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An oil refinery or petroleum refinery is an
industrial process Industrial processes are procedures involving chemical, physical, electrical or mechanical steps to aid in the manufacturing of an item or items, usually carried out on a very large scale. Industrial processes are the key components of heavy in ...
plant Plants are predominantly photosynthetic eukaryotes of the kingdom Plantae. Historically, the plant kingdom encompassed all living things that were not animals, and included algae and fungi; however, all current definitions of Plantae excl ...
where
petroleum Petroleum, also known as crude oil, or simply oil, is a naturally occurring yellowish-black liquid mixture of mainly hydrocarbons, and is found in geological formations. The name ''petroleum'' covers both naturally occurring unprocessed crud ...
(crude oil) is transformed and refined into useful products such as
gasoline Gasoline (; ) or petrol (; ) (see ) is a transparent, petroleum-derived flammable liquid that is used primarily as a fuel in most spark-ignited internal combustion engines (also known as petrol engines). It consists mostly of organic c ...
(petrol),
diesel fuel Diesel fuel , also called diesel oil, is any liquid fuel specifically designed for use in a diesel engine, a type of internal combustion engine in which fuel ignition takes place without a spark as a result of compression of the inlet air and ...
, asphalt base,
fuel oil Fuel oil is any of various fractions obtained from the distillation of petroleum (crude oil). Such oils include distillates (the lighter fractions) and residues (the heavier fractions). Fuel oils include heavy fuel oil, marine fuel oil (MFO), b ...
s,
heating oil Heating oil is any petroleum product or other oil used for heating; a fuel oil. Most commonly, it refers to low viscosity grades of fuel oil used for furnaces or boilers use for home heating and in other buildings. Home heating oil is often ...
,
kerosene Kerosene, paraffin, or lamp oil is a combustible hydrocarbon liquid which is derived from petroleum. It is widely used as a fuel in aviation as well as households. Its name derives from el, κηρός (''keros'') meaning " wax", and was re ...
,
liquefied petroleum gas Liquefied petroleum gas (LPG or LP gas) is a fuel gas which contains a flammable mixture of hydrocarbon gases, specifically propane, propylene, butylene, isobutane and n-butane. LPG is used as a fuel gas in heating appliances, cookin ...
and
petroleum naphtha 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 and then catalytically reformed, which rearranges or restructures the hydrocarbon mo ...
.
Petrochemical Petrochemicals (sometimes abbreviated as petchems) are the chemical products obtained from petroleum by refining. Some chemical compounds made from petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewabl ...
s feedstock like
ethylene Ethylene (IUPAC name: ethene) is a hydrocarbon which has the formula or . It is a colourless, flammable gas with a faint "sweet and musky" odour when pure. It is the simplest alkene (a hydrocarbon with carbon-carbon double bonds). Ethylene ...
and
propylene Propylene, also known as propene, is an unsaturated organic compound with the chemical formula CH3CH=CH2. It has one double bond, and is the second simplest member of the alkene class of hydrocarbons. It is a colorless gas with a faint petro ...
can also be produced directly by cracking crude oil without the need of using refined products of crude oil such as naphtha. The crude oil feedstock has typically been processed by an
oil production plant An oil production plant is a facility which processes production fluids from oil wells in order to separate out key components and prepare them for export. Typical oil well production fluids are a mixture of oil, gas and produced water. An oil p ...
. There is usually an
oil depot An oil terminal (also called a tank farm, tankfarm, oil installation or oil depot) is an industrial facility for the storage of oil, petroleum and petrochemical products, and from which these products are transported to end users or other stor ...
at or near an oil refinery for the storage of incoming crude oil feedstock as well as bulk liquid products. In 2020, the total capacity of global refineries for crude oil was about 101.2 million barrels per day. Oil refineries are typically large, sprawling industrial complexes with extensive
piping Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid. Industrial process piping (and accompa ...
running throughout, carrying streams of
fluid In physics, a fluid is a liquid, gas, or other material that continuously deforms (''flows'') under an applied shear stress, or external force. They have zero shear modulus, or, in simpler terms, are substances which cannot resist any shear ...
s between large
chemical process In a scientific sense, a chemical process is a method or means of somehow changing one or more chemicals or chemical compounds. Such a chemical process can occur by itself or be caused by an outside force, and involves a chemical reaction of some ...
ing units, such as
distillation Distillation, or classical distillation, is the process of separating the components or substances from a liquid mixture by using selective boiling and condensation, usually inside an apparatus known as a still. Dry distillation is the he ...
columns. In many ways, oil refineries use much of the technology and can be thought of, as types of
chemical plant A chemical plant is an industrial process plant that manufactures (or otherwise processes) chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transfo ...
s. Since December 2008, the world’s largest oil refinery has been the Jamnagar Refinery owned by
Reliance Industries Reliance Industries Limited is an Indian multinational conglomerate company, headquartered in Mumbai. It has diverse businesses including energy, petrochemicals, natural gas, retail, telecommunications, mass media, and textiles. Relian ...
, located in
Gujarat Gujarat (, ) is a state along the western coast of India. Its coastline of about is the longest in the country, most of which lies on the Kathiawar peninsula. Gujarat is the fifth-largest Indian state by area, covering some ; and the ninth ...
, India, with a processing capacity of . Some modern petroleum refineries process as much as 800,000 to 900,000 barrels (120,000 to 143,000 cubic meters) of crude oil per day. An oil refinery is considered an essential part of the
downstream Downstream may refer to: * Downstream (bioprocess) * Downstream (manufacturing) * Downstream (networking) * Downstream (software development) * Downstream (petroleum industry) * Upstream and downstream (DNA), determining relative positions on DNA ...
side of the
petroleum industry The petroleum industry, also known as the oil industry or the oil patch, includes the global processes of exploration, extraction, refining, transportation (often by oil tankers and pipelines), and marketing of petroleum products. The larg ...
.


History

The Chinese were among the first civilizations to refine oil. As early as the first century, the Chinese were refining crude oil for use as an energy source. Between 512 and 518, in the late
Northern Wei Dynasty Wei (), known in historiography as the Northern Wei (), Tuoba Wei (), Yuan Wei () and Later Wei (), was founded by the Tuoba (Tabgach) clan of the Xianbei. The first of the Northern dynasties, it ruled northern China from 386 to 535 during t ...
, the Chinese geographer, writer and politician
Li Daoyuan Li Daoyuan (; 466 or 472 in Zhuo County, Hebei – 527) was a Chinese geographer, writer, and politician during the Northern Wei Dynasty. He is known as the author of the '' Commentary on the Water Classic'' (''Shuijingzhu''), a monumental work o ...
introduced the process of refining oil into various lubricants in his famous work ''
Commentary on the Water Classic The ''Commentary on the Water Classic'' (), or ''Commentaries on the Water Classic'', commonly known as ''Shui Jing Zhu'', is a work on the Chinese geography in ancient times, describing the traditional understanding of its waterways and ancie ...
''.
Crude oil Petroleum, also known as crude oil, or simply oil, is a naturally occurring yellowish-black liquid mixture of mainly hydrocarbons, and is found in geological formations. The name ''petroleum'' covers both naturally occurring unprocessed crude ...
was often distilled by Arab chemists, with clear descriptions given in Arabic handbooks such as those of
Muhammad ibn Zakarīya Rāzi Abū Bakr al-Rāzī (full name: ar, أبو بکر محمد بن زکریاء الرازي, translit=Abū Bakr Muḥammad ibn Zakariyyāʾ al-Rāzī, label=none), () rather than ar, زکریاء, label=none (), as for example in , or in . In m ...
(). The streets of
Baghdad Baghdad (; ar, بَغْدَاد , ) is the capital of Iraq and the second-largest city in the Arab world after Cairo. It is located on the Tigris near the ruins of the ancient city of Babylon and the Sassanid Persian capital of Ctesiphon ...
were paved with
tar Tar is a dark brown or black viscous liquid of hydrocarbons and free carbon, obtained from a wide variety of organic materials through destructive distillation. Tar can be produced from coal, wood, petroleum, or peat. "a dark brown or black bi ...
, derived from petroleum that became accessible from natural fields in the region. In the 9th century,
oil field A petroleum reservoir or oil and gas reservoir is a subsurface accumulation of hydrocarbons contained in porous or fractured rock formations. Such reservoirs form when kerogen (ancient plant matter) is created in surrounding rock by the presen ...
s were exploited in the area around modern
Baku Baku (, ; az, Bakı ) is the capital and largest city of Azerbaijan, as well as the largest city on the Caspian Sea and of the Caucasus region. Baku is located below sea level, which makes it the lowest lying national capital in the world an ...
, Azerbaijan. These fields were described by the
Arab geographer Medieval Islamic geography and cartography refer to the study of geography and cartography in the Muslim world during the Islamic Golden Age (variously dated between the 8th century and 16th century). Muslim scholars made advances to the map-m ...
Abu al-Hasan 'Alī al-Mas'ūdī Al-Mas'udi ( ar, أَبُو ٱلْحَسَن عَلِيّ ٱبْن ٱلْحُسَيْن ٱبْن عَلِيّ ٱلْمَسْعُودِيّ, '; –956) was an Arab historian, geographer and traveler. He is sometimes referred to as the "Herodotus ...
in the 10th century, and by
Marco Polo Marco Polo (, , ; 8 January 1324) was a Venetian merchant, explorer and writer who travelled through Asia along the Silk Road between 1271 and 1295. His travels are recorded in '' The Travels of Marco Polo'' (also known as ''Book of the Marv ...
in the 13th century, who described the output of those wells as hundreds of shiploads. Arab and Persian chemists also distilled crude oil in order to produce
flammable A combustible material is something that can burn (i.e., ''combust'') in air. A combustible material is flammable if it ignites easily at ambient temperatures. In other words, a combustible material ignites with some effort and a flammable mat ...
products for military purposes. Through
Islamic Spain Al-Andalus translit. ; an, al-Andalus; ast, al-Ándalus; eu, al-Andalus; ber, ⴰⵏⴷⴰⵍⵓⵙ, label= Berber, translit=Andalus; ca, al-Àndalus; gl, al-Andalus; oc, Al Andalús; pt, al-Ândalus; es, al-Ándalus () was the Mu ...
, distillation became available in
Western Europe Western Europe is the western region of Europe. The region's countries and territories vary depending on context. The concept of "the West" appeared in Europe in juxtaposition to "the East" and originally applied to the ancient Mediterranean ...
by the 12th century. In the
Northern Song Dynasty Northern may refer to the following: Geography * North, a point in direction * Northern Europe, the northern part or region of Europe * Northern Highland, a region of Wisconsin, United States * Northern Province, Sri Lanka * Northern Range, a ...
(960–1127), a workshop called the "Fierce Oil Workshop", was established in the city of Kaifeng to produce refined oil for the Song military as a weapon. The troops would then fill iron cans with refined oil and throw them toward the enemy troops, causing a fire – effectively the world's first " fire bomb". The workshop was one of the world's earliest oil refining factories where thousands of people worked to produce Chinese oil-powered weaponry. Prior to the nineteenth century, petroleum was known and utilized in various fashions in
Babylon ''Bābili(m)'' * sux, 𒆍𒀭𒊏𒆠 * arc, 𐡁𐡁𐡋 ''Bāḇel'' * syc, ܒܒܠ ''Bāḇel'' * grc-gre, Βαβυλών ''Babylṓn'' * he, בָּבֶל ''Bāvel'' * peo, 𐎲𐎠𐎲𐎡𐎽𐎢 ''Bābiru'' * elx, 𒀸𒁀𒉿𒇷 ''Babi ...
,
Egypt Egypt ( ar, مصر , ), officially the Arab Republic of Egypt, is a List of transcontinental countries, transcontinental country spanning the North Africa, northeast corner of Africa and Western Asia, southwest corner of Asia via a land bridg ...
,
China China, officially the People's Republic of China (PRC), is a country in East Asia. It is the world's List of countries and dependencies by population, most populous country, with a Population of China, population exceeding 1.4 billion, slig ...
,
Philippines The Philippines (; fil, Pilipinas, links=no), officially the Republic of the Philippines ( fil, Republika ng Pilipinas, links=no), * bik, Republika kan Filipinas * ceb, Republika sa Pilipinas * cbk, República de Filipinas * hil, Republ ...
,
Rome , established_title = Founded , established_date = 753 BC , founder = King Romulus ( legendary) , image_map = Map of comune of Rome (metropolitan city of Capital Rome, region Lazio, Italy).svg , map_caption ...
and
Azerbaijan Azerbaijan (, ; az, Azərbaycan ), officially the Republic of Azerbaijan, , also sometimes officially called the Azerbaijan Republic is a transcontinental country located at the boundary of Eastern Europe and Western Asia. It is a part of th ...
. However, the modern history of the petroleum industry is said to have begun in 1846 when Abraham Gessner of
Nova Scotia Nova Scotia ( ; ; ) is one of the thirteen provinces and territories of Canada. It is one of the three Maritime provinces and one of the four Atlantic provinces. Nova Scotia is Latin for "New Scotland". Most of the population are native Eng ...
,
Canada Canada is a country in North America. Its ten provinces and three territories extend from the Atlantic Ocean to the Pacific Ocean and northward into the Arctic Ocean, covering over , making it the world's second-largest country by to ...
devised a process to produce kerosene from coal. Shortly thereafter, in 1854,
Ignacy Łukasiewicz Jan Józef Ignacy Łukasiewicz (; 8 March 1822 – 7 January 1882) was a Polish pharmacist, engineer, businessman, inventor, and philanthropist. He was one of the most prominent philanthropists in the Kingdom of Galicia and Lodomeria, crown land o ...
began producing kerosene from hand-dug oil wells near the town of
Krosno Krosno (in full ''The Royal Free City of Krosno'', pl, Królewskie Wolne Miasto Krosno) is a historical town and county in the Subcarpathian Voivodeship, in southeastern Poland. The estimated population of the town is 47,140 inhabitants as of 2 ...
,
Poland Poland, officially the Republic of Poland, is a country in Central Europe. It is divided into 16 administrative provinces called voivodeships, covering an area of . Poland has a population of over 38 million and is the fifth-most populou ...
. The world's first industrial petroleum refinery was built in
Ploiești Ploiești ( , , ), formerly spelled Ploești, is a city and county seat in Prahova County, Romania. Part of the historical region of Muntenia, it is located north of Bucharest. The area of Ploiești is around , and it borders the Blejoi commun ...
, Romania, in 1856 using the abundant oil available in Romania. In North America, the first oil well was drilled in 1858 by
James Miller Williams James Miller Williams (September 14, 1818 – November 25, 1890) was a Canadian-American businessman and politician. Williams is best known for establishing the first commercially successful oil well in 1858 and igniting the first oil boom i ...
in
Oil Springs, Ontario Oil Springs is a village in Lambton County, Ontario, Canada, located along Former Provincial Highway 21 south of Oil City. The village, an enclave within Enniskillen Township, is the site of North America's first commercial oil well. It is home ...
, Canada. In the United States, the petroleum industry began in 1859 when
Edwin Drake Edwin Laurentine Drake (March 29, 1819 – November 9, 1880), also known as Colonel Drake, was an American businessman and the first American to successfully drill for oil. Early life Edwin Drake was born in Greenville, New York on March 2 ...
found oil near Titusville,
Pennsylvania Pennsylvania (; ( Pennsylvania Dutch: )), officially the Commonwealth of Pennsylvania, is a state spanning the Mid-Atlantic, Northeastern, Appalachian, and Great Lakes regions of the United States. It borders Delaware to its southeast, ...
. The industry grew slowly in the 1800s, primarily producing kerosene for oil lamps. In the early twentieth century, the introduction of the internal combustion engine and its use in automobiles created a market for gasoline that was the impetus for fairly rapid growth of the petroleum industry. The early finds of petroleum like those in Ontario and
Pennsylvania Pennsylvania (; ( Pennsylvania Dutch: )), officially the Commonwealth of Pennsylvania, is a state spanning the Mid-Atlantic, Northeastern, Appalachian, and Great Lakes regions of the United States. It borders Delaware to its southeast, ...
were soon outstripped by large oil "booms" in
Oklahoma Oklahoma (; Choctaw: ; chr, ᎣᎧᎳᎰᎹ, ''Okalahoma'' ) is a state in the South Central region of the United States, bordered by Texas on the south and west, Kansas on the north, Missouri on the northeast, Arkansas on the east, New ...
,
Texas Texas (, ; Spanish: ''Texas'', ''Tejas'') is a state in the South Central region of the United States. At 268,596 square miles (695,662 km2), and with more than 29.1 million residents in 2020, it is the second-largest U.S. state by ...
and
California California is a state in the Western United States, located along the Pacific Coast. With nearly 39.2million residents across a total area of approximately , it is the most populous U.S. state and the 3rd largest by area. It is also the m ...
.
Samuel Kier Samuel Martin Kier (July 19, 1813 – October 6, 1874) was an American inventor and businessman who is credited with founding the American petroleum refining industry. He was the first person in the United States to refine crude oil into lam ...
established America's first oil refinery in Pittsburgh on Seventh Avenue near Grant Street, in 1853. Polish pharmacist and inventor
Ignacy Łukasiewicz Jan Józef Ignacy Łukasiewicz (; 8 March 1822 – 7 January 1882) was a Polish pharmacist, engineer, businessman, inventor, and philanthropist. He was one of the most prominent philanthropists in the Kingdom of Galicia and Lodomeria, crown land o ...
established an oil refinery in
Jasło Jasło is a county town in south-eastern Poland with 36,641 inhabitants, as of 31 December 2012. It is situated in the Subcarpathian Voivodeship (since 1999), and it was previously part of Krosno Voivodeship (1975–1998). It is located in Lesse ...
, then part of the Austro-Hungarian Empire (now in
Poland Poland, officially the Republic of Poland, is a country in Central Europe. It is divided into 16 administrative provinces called voivodeships, covering an area of . Poland has a population of over 38 million and is the fifth-most populou ...
) in 1854. The first large refinery opened at Ploiești, Romania, in 1856–1857. After being taken over by
Nazi Germany Nazi Germany (lit. "National Socialist State"), ' (lit. "Nazi State") for short; also ' (lit. "National Socialist Germany") (officially known as the German Reich from 1933 until 1943, and the Greater German Reich from 1943 to 1945) was ...
, the Ploiești refineries were bombed in
Operation Tidal Wave Operation Tidal Wave was an air attack by bombers of the United States Army Air Forces (USAAF) based in Libya on nine oil refineries around Ploiești, Romania on 1 August 1943, during World War II. It was a strategic bombing mission and part o ...
by the
Allies An alliance is a relationship among people, groups, or states that have joined together for mutual benefit or to achieve some common purpose, whether or not explicit agreement has been worked out among them. Members of an alliance are called ...
during the Oil Campaign of World War II. Another close contender for the title of hosting the world's oldest oil refinery is
Salzbergen Salzbergen is a municipality in the Emsland district, Lower Saxony, Germany. It is situated on the river Ems, approx. 25 km south of Lingen, and 10 km northwest of Rheine. It has the oldest oil refinery An oil refinery or petrol ...
in
Lower Saxony Lower Saxony (german: Niedersachsen ; nds, Neddersassen; stq, Läichsaksen) is a German state (') in northwestern Germany. It is the second-largest state by land area, with , and fourth-largest in population (8 million in 2021) among the 16 ...
, Germany. Salzbergen's refinery was opened in 1860. At one point, the refinery in
Ras Tanura Ras Tanura ( ar, رأس تنورة, Ra's Tannūrah, lit=cape oven, cape brazier, presumably due to the unusual heat prevalent at the cape that projects into the sea) is a city in the Eastern Province of Saudi Arabia located on a peninsula extend ...
,
Saudi Arabia Saudi Arabia, officially the Kingdom of Saudi Arabia (KSA), is a country in Western Asia. It covers the bulk of the Arabian Peninsula, and has a land area of about , making it the fifth-largest country in Asia, the second-largest in the Ara ...
owned by
Saudi Aramco Saudi Aramco ( ar, أرامكو السعودية '), officially the Saudi Arabian Oil Company (formerly Arabian-American Oil Company) or simply Aramco, is a Saudi Arabian public petroleum and natural gas company based in Dhahran. , it is one of ...
was claimed to be the largest oil refinery in the world. For most of the 20th century, the largest refinery was the
Abadan Refinery The Abadan refinery ( fa, پالایشگاه آبادان ''Pālāyeshgāh-e Ābādān'') is an oil refinery located in Abadan near the coast of the Persian Gulf. History Built by the Anglo-Persian Oil Company (later BP) on the basis of a lease o ...
in
Iran Iran, officially the Islamic Republic of Iran, and also called Persia, is a country located in Western Asia. It is bordered by Iraq and Turkey to the west, by Azerbaijan and Armenia to the northwest, by the Caspian Sea and Turkmeni ...
. This refinery suffered extensive damage during the
Iran–Iraq War The Iran–Iraq War was an armed conflict between Iran and Iraq that lasted from September 1980 to August 1988. It began with the Iraqi invasion of Iran and lasted for almost eight years, until the acceptance of United Nations Security Counci ...
. Since 25 December 2008, the world's largest refinery complex is the Jamnagar Refinery Complex, consisting of two refineries side by side operated by
Reliance Industries Limited Reliance Industries Limited is an Indian multinational conglomerate company, headquartered in Mumbai. It has diverse businesses including energy, petrochemicals, natural gas, retail, telecommunications, mass media, and textiles. Reliance is o ...
in Jamnagar, India with a combined production capacity of .
PDVSA Petróleos de Venezuela, S.A. (PDVSA, ) (English: Petroleum of Venezuela) is the Venezuelan state-owned oil and natural gas company. It has activities in exploration, production, refining and exporting oil as well as exploration and productio ...
's
Paraguaná Refinery Complex The Paraguaná Refinery Complex ( es, Centro de Refinación de Paraguaná) is a crude oil refinery complex in Venezuela. It is considered the world's third largest refinery complex, just after Jamnagar Refinery (India) and (South Korea). The Pa ...
in
Paraguaná Peninsula The Paraguaná Peninsula () is a peninsula in Venezuela, situated in the north of Falcón State, and comprises the municipalities of Carirubana, Los Taques and Falcón. The island of Aruba lies to the north. Bonaire and Curaçao are slightly ...
,
Venezuela Venezuela (; ), officially the Bolivarian Republic of Venezuela ( es, link=no, República Bolivariana de Venezuela), is a country on the northern coast of South America, consisting of a continental landmass and many islands and islets in th ...
, with a capacity of and
SK Energy SK Innovation Co., Ltd. () is an intermediate holding company of SK Group engaged in petroleum, alternative energy, and oil exploration. It runs its business through eight major subsidiaries, including SK Energy, SK Geo Centric, SK On, SK Enmo ...
's
Ulsan Ulsan (), officially the Ulsan Metropolitan City is South Korea's seventh-largest metropolitan city and the eighth-largest city overall, with a population of over 1.1 million inhabitants. It is located in the south-east of the country, neighboring ...
in
South Korea South Korea, officially the Republic of Korea (ROK), is a country in East Asia, constituting the southern part of the Korea, Korean Peninsula and sharing a Korean Demilitarized Zone, land border with North Korea. Its western border is formed ...
with are the second and third largest, respectively. Prior to World War II in the early 1940s, most petroleum refineries in the United States consisted simply of crude oil distillation units (often referred to as atmospheric crude oil distillation units). Some refineries also had
vacuum distillation Vacuum distillation is distillation performed under reduced pressure, which allows the purification of compounds not readily distilled at ambient pressures or simply to save time or energy. This technique separates compounds based on differences i ...
units as well as
thermal cracking In petrochemistry, petroleum geology and organic chemistry, cracking is the process whereby complex organic molecules such as kerogens or long-chain hydrocarbons are broken down into simpler molecules such as light hydrocarbons, by the breaking of ...
units such as
visbreaker A visbreaker is a processing unit in an oil refinery whose purpose is to reduce the quantity of residual oil produced in the distillation of crude oil and to increase the yield of more valuable middle distillates (heating oil and diesel) by the re ...
s (viscosity breakers, units to lower the
viscosity The viscosity of a fluid is a measure of its resistance to deformation at a given rate. For liquids, it corresponds to the informal concept of "thickness": for example, syrup has a higher viscosity than water. Viscosity quantifies the int ...
of the oil). All of the many other refining processes discussed below were developed during the war or within a few years after the war. They became commercially available within 5 to 10 years after the war ended and the worldwide petroleum industry experienced very rapid growth. The driving force for that growth in technology and in the number and size of refineries worldwide was the growing demand for automotive gasoline and aircraft fuel. In the United States, for various complex economic and political reasons, the construction of new refineries came to a virtual stop in about the 1980s. However, many of the existing refineries in the United States have revamped many of their units and/or constructed add-on units in order to: increase their crude oil processing capacity, increase the
octane Octane is a hydrocarbon and an alkane with the chemical formula , and the condensed structural formula . Octane has many structural isomers that differ by the amount and location of branching in the carbon chain. One of these isomers, 2,2,4-t ...
rating of their product gasoline, lower the
sulfur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formul ...
content of their diesel fuel and home heating fuels to comply with environmental regulations and comply with environmental air pollution and water pollution requirements. The size of the oil refining market in 2017 was valued at over US$6 trillion in 2017 and is set to witness a consumption of over 100 million barrels per day (MBPD) by 2024. The oil refining market will witness an appreciable growth because of rapid industrialization and economic transformation. Changing demographics, growing population, and improvement in living standards across developing nations are some of the factors positively influencing the industry landscape.


United States

In the 19th century, refineries in the U.S. processed crude oil primarily to recover the
kerosene Kerosene, paraffin, or lamp oil is a combustible hydrocarbon liquid which is derived from petroleum. It is widely used as a fuel in aviation as well as households. Its name derives from el, κηρός (''keros'') meaning " wax", and was re ...
. There was no market for the more volatile fraction, including gasoline, which was considered waste and was often dumped directly into the nearest river. The invention of the automobile shifted the demand to gasoline and diesel, which remain the primary refined products today. Today, national and state legislation require refineries to meet stringent air and water cleanliness standards. In fact, oil companies in the U.S. perceive obtaining a permit to build a modern refinery to be so difficult and costly that no new refineries were built (though many have been expanded) in the U.S. from 1976 until 2014 when the small Dakota Prairie Refinery in North Dakota began operation. More than half the refineries that existed in 1981 are now closed due to low utilization rates and accelerating mergers. As a result of these closures total US refinery capacity fell between 1981 and 1995, though the operating capacity stayed fairly constant in that time period at around . Increases in facility size and improvements in efficiencies have offset much of the lost physical capacity of the industry. In 1982 (the earliest data provided), the United States operated 301 refineries with a combined capacity of of crude oil each calendar day. In 2010, there were 149 operable U.S. refineries with a combined capacity of per calendar day. By 2014 the number of refinery had reduced to 140 but the total capacity increased to per calendar day. Indeed, in order to reduce operating costs and depreciation, refining is operated in fewer sites but of bigger capacity. In 2009 through 2010, as revenue streams in the oil business dried up and profitability of oil refineries fell due to lower demand for product and high reserves of supply preceding the
economic recession In economics, a recession is a business cycle contraction when there is a general decline in economic activity. Recessions generally occur when there is a widespread drop in spending (an adverse demand shock). This may be triggered by variou ...
, oil companies began to close or sell the less profitable refineries.


Operation

Raw or unprocessed crude oil is not generally useful in industrial applications, although "light, sweet" (low viscosity, low
sulfur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formul ...
) crude oil has been used directly as a burner fuel to produce steam for the propulsion of seagoing vessels. The lighter elements, however, form explosive vapors in the fuel tanks and are therefore hazardous, especially in
warships A warship or combatant ship is a naval ship that is built and primarily intended for naval warfare. Usually they belong to the armed forces of a state. As well as being armed, warships are designed to withstand damage and are usually faster an ...
. Instead, the hundreds of different hydrocarbon molecules in crude oil are separated in a refinery into components that can be used as
fuels A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy but ...
,
lubricants A lubricant (sometimes shortened to lube) is a substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, t ...
, and feedstocks in
petrochemical Petrochemicals (sometimes abbreviated as petchems) are the chemical products obtained from petroleum by refining. Some chemical compounds made from petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewabl ...
processes that manufacture such products as
plastic Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be moulded, extruded or pressed into solid objects of various shapes. This adapta ...
s,
detergent A detergent is a surfactant or a mixture of surfactants with cleansing properties when in dilute solutions. There are a large variety of detergents, a common family being the alkylbenzene sulfonates, which are soap-like compounds that are m ...
s,
solvent A solvent (s) (from the Latin '' solvō'', "loosen, untie, solve") is a substance that dissolves a solute, resulting in a solution. A solvent is usually a liquid but can also be a solid, a gas, or a supercritical fluid. Water is a solvent for ...
s,
elastomer An elastomer is a polymer with viscoelasticity (i.e. both viscosity and Elasticity (physics), elasticity) and with weak intermolecular forces, generally low Young's modulus and high Deformation (mechanics), failure strain compared with other mate ...
s, and
fiber Fiber or fibre (from la, fibra, links=no) is a natural or artificial substance that is significantly longer than it is wide. Fibers are often used in the manufacture of other materials. The strongest engineering materials often incorporate ...
s such as
nylon Nylon is a generic designation for a family of synthetic polymers composed of polyamides ( repeating units linked by amide links).The polyamides may be aliphatic or semi-aromatic. Nylon is a silk-like thermoplastic, generally made from pet ...
and
polyesters Polyester is a category of polymers that contain the ester functional group in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include natural ...
.
Petroleum Petroleum, also known as crude oil, or simply oil, is a naturally occurring yellowish-black liquid mixture of mainly hydrocarbons, and is found in geological formations. The name ''petroleum'' covers both naturally occurring unprocessed crud ...
fossil fuels A fossil fuel is a hydrocarbon-containing material formed naturally in the Earth's crust from the remains of dead plants and animals that is extracted and burned as a fuel. The main fossil fuels are coal, oil, and natural gas. Fossil fuels ma ...
are burned in internal combustion engines to provide power for
ships A ship is a large watercraft that travels the world's oceans and other sufficiently deep waterways, carrying cargo or passengers, or in support of specialized missions, such as defense, research, and fishing. Ships are generally distinguished ...
,
automobiles A car or automobile is a motor vehicle with wheels. Most definitions of ''cars'' say that they run primarily on roads, seat one to eight people, have four wheels, and mainly transport people instead of goods. The year 1886 is regarded ...
,
aircraft engine An aircraft engine, often referred to as an aero engine, is the power component of an aircraft propulsion system. Most aircraft engines are either piston engines or gas turbines, although a few have been rocket powered and in recent years ma ...
s,
lawn mower A lawn mower (also known as a mower, grass cutter or lawnmower) is a device utilizing one or more revolving blades (or a reel) to cut a grass surface to an even height. The height of the cut grass may be fixed by the design of the mower, but g ...
s,
dirt bikes The six main types of motorcycles are generally recognized as ''standard'', ''cruiser'', ''touring'', ''sports'', ''off-road'', and ''dual-purpose''. ''Sport touring'' is sometimes recognized as a seventh category or integrated with the ''touring' ...
, and other machines. Different
boiling point The boiling point of a substance is the temperature at which the vapor pressure of a liquid equals the pressure surrounding the liquid and the liquid changes into a vapor. The boiling point of a liquid varies depending upon the surrounding env ...
s allow the
hydrocarbon In organic chemistry, a hydrocarbon is an organic compound consisting entirely of hydrogen and carbon. Hydrocarbons are examples of group 14 hydrides. Hydrocarbons are generally colourless and hydrophobic, and their odors are usually weak or ...
s to be separated by
distillation Distillation, or classical distillation, is the process of separating the components or substances from a liquid mixture by using selective boiling and condensation, usually inside an apparatus known as a still. Dry distillation is the he ...
. Since the lighter liquid products are in great demand for use in internal combustion engines, a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher-value products. Oil can be used in a variety of ways because it contains hydrocarbons of varying
molecular mass The molecular mass (''m'') is the mass of a given molecule: it is measured in daltons (Da or u). Different molecules of the same compound may have different molecular masses because they contain different isotopes of an element. The related quant ...
es, forms and lengths such as paraffins,
aromatic In chemistry, aromaticity is a chemical property of cyclic ( ring-shaped), ''typically'' planar (flat) molecular structures with pi bonds in resonance (those containing delocalized electrons) that gives increased stability compared to satur ...
s, naphthenes (or
cycloalkane In organic chemistry, the cycloalkanes (also called naphthenes, but distinct from naphthalene) are the monocyclic saturated hydrocarbons. In other words, a cycloalkane consists only of hydrogen and carbon atoms arranged in a structure containin ...
s),
alkene In organic chemistry, an alkene is a hydrocarbon containing a carbon–carbon double bond. Alkene is often used as synonym of olefin, that is, any hydrocarbon containing one or more double bonds.H. Stephen Stoker (2015): General, Organic ...
s,
diene In organic chemistry a diene ( ) (diolefin ( ) or alkadiene) is a covalent compound that contains two double bonds, usually among carbon atoms. They thus contain two alk''ene'' units, with the standard prefix ''di'' of systematic nomenclature. ...
s, and
alkyne \ce \ce Acetylene \ce \ce \ce Propyne \ce \ce \ce \ce 1-Butyne In organic chemistry, an alkyne is an unsaturated hydrocarbon containing at least one carbon—carbon triple bond. The simplest acyclic alkynes with only one triple bond and n ...
s. While the molecules in crude oil include different atoms such as sulfur and nitrogen, the hydrocarbons are the most common form of molecules, which are molecules of varying lengths and complexity made of
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-to ...
and
carbon Carbon () is a chemical element with the symbol C and atomic number 6. It is nonmetallic and tetravalent—its atom making four electrons available to form covalent chemical bonds. It belongs to group 14 of the periodic table. Carbon ma ...
atom Every atom is composed of a nucleus and one or more electrons bound to the nucleus. The nucleus is made of one or more protons and a number of neutrons. Only the most common variety of hydrogen has no neutrons. Every solid, liquid, gas, a ...
s, and a small number of oxygen atoms. The differences in the structure of these molecules account for their varying
physical Physical may refer to: * Physical examination, a regular overall check-up with a doctor * ''Physical'' (Olivia Newton-John album), 1981 ** "Physical" (Olivia Newton-John song) * ''Physical'' (Gabe Gurnsey album) * "Physical" (Alcazar song) (2004) * ...
and
chemical properties A chemical property is any of a material's properties that becomes evident during, or after, a chemical reaction; that is, any quality that can be established only by changing a substance's chemical identity.William L. Masterton, Cecile N. Hurley, ...
, and it is this variety that makes crude oil useful in a broad range of several applications. Once separated and purified of any contaminants and impurities, the fuel or lubricant can be sold without further processing. Smaller molecules such as
isobutane Isobutane, also known as ''i''-butane, 2-methylpropane or methylpropane, is a chemical compound with molecular formula HC(CH3)3. It is an isomer of butane. Isobutane is a colourless, odourless gas. It is the simplest alkane with a tertiary carbo ...
and
propylene Propylene, also known as propene, is an unsaturated organic compound with the chemical formula CH3CH=CH2. It has one double bond, and is the second simplest member of the alkene class of hydrocarbons. It is a colorless gas with a faint petro ...
or
butylene Butene, also known as butylene, is an alkene with the formula . The word ''butene'' may refer to any of the individual compounds. They are colourless gases that are present in crude oil as a minor constituent in quantities that are too small for ...
s can be recombined to meet specific
octane Octane is a hydrocarbon and an alkane with the chemical formula , and the condensed structural formula . Octane has many structural isomers that differ by the amount and location of branching in the carbon chain. One of these isomers, 2,2,4-t ...
requirements by processes such as
alkylation Alkylation is the transfer of an alkyl group from one molecule to another. The alkyl group may be transferred as an alkyl carbocation, a free radical, a carbanion, or a carbene (or their equivalents). Alkylating agents are reagents for effectin ...
, or more commonly,
dimerization A dimer () ('' di-'', "two" + ''-mer'', "parts") is an oligomer consisting of two monomers joined by bonds that can be either strong or weak, covalent or intermolecular. Dimers also have significant implications in polymer chemistry, inorganic che ...
. The octane grade of gasoline can also be improved by
catalytic reforming Catalytic reforming is a chemical process used to convert petroleum refinery naphthas distilled from crude oil (typically having low octane ratings) into high-octane liquid products called reformates, which are premium blending stocks for high-oc ...
, which involves removing
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-to ...
from hydrocarbons producing compounds with higher octane ratings such as
aromatics Aromatic compounds, also known as "mono- and polycyclic aromatic hydrocarbons", are organic compounds containing one or more aromatic rings. The parent member of aromatic compounds is benzene. The word "aromatic" originates from the past groupin ...
. Intermediate products such as
gasoil Fuel oil is any of various fractions obtained from the distillation of petroleum (crude oil). Such oils include distillates (the lighter fractions) and residues (the heavier fractions). Fuel oils include heavy fuel oil, marine fuel oil (MFO), b ...
s can even be reprocessed to break a heavy, long-chained oil into a lighter short-chained one, by various forms of cracking such as
fluid catalytic cracking Fluid Catalytic Cracking (FCC) is the conversion process used in petroleum refineries to convert the high-boiling point, high-molecular weight hydrocarbon fractions of petroleum (crude oils) into gasoline, olefinic gases, and other petroleum prod ...
,
thermal cracking In petrochemistry, petroleum geology and organic chemistry, cracking is the process whereby complex organic molecules such as kerogens or long-chain hydrocarbons are broken down into simpler molecules such as light hydrocarbons, by the breaking of ...
, and
hydrocracking In petrochemistry, petroleum geology and organic chemistry, cracking is the process whereby complex organic molecules such as kerogens or long-chain hydrocarbons are broken down into simpler molecules such as light hydrocarbons, by the breaking o ...
. The final step in gasoline production is the blending of fuels with different octane ratings,
vapor pressure Vapor pressure (or vapour pressure in English-speaking countries other than the US; see spelling differences) or equilibrium vapor pressure is defined as the pressure exerted by a vapor in thermodynamic equilibrium with its condensed pha ...
s, and other properties to meet product specifications. Another method for reprocessing and upgrading these intermediate products (residual oils) uses a devolatilization process to separate usable oil from the waste asphaltene material. Oil refineries are large-scale plants, processing about a hundred thousand to several hundred thousand
barrel A barrel or cask is a hollow cylindrical container with a bulging center, longer than it is wide. They are traditionally made of wooden staves and bound by wooden or metal hoops. The word vat is often used for large containers for liquids, ...
s of crude oil a day. Because of the high capacity, many of the units operate continuously, as opposed to processing in batches, at
steady state In systems theory, a system or a process is in a steady state if the variables (called state variables) which define the behavior of the system or the process are unchanging in time. In continuous time, this means that for those properties ''p' ...
or nearly steady state for months to years. The high capacity also makes
process optimization Process optimization is the discipline of adjusting a process so as to optimize (make the best or most effective use of) some specified set of parameters without violating some constraint. The most common goals are minimizing cost and maximizing ...
and advanced process control very desirable.


Major products

Petroleum products are materials derived from crude oil (
petroleum Petroleum, also known as crude oil, or simply oil, is a naturally occurring yellowish-black liquid mixture of mainly hydrocarbons, and is found in geological formations. The name ''petroleum'' covers both naturally occurring unprocessed crud ...
) as it is processed in
oil refineries An oil refinery or petroleum refinery is an industrial process plant where petroleum (crude oil) is transformed and refined into useful products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, li ...
. The majority of petroleum is converted to petroleum products, which includes several classes of fuels. Oil refineries also produce various intermediate products such as
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-to ...
, light hydrocarbons,
reformate Catalytic reforming is a chemical process used to convert petroleum refinery naphthas distilled from crude oil (typically having low octane ratings) into high-octane liquid products called reformates, which are premium blending stocks for high-o ...
and
pyrolysis gasoline Pyrolysis gasoline or Pygas is a naphtha-range product with high aromatics content. It is a by-product of high temperature naphtha cracking during ethylene and propylene production. Also, it is a high octane number mixture that contains aromati ...
. These are not usually transported but instead are blended or processed further on-site. Chemical plants are thus often adjacent to oil refineries or a number of further chemical processes are integrated into it. For example, light hydrocarbons are steam-cracked in an
ethylene Ethylene (IUPAC name: ethene) is a hydrocarbon which has the formula or . It is a colourless, flammable gas with a faint "sweet and musky" odour when pure. It is the simplest alkene (a hydrocarbon with carbon-carbon double bonds). Ethylene ...
plant, and the produced ethylene is polymerized to produce polyethene. To ensure both proper separation and environmental protection, a very low sulfur content is necessary in all but the heaviest products. The crude sulfur contaminant is transformed to
hydrogen sulfide Hydrogen sulfide is a chemical compound with the formula . It is a colorless chalcogen-hydride gas, and is poisonous, corrosive, and flammable, with trace amounts in ambient atmosphere having a characteristic foul odor of rotten eggs. The under ...
via catalytic
hydrodesulfurization Hydrodesulfurization (HDS) is a catalytic chemical process widely used to remove sulfur (S) from natural gas and from refined petroleum products, such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The purpose of rem ...
and removed from the product stream via
amine gas treating Amine gas treating, also known as amine scrubbing, gas sweetening and acid gas removal, refers to a group of processes that use aqueous solutions of various alkylamines (commonly referred to simply as amines) to remove hydrogen sulfide (H2S) and c ...
. Using the
Claus process The Claus process is the most significant gas desulfurizing process, recovering elemental sulfur from gaseous hydrogen sulfide. First patented in 1883 by the chemist Carl Friedrich Claus, the Claus process has become the industry standard. Th ...
, hydrogen sulfide is afterward transformed to elementary sulfur to be sold to the chemical industry. The rather large heat energy freed by this process is directly used in the other parts of the refinery. Often an electrical power plant is combined into the whole refinery process to take up the excess heat. According to the composition of the crude oil and depending on the demands of the market, refineries can produce different shares of petroleum products. The largest share of oil products is used as "energy carriers", i.e. various grades of
fuel oil Fuel oil is any of various fractions obtained from the distillation of petroleum (crude oil). Such oils include distillates (the lighter fractions) and residues (the heavier fractions). Fuel oils include heavy fuel oil, marine fuel oil (MFO), b ...
and
gasoline Gasoline (; ) or petrol (; ) (see ) is a transparent, petroleum-derived flammable liquid that is used primarily as a fuel in most spark-ignited internal combustion engines (also known as petrol engines). It consists mostly of organic c ...
. These
fuel A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy b ...
s include or can be blended to give gasoline,
jet fuel Jet fuel or aviation turbine fuel (ATF, also abbreviated avtur) is a type of aviation fuel designed for use in aircraft powered by gas-turbine engines. It is colorless to straw-colored in appearance. The most commonly used fuels for commercial a ...
,
diesel fuel Diesel fuel , also called diesel oil, is any liquid fuel specifically designed for use in a diesel engine, a type of internal combustion engine in which fuel ignition takes place without a spark as a result of compression of the inlet air and ...
,
heating oil Heating oil is any petroleum product or other oil used for heating; a fuel oil. Most commonly, it refers to low viscosity grades of fuel oil used for furnaces or boilers use for home heating and in other buildings. Home heating oil is often ...
, and heavier fuel oils. Heavier (less volatile) fractions can also be used to produce
asphalt Asphalt, also known as bitumen (, ), is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It may be found in natural deposits or may be a refined product, and is classed as a pitch. Before the 20th century, the term ...
,
tar Tar is a dark brown or black viscous liquid of hydrocarbons and free carbon, obtained from a wide variety of organic materials through destructive distillation. Tar can be produced from coal, wood, petroleum, or peat. "a dark brown or black bi ...
,
paraffin wax Paraffin wax (or petroleum wax) is a soft colorless solid derived from petroleum, coal, or oil shale that consists of a mixture of hydrocarbon molecules containing between 20 and 40 carbon atoms. It is solid at room temperature and begins t ...
,
lubricating Lubrication is the process or technique of using a lubricant to reduce friction and wear and tear in a contact between two surfaces. The study of lubrication is a discipline in the field of tribology. Lubrication mechanisms such as fluid-lubrica ...
and other heavy oils. Refineries also produce other
chemicals A chemical substance is a form of matter having constant chemical composition and characteristic properties. Some references add that chemical substance cannot be separated into its constituent elements by physical separation methods, i.e., wit ...
, some of which are used in
chemical process In a scientific sense, a chemical process is a method or means of somehow changing one or more chemicals or chemical compounds. Such a chemical process can occur by itself or be caused by an outside force, and involves a chemical reaction of some ...
es to produce
plastics Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be moulded, extruded or pressed into solid objects of various shapes. This adaptabi ...
and other useful materials. Since petroleum often contains a few percent
sulfur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formul ...
-containing molecules, elemental sulfur is also often produced as a petroleum product.
Carbon Carbon () is a chemical element with the symbol C and atomic number 6. It is nonmetallic and tetravalent—its atom making four electrons available to form covalent chemical bonds. It belongs to group 14 of the periodic table. Carbon ma ...
, in the form of
petroleum coke Petroleum coke, abbreviated coke or petcoke, is a final carbon-rich solid material that derives from oil refining, and is one type of the group of fuels referred to as cokes. Petcoke is the coke that, in particular, derives from a final crack ...
, and hydrogen may also be produced as petroleum products. The hydrogen produced is often used as an intermediate product for other oil refinery processes such as
hydrocracking In petrochemistry, petroleum geology and organic chemistry, cracking is the process whereby complex organic molecules such as kerogens or long-chain hydrocarbons are broken down into simpler molecules such as light hydrocarbons, by the breaking o ...
and
hydrodesulfurization Hydrodesulfurization (HDS) is a catalytic chemical process widely used to remove sulfur (S) from natural gas and from refined petroleum products, such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The purpose of rem ...
. Petroleum products are usually grouped into four categories: light distillates (LPG, gasoline, naphtha), middle distillates (kerosene, jet fuel, diesel), heavy distillates, and residuum (heavy fuel oil, lubricating oils, wax, asphalt). These require blending various feedstocks, mixing appropriate additives, providing short-term storage, and preparation for bulk loading to trucks, barges, product ships, and railcars. This classification is based on the way crude oil is distilled and separated into fractions. *
Gaseous fuel Fuel gas is any one of a number of fuels that under ordinary conditions are gaseous. Most fuel gases are composed of hydrocarbons (such as methane or propane), hydrogen, carbon monoxide, or mixtures thereof. Such gases are sources energy ...
such as
liquified petroleum gas Liquefied petroleum gas (LPG or LP gas) is a fuel gas which contains a flammable mixture of hydrocarbon gases, specifically propane, propylene, butylene, isobutane and n-butane. LPG is used as a fuel gas in heating appliances, cookin ...
and
propane Propane () is a three-carbon alkane with the molecular formula . It is a gas at standard temperature and pressure, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used as ...
, stored and shipped in liquid form under pressure. *
Lubricant A lubricant (sometimes shortened to lube) is a substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, t ...
s (produces light machine oils,
motor oil Motor oil, engine oil, or engine lubricant is any one of various substances used for the lubrication of internal combustion engines. They typically consist of base oils enhanced with various additives, particularly antiwear additives, deterg ...
s, and greases, adding
viscosity The viscosity of a fluid is a measure of its resistance to deformation at a given rate. For liquids, it corresponds to the informal concept of "thickness": for example, syrup has a higher viscosity than water. Viscosity quantifies the int ...
stabilizers as required), usually shipped in bulk to an offsite packaging plant. *
Paraffin wax Paraffin wax (or petroleum wax) is a soft colorless solid derived from petroleum, coal, or oil shale that consists of a mixture of hydrocarbon molecules containing between 20 and 40 carbon atoms. It is solid at room temperature and begins t ...
, used in the
candle A candle is an ignitable wick embedded in wax, or another flammable solid substance such as tallow, that provides light, and in some cases, a fragrance. A candle can also provide heat or a method of keeping time. A person who makes candle ...
industry, among others. May be shipped in bulk to a site to prepare as packaged blocks. Used for wax emulsions, candles, matches, rust protection, vapor barriers, construction board, and packaging of
frozen food Freezing food preserves it from the time it is prepared to the time it is eaten. Since early times, farmers, fishermen, and trappers have preserved grains and produce in unheated buildings during the winter season. Freezing food slows decompositi ...
s. *
Sulfur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formul ...
(or
sulfuric acid Sulfuric acid (American spelling and the preferred IUPAC name) or sulphuric acid ( Commonwealth spelling), known in antiquity as oil of vitriol, is a mineral acid composed of the elements sulfur, oxygen and hydrogen, with the molecular fo ...
), byproducts of sulfur removal from petroleum which may have up to a couple of percent sulfur as organic sulfur-containing compounds. Sulfur and sulfuric acid are useful industrial materials. Sulfuric acid is usually prepared and shipped as the acid precursor
oleum Oleum (Latin ''oleum'', meaning oil), or fuming sulfuric acid, is a term referring to solutions of various compositions of sulfur trioxide in sulfuric acid, or sometimes more specifically to disulfuric acid (also known as pyrosulfuric acid). Ol ...
. * Bulk
tar Tar is a dark brown or black viscous liquid of hydrocarbons and free carbon, obtained from a wide variety of organic materials through destructive distillation. Tar can be produced from coal, wood, petroleum, or peat. "a dark brown or black bi ...
shipping for offsite unit packaging for use in tar-and-gravel roofing. *
Asphalt Asphalt, also known as bitumen (, ), is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It may be found in natural deposits or may be a refined product, and is classed as a pitch. Before the 20th century, the term ...
used as a binder for
gravel Gravel is a loose aggregation of rock fragments. Gravel occurs naturally throughout the world as a result of sedimentary and erosive geologic processes; it is also produced in large quantities commercially as crushed stone. Gravel is classifi ...
to form
asphalt concrete Asphalt concrete (commonly called asphalt, blacktop, or pavement in North America, and tarmac, bitumen macadam, or rolled asphalt in the United Kingdom and the Republic of Ireland) is a composite material commonly used to surface roads, parki ...
, which is used for paving roads, lots, etc. An asphalt unit prepares bulk asphalt for shipment. *
Petroleum coke Petroleum coke, abbreviated coke or petcoke, is a final carbon-rich solid material that derives from oil refining, and is one type of the group of fuels referred to as cokes. Petcoke is the coke that, in particular, derives from a final crack ...
, used in specialty
carbon Carbon () is a chemical element with the symbol C and atomic number 6. It is nonmetallic and tetravalent—its atom making four electrons available to form covalent chemical bonds. It belongs to group 14 of the periodic table. Carbon ma ...
products like
electrode An electrode is an electrical conductor used to make contact with a nonmetallic part of a circuit (e.g. a semiconductor, an electrolyte, a vacuum or air). Electrodes are essential parts of batteries that can consist of a variety of materials ...
s or as solid fuel. *
Petrochemical Petrochemicals (sometimes abbreviated as petchems) are the chemical products obtained from petroleum by refining. Some chemical compounds made from petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewabl ...
s are
organic compound In chemistry, organic compounds are generally any chemical compounds that contain carbon-hydrogen or carbon-carbon bonds. Due to carbon's ability to catenate (form chains with other carbon atoms), millions of organic compounds are known. Th ...
s that are the ingredients for the chemical industry, ranging from polymers and pharmaceuticals, including
ethylene Ethylene (IUPAC name: ethene) is a hydrocarbon which has the formula or . It is a colourless, flammable gas with a faint "sweet and musky" odour when pure. It is the simplest alkene (a hydrocarbon with carbon-carbon double bonds). Ethylene ...
and
benzene Benzene is an organic chemical compound with the molecular formula C6H6. The benzene molecule is composed of six carbon atoms joined in a planar ring with one hydrogen atom attached to each. Because it contains only carbon and hydrogen atoms ...
-
toluene Toluene (), also known as toluol (), is a substituted aromatic hydrocarbon. It is a colorless, water-insoluble liquid with the smell associated with paint thinners. It is a mono-substituted benzene derivative, consisting of a methyl group (CH3) ...
-
xylene In organic chemistry, xylene or xylol (; IUPAC name: dimethylbenzene) are any of three organic compounds with the formula . They are derived from the substitution of two hydrogen atoms with methyl groups in a benzene ring; which hydrogens are s ...
s ("BTX") which are often sent to petro
chemical plant A chemical plant is an industrial process plant that manufactures (or otherwise processes) chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transfo ...
s for further processing in a variety of ways. The petrochemicals may be
olefin In organic chemistry, an alkene is a hydrocarbon containing a carbon–carbon double bond. Alkene is often used as synonym of olefin, that is, any hydrocarbon containing one or more double bonds.H. Stephen Stoker (2015): General, Organic, a ...
s or their precursors, or various types of
aromatic In chemistry, aromaticity is a chemical property of cyclic ( ring-shaped), ''typically'' planar (flat) molecular structures with pi bonds in resonance (those containing delocalized electrons) that gives increased stability compared to satur ...
petrochemicals. *
Gasoline Gasoline (; ) or petrol (; ) (see ) is a transparent, petroleum-derived flammable liquid that is used primarily as a fuel in most spark-ignited internal combustion engines (also known as petrol engines). It consists mostly of organic c ...
*
Naphtha Naphtha ( or ) is a flammable liquid hydrocarbon mixture. Mixtures labelled ''naphtha'' have been produced from natural gas condensates, petroleum distillates, and the distillation of coal tar and peat. In different industries and regions ' ...
*
Kerosene Kerosene, paraffin, or lamp oil is a combustible hydrocarbon liquid which is derived from petroleum. It is widely used as a fuel in aviation as well as households. Its name derives from el, κηρός (''keros'') meaning " wax", and was re ...
and related jet aircraft fuels *
Diesel fuel Diesel fuel , also called diesel oil, is any liquid fuel specifically designed for use in a diesel engine, a type of internal combustion engine in which fuel ignition takes place without a spark as a result of compression of the inlet air and ...
and
fuel oil Fuel oil is any of various fractions obtained from the distillation of petroleum (crude oil). Such oils include distillates (the lighter fractions) and residues (the heavier fractions). Fuel oils include heavy fuel oil, marine fuel oil (MFO), b ...
s *
Heat In thermodynamics, heat is defined as the form of energy crossing the boundary of a thermodynamic system by virtue of a temperature difference across the boundary. A thermodynamic system does not ''contain'' heat. Nevertheless, the term is ...
*
Electricity Electricity is the set of physical phenomena associated with the presence and motion of matter that has a property of electric charge. Electricity is related to magnetism, both being part of the phenomenon of electromagnetism, as describe ...
Over 6,000 items are made from petroleum waste by-products, including
fertilizer A fertilizer (American English) or fertiliser (British English; see spelling differences) is any material of natural or synthetic origin that is applied to soil or to plant tissues to supply plant nutrients. Fertilizers may be distinct from ...
, floor coverings,
perfume Perfume (, ; french: parfum) is a mixture of fragrant essential oils or aroma compounds (fragrances), fixatives and solvents, usually in liquid form, used to give the human body, animals, food, objects, and living-spaces an agreeable scent ...
,
insecticide Insecticides are substances used to kill insects. They include ovicides and larvicides used against insect eggs and larvae, respectively. Insecticides are used in agriculture, medicine, industry and by consumers. Insecticides are claimed t ...
,
petroleum jelly Petroleum jelly, petrolatum, white petrolatum, soft paraffin, or multi-hydrocarbon, CAS number 8009-03-8, is a semi-solid mixture of hydrocarbons (with carbon numbers mainly higher than 25), originally promoted as a topical ointment for its h ...
,
soap Soap is a salt of a fatty acid used in a variety of cleansing and lubricating products. In a domestic setting, soaps are surfactants usually used for washing, bathing, and other types of housekeeping. In industrial settings, soaps are us ...
,
vitamin capsules A vitamin is an organic molecule (or a set of molecules closely related chemically, i.e. vitamers) that is an essential micronutrient that an organism needs in small quantities for the proper functioning of its metabolism. Essential nutrien ...
. File:Petroleum.JPG, Sample of
crude oil Petroleum, also known as crude oil, or simply oil, is a naturally occurring yellowish-black liquid mixture of mainly hydrocarbons, and is found in geological formations. The name ''petroleum'' covers both naturally occurring unprocessed crude ...
(petroleum) File:LPG cylinders.JPG,
Cylinders A cylinder (from ) has traditionally been a three-dimensional solid, one of the most basic of curvilinear geometric shapes. In elementary geometry, it is considered a prism with a circle as its base. A cylinder may also be defined as an in ...
of
liquified petroleum gas Liquefied petroleum gas (LPG or LP gas) is a fuel gas which contains a flammable mixture of hydrocarbon gases, specifically propane, propylene, butylene, isobutane and n-butane. LPG is used as a fuel gas in heating appliances, cookin ...
File:Gasoline in mason jar.jpg, Sample of
gasoline Gasoline (; ) or petrol (; ) (see ) is a transparent, petroleum-derived flammable liquid that is used primarily as a fuel in most spark-ignited internal combustion engines (also known as petrol engines). It consists mostly of organic c ...
File:Kerosene in mason jar.JPG, Sample of
kerosene Kerosene, paraffin, or lamp oil is a combustible hydrocarbon liquid which is derived from petroleum. It is widely used as a fuel in aviation as well as households. Its name derives from el, κηρός (''keros'') meaning " wax", and was re ...
File:Diesel in mason jar.JPG, Sample of
diesel fuel Diesel fuel , also called diesel oil, is any liquid fuel specifically designed for use in a diesel engine, a type of internal combustion engine in which fuel ignition takes place without a spark as a result of compression of the inlet air and ...
File:Motor oil.JPG,
motor oil Motor oil, engine oil, or engine lubricant is any one of various substances used for the lubrication of internal combustion engines. They typically consist of base oils enhanced with various additives, particularly antiwear additives, deterg ...
File:Asphalt Concrete.jpg, Pile of
asphalt Asphalt, also known as bitumen (, ), is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It may be found in natural deposits or may be a refined product, and is classed as a pitch. Before the 20th century, the term ...
-covered aggregate for formation into
asphalt concrete Asphalt concrete (commonly called asphalt, blacktop, or pavement in North America, and tarmac, bitumen macadam, or rolled asphalt in the United Kingdom and the Republic of Ireland) is a composite material commonly used to surface roads, parki ...
File:Sulfur-sample.jpg,
Sulphur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formula ...


Chemical processes

*
Desalter A desalter is a process unit in an oil refinery that removes salt from the crude oil. The salt is dissolved in the water in the crude oil, not in the crude oil itself. The desalting is usually the first process in crude oil refining. The salt cont ...
unit washes out salt from the crude oil before it enters the atmospheric distillation unit. * Crude oil distillation unit distills the incoming crude oil into various fractions for further processing in other units. See
continuous distillation Continuous distillation, a form of distillation, is an ongoing separation in which a mixture is continuously (without interruption) fed into the process and separated fractions are removed continuously as output streams. Distillation is the sep ...
. *
Vacuum distillation Vacuum distillation is distillation performed under reduced pressure, which allows the purification of compounds not readily distilled at ambient pressures or simply to save time or energy. This technique separates compounds based on differences i ...
further distills the residue oil from the bottom of the crude oil distillation unit. The vacuum distillation is performed at a pressure well below atmospheric pressure. * Naphtha hydrotreater unit uses
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-to ...
to desulfurize naphtha from atmospheric distillation. Naphtha must be desulfurized before sending it to a catalytic reformer unit. *
Catalytic reformer Catalytic reforming is a chemical process used to convert petroleum refinery naphthas distilled from crude oil (typically having low octane ratings) into high-octane liquid products called reformates, which are premium blending stocks for high-oc ...
converts the desulfurized
naphtha Naphtha ( or ) is a flammable liquid hydrocarbon mixture. Mixtures labelled ''naphtha'' have been produced from natural gas condensates, petroleum distillates, and the distillation of coal tar and peat. In different industries and regions ' ...
molecule A molecule is a group of two or more atoms held together by attractive forces known as chemical bonds; depending on context, the term may or may not include ions which satisfy this criterion. In quantum physics, organic chemistry, and b ...
s into higher-octane molecules to produce
reformate Catalytic reforming is a chemical process used to convert petroleum refinery naphthas distilled from crude oil (typically having low octane ratings) into high-octane liquid products called reformates, which are premium blending stocks for high-o ...
(reformer product). The reformate has higher content of aromatics and cyclic hydrocarbons which is a component of the end-product gasoline or petrol. An important byproduct of a reformer is hydrogen released during the catalyst reaction. The hydrogen is used either in the hydrotreaters or the hydrocracker. * Distillate hydrotreater desulfurizes distillates (such as diesel) after atmospheric distillation. Uses
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-to ...
to desulfurize the
naphtha Naphtha ( or ) is a flammable liquid hydrocarbon mixture. Mixtures labelled ''naphtha'' have been produced from natural gas condensates, petroleum distillates, and the distillation of coal tar and peat. In different industries and regions ' ...
fraction from the crude oil distillation or other units within the refinery. *
Fluid catalytic cracker In physics, a fluid is a liquid, gas, or other material that continuously deforms (''flows'') under an applied shear stress, or external force. They have zero shear modulus, or, in simpler terms, are substances which cannot resist any shea ...
(FCC) upgrades the heavier, higher-boiling fractions from the crude oil distillation by converting them into lighter and lower boiling, more valuable products. *
Hydrocracker In petrochemistry, petroleum geology and organic chemistry, cracking is the process whereby complex organic molecules such as kerogens or long-chain hydrocarbons are broken down into simpler molecules such as light hydrocarbons, by the breaking of ...
uses hydrogen to upgrade heavy residual oils from the vacuum distillation unit by thermally cracking them into lighter, more valuable reduced viscosity products. *
Merox Merox is an acronym for mercaptan oxidation. It is a proprietary catalytic chemical process developed by UOP used in oil refineries and natural gas processing plants to remove mercaptans from LPG, propane, butanes, light naphthas, kerosene and ...
desulfurize LPG, kerosene or jet fuel by oxidizing
mercaptan In organic chemistry, a thiol (; ), or thiol derivative, is any organosulfur compound of the form , where R represents an alkyl or other organic substituent. The functional group itself is referred to as either a thiol group or a sulfhydryl gro ...
s to organic
disulfide In biochemistry, a disulfide (or disulphide in British English) refers to a functional group with the structure . The linkage is also called an SS-bond or sometimes a disulfide bridge and is usually derived by the coupling of two thiol groups. In ...
s. * Alternative processes for removing mercaptans are known, e.g.
doctor sweetening process The doctor sweetening process is an industrial chemical process for converting mercaptans in sour gasoline into disulfides. Sulfur compounds darken gasoline, give it an offensive odor and increase toxic sulfur dioxide engine emissions. However, th ...
and caustic washing. * Coking units (
delayed coker A delayed coker is a type of coker whose process consists of heating a residual oil feed to its thermal cracking temperature in a furnace with multiple parallel passes. This cracks the heavy, long chain hydrocarbon molecules of the residual oil ...
, fluid coker, and flexicoker) process very heavy residual oils into gasoline and diesel fuel, leaving petroleum coke as a residual product. *
Alkylation Alkylation is the transfer of an alkyl group from one molecule to another. The alkyl group may be transferred as an alkyl carbocation, a free radical, a carbanion, or a carbene (or their equivalents). Alkylating agents are reagents for effectin ...
unit uses
sulfuric acid Sulfuric acid (American spelling and the preferred IUPAC name) or sulphuric acid ( Commonwealth spelling), known in antiquity as oil of vitriol, is a mineral acid composed of the elements sulfur, oxygen and hydrogen, with the molecular fo ...
or
hydrofluoric acid Hydrofluoric acid is a solution of hydrogen fluoride (HF) in water. Solutions of HF are colourless, acidic and highly corrosive. It is used to make most fluorine-containing compounds; examples include the commonly used pharmaceutical antidepres ...
to produce high-octane components for gasoline blending. The "alky" unit converts light end
isobutane Isobutane, also known as ''i''-butane, 2-methylpropane or methylpropane, is a chemical compound with molecular formula HC(CH3)3. It is an isomer of butane. Isobutane is a colourless, odourless gas. It is the simplest alkane with a tertiary carbo ...
and
butylene Butene, also known as butylene, is an alkene with the formula . The word ''butene'' may refer to any of the individual compounds. They are colourless gases that are present in crude oil as a minor constituent in quantities that are too small for ...
s from the FCC process into ''alkylate'', a very high-octane component of the end-product gasoline or petrol. *
Dimerization A dimer () ('' di-'', "two" + ''-mer'', "parts") is an oligomer consisting of two monomers joined by bonds that can be either strong or weak, covalent or intermolecular. Dimers also have significant implications in polymer chemistry, inorganic che ...
unit converts
olefins In organic chemistry, an alkene is a hydrocarbon containing a carbon–carbon double bond. Alkene is often used as synonym of olefin, that is, any hydrocarbon containing one or more double bonds.H. Stephen Stoker (2015): General, Organic, a ...
into higher-octane gasoline blending components. For example,
butene Butene, also known as butylene, is an alkene with the formula . The word ''butene'' may refer to any of the individual compounds. They are colourless gases that are present in crude oil as a minor constituent in quantities that are too small for ...
s can be dimerized into isooctene which may subsequently be hydrogenated to form
isooctane 2,2,4-Trimethylpentane, also known as isooctane or iso-octane, is an organic compound with the formula (CH3)3CCH2CH(CH3)2. It is one of several isomers of octane (C8H18). This particular isomer is the standard 100 point on the octane rating sc ...
. There are also other uses for dimerization. Gasoline produced through dimerization is highly unsaturated and very reactive. It tends spontaneously to form gums. For this reason, the effluent from the dimerization needs to be blended into the finished gasoline pool immediately or hydrogenated. *
Isomerization In chemistry, isomerization or isomerisation is the process in which a molecule, polyatomic ion or molecular fragment is transformed into an isomer with a different chemical structure. Enolization is an example of isomerization, as is tautomeriz ...
converts linear molecules such as normal
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 ...
to higher-octane branched molecules for blending into gasoline or feed to alkylation units. Also used to convert linear normal
butane Butane () or ''n''-butane is an alkane with the formula C4H10. Butane is a gas at room temperature and atmospheric pressure. Butane is a highly flammable, colorless, easily liquefied gas that quickly vaporizes at room temperature. The name but ...
into isobutane for use in the alkylