is the branch of engineering that deals with physical science , and life sciences with mathematics and economics, to the process of converting raw materials or chemicals into more useful or valuable forms...

 unit processes and unit operation
Unit operation
In chemical engineering and related fields, a unit operation is a basic step in a process.Unit operation involves bringing a physical change such as separation, crystallization, evaporation, filtration etc.. For example in milk processing, homogenization, pasteurization, chilling, and packaging are...

s refining
Refining
Refining is the process of purification of a substance or a form. The term is usually used of a natural resource that is almost in a usable form, but which is more useful in its pure form. For instance, most types of natural petroleum will burn straight from the ground, but it will burn poorly...

 certain materials or converting raw material into products of value.

Types of refineries


Different types of refineries are as follows:
  • oil refinery
    Oil refinery
    An oil refinery or petroleum refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas...

    , which converts crude oil into high-octane
    Octane rating
    Octane rating or octane number is a standard measure of the anti-knock properties of a motor or aviation fuel. The higher the octane number, the more compression the fuel can withstand before detonating...

     motor fuel (gasoline
    Gasoline
    Gasoline , or petrol , is a toxic, translucent, petroleum-derived liquid that is primarily used as a fuel in internal combustion engines. It consists mostly of organic compounds obtained by the fractional distillation of petroleum, enhanced with a variety of additives. Some gasolines also contain...

    /petrol), diesel oil, liquefied petroleum gases (LPG), jet aircraft fuel, kerosene
    Kerosene
    Kerosene, sometimes spelled kerosine in scientific and industrial usage, also known as paraffin or paraffin oil in the United Kingdom, Hong Kong, Ireland and South Africa, is a combustible hydrocarbon liquid. The name is derived from Greek keros...

    , heating fuel oil
    Fuel oil
    Fuel oil is a fraction obtained from petroleum distillation, either as a distillate or a residue. Broadly speaking, fuel oil is any liquid petroleum product that is burned in a furnace or boiler for the generation of heat or used in an engine for the generation of power, except oils having a flash...

    s, lubricating oils, asphalt
    Asphalt
    Asphalt or , also known as bitumen, is a sticky, black and highly viscous liquid or semi-solid that is present in most crude petroleums and in some natural deposits, it is a substance classed as a pitch...

     and petroleum coke
    Petroleum coke
    Petroleum coke is a carbonaceous solid derived from oil refinery coker units or other cracking processes. Other coke has traditionally been derived from coal....

    ;
  • sugar refinery
    Sugarcane
    Sugarcane refers to any of six to 37 species of tall perennial grasses of the genus Saccharum . Native to the warm temperate to tropical regions of South Asia, they have stout, jointed, fibrous stalks that are rich in sugar, and measure two to six metres tall...

    , which converts sugar
    Sugar
    Sugar is a class of edible crystalline carbohydrates, mainly sucrose, lactose, and fructose, characterized by a sweet flavor.Sucrose in its refined form primarily comes from sugar cane and sugar beet...

     cane and sugar beets into crystallized sugar and sugar syrups;
  • natural gas processing
    Natural gas processing
    Natural-gas processing is a complex industrial process designed to clean raw natural gas by separating impurities and various non-methane hydrocarbons and fluids to produce what is known as pipeline quality dry natural gas.-Background:...

     plant, which purifies and converts raw natural gas into residential, commercial and industrial fuel gas, and also recovers natural gas liquids (NGL) such as ethane
    Ethane
    Ethane is a chemical compound with chemical formula C2H6. It is the only two-carbon alkane that is an aliphatic hydrocarbon. At standard temperature and pressure, ethane is a colorless, odorless gas....

    , propane
    Propane
    Propane is a three-carbon alkane with the molecular formula , normally a gas, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used as a fuel for engines, oxy-gas torches, barbecues, portable stoves, and residential central...

    , butane
    Butane
    Butane is a gas with the formula C4H10 that is an alkane with four carbon atoms. The term may refer to any of two structural isomers, or to a mixture of them: in the IUPAC nomenclature, however, butane refers only to the unbranched n-butane isomer; the other one being called "methylpropane" or...

    s and pentane
    Pentane
    Pentane is an organic compound with the formula C5H12 — that is, an alkane with five carbon atoms. The term may refer to any of three structural isomers, or to a mixture of them: in the IUPAC nomenclature, however, pentane means exclusively the n-pentane isomer; the other two being called...

    s;
  • salt refinery, which cleans common salt (NaCl
    Sodium chloride
    Sodium chloride, also known as salt, common salt, table salt or halite, is an inorganic compound with the formula NaCl. Sodium chloride is the salt most responsible for the salinity of the ocean and of the extracellular fluid of many multicellular organisms...

    ), produced by the solar evaporation of sea water, followed by washing and re-crystallization
    Crystallization
    Crystallization is the process of formation of solid crystals precipitating from a solution, melt or more rarely deposited directly from a gas. Crystallization is also a chemical solid–liquid separation technique, in which mass transfer of a solute from the liquid solution to a pure solid...

    ;
  • metal refineries refining metals such as alumina, copper
    Copper
    Copper is a chemical element with the symbol Cu and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is soft and malleable; an exposed surface has a reddish-orange tarnish...

    , gold
    Gold
    Gold is a chemical element with the symbol Au and an atomic number of 79. Gold is a dense, soft, shiny, malleable and ductile metal. Pure gold has a bright yellow color and luster traditionally considered attractive, which it maintains without oxidizing in air or water. Chemically, gold is a...

    , lead
    Lead
    Lead is a main-group element in the carbon group with the symbol Pb and atomic number 82. Lead is a soft, malleable poor metal. It is also counted as one of the heavy metals. Metallic lead has a bluish-white color after being freshly cut, but it soon tarnishes to a dull grayish color when exposed...

    , nickel
    Nickel
    Nickel is a chemical element with the chemical symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel belongs to the transition metals and is hard and ductile...

    , silver
    Silver
    Silver is a metallic chemical element with the chemical symbol Ag and atomic number 47. A soft, white, lustrous transition metal, it has the highest electrical conductivity of any element and the highest thermal conductivity of any metal...

    , uranium
    Uranium
    Uranium is a silvery-white metallic chemical element in the actinide series of the periodic table, with atomic number 92. It is assigned the chemical symbol U. A uranium atom has 92 protons and 92 electrons, of which 6 are valence electrons...

    , and zinc
    Zinc
    Zinc , or spelter , is a metallic chemical element; it has the symbol Zn and atomic number 30. It is the first element in group 12 of the periodic table. Zinc is, in some respects, chemically similar to magnesium, because its ion is of similar size and its only common oxidation state is +2...

    ;
  • vegetable oil refinery

A typical oil refinery



The image below is a schematic flow diagram
Process Flow diagram
A process flow diagram is a diagram commonly used in engineering to indicate the general flow of plant processes and equipment.The PFD displays the relationship between major equipment of a plant facility and does not show minor details such as piping details and designations...

 of a typical oil refinery depicting various unit processes and the flow of intermediate products between the inlet crude oil feedstock and the final products. The diagram depicts only one of the hundreds of different configurations. It does not include any of the usual facilities providing utilities such as steam, cooling water, and electric power as well as storage tanks for crude oil feedstock and for intermediate products and end products.


A typical natural gas processing plant



The image below is a schematic block flow diagram
Process Flow diagram
A process flow diagram is a diagram commonly used in engineering to indicate the general flow of plant processes and equipment.The PFD displays the relationship between major equipment of a plant facility and does not show minor details such as piping details and designations...

 of a typical natural gas processing plant. It shows various unit processes converting raw natural gas into gas pipelined to end users.

The block flow diagram also shows how processing of the raw natural gas yields byproduct sulfur, byproduct ethane, and natural gas liquids (NGL) propane, butanes and natural gasoline (denoted as pentanes +).

Sugar refining




Sugar is generally produced from sugarcane
Sugarcane
Sugarcane refers to any of six to 37 species of tall perennial grasses of the genus Saccharum . Native to the warm temperate to tropical regions of South Asia, they have stout, jointed, fibrous stalks that are rich in sugar, and measure two to six metres tall...

 or sugar beet
Sugar beet
Sugar beet, a cultivated plant of Beta vulgaris, is a plant whose tuber contains a high concentration of sucrose. It is grown commercially for sugar production. Sugar beets and other B...

s. However, the global production of sugar from sugarcane is at least twice the production from sugar beets. Therefore, this section focuses on sugar from sugarcane.

Milling


Sugarcane is traditionally refined into sugar in two stages. In the first stage, raw sugar is produced by the milling of freshly harvested sugarcane. In a sugar mill, sugarcane is washed, chopped, and shredded by revolving knives. The shredded cane is mixed with water and crushed. The juices (containing 10-15 percent sucrose
Sucrose
Sucrose is the organic compound commonly known as table sugar and sometimes called saccharose. A white, odorless, crystalline powder with a sweet taste, it is best known for its role in human nutrition. The molecule is a disaccharide composed of glucose and fructose with the molecular formula...

) are collected and mixed with lime
Lime (mineral)
Lime is a general term for calcium-containing inorganic materials, in which carbonates, oxides and hydroxides predominate. Strictly speaking, lime is calcium oxide or calcium hydroxide. It is also the name for a single mineral of the CaO composition, occurring very rarely...

 to adjust pH
PH
In chemistry, pH is a measure of the acidity or basicity of an aqueous solution. Pure water is said to be neutral, with a pH close to 7.0 at . Solutions with a pH less than 7 are said to be acidic and solutions with a pH greater than 7 are basic or alkaline...

 to 7, prevent decay into glucose
Glucose
Glucose is a simple sugar and an important carbohydrate in biology. Cells use it as the primary source of energy and a metabolic intermediate...

 and fructose
Fructose
Fructose, or fruit sugar, is a simple monosaccharide found in many plants. It is one of the three dietary monosaccharides, along with glucose and galactose, that are absorbed directly into the bloodstream during digestion. Fructose was discovered by French chemist Augustin-Pierre Dubrunfaut in 1847...

, and precipitate impurities. The lime and other suspended solids are settled out, and the clarified juice is concentrated in a multiple-effect evaporator
Multiple-effect evaporator
A multiple-effect evaporator, as defined in chemical engineering, is an apparatus for efficiently using the heat from steam to evaporate water. In a multiple-effect evaporator, water is boiled in a sequence of vessels, each held at a lower pressure than the last...

 to make a syrup with about 60 weight percent sucrose. The syrup is further concentrated under vacuum
Vacuum
In everyday usage, vacuum is a volume of space that is essentially empty of matter, such that its gaseous pressure is much less than atmospheric pressure. The word comes from the Latin term for "empty". A perfect vacuum would be one with no particles in it at all, which is impossible to achieve in...

 until it becomes supersaturated, and then seeded with crystalline sugar. Upon cooling, sugar crystallizes out of the syrup. Centrifuging
Centrifuge
A centrifuge is a piece of equipment, generally driven by an electric motor , that puts an object in rotation around a fixed axis, applying a force perpendicular to the axis...

 then separates the sugar from the remaining liquid (molasses). Raw sugar has a yellow to brown color. To produce a white sugar, sulfur dioxide
Sulfur dioxide
Sulfur dioxide is the chemical compound with the formula . It is released by volcanoes and in various industrial processes. Since coal and petroleum often contain sulfur compounds, their combustion generates sulfur dioxide unless the sulfur compounds are removed before burning the fuel...

 is bubbled through the cane juice before evaporation so as to bleach color-forming impurities into colourless ones. Sugar bleached white by this means is called mill white, plantation white, and crystal sugar. It is the form of sugar most often consumed in the sugarcane-producing countries.

The fibrous solids, called bagasse, remaining after the crushing of the shredded sugarcane, are burned for fuel, which helps a sugar mill to become self-sufficient in energy. Any excess bagasse can be used for animal feed, to produce paper, or burned to generate electricity for the local power grid.

Refining


Main article: Sugar refinery
Sugar refinery
A sugar refinery is a factory which refines raw sugar.Many cane sugar mills produce raw sugar, i.e. sugar with more colour and therefore more impurities than the white sugar which is normally consumed in households and used as an ingredient in soft drinks, cookies and so forth...



The second stage is often executed in heavy sugar-consuming regions such as North America
North America
North America is a continent wholly within the Northern Hemisphere and almost wholly within the Western Hemisphere. It is also considered a northern subcontinent of the Americas...

, Europe
Europe
Europe is, by convention, one of the world's seven continents. Comprising the westernmost peninsula of Eurasia, Europe is generally 'divided' from Asia to its east by the watershed divides of the Ural and Caucasus Mountains, the Ural River, the Caspian and Black Seas, and the waterways connecting...

, and Japan
Japan
Japan is an island nation in East Asia. Located in the Pacific Ocean, it lies to the east of the Sea of Japan, China, North Korea, South Korea and Russia, stretching from the Sea of Okhotsk in the north to the East China Sea and Taiwan in the south...

. In the second stage, white sugar is produced that is more than 99 percent pure sucrose
Sucrose
Sucrose is the organic compound commonly known as table sugar and sometimes called saccharose. A white, odorless, crystalline powder with a sweet taste, it is best known for its role in human nutrition. The molecule is a disaccharide composed of glucose and fructose with the molecular formula...

. In such refineries, raw sugar is further purified.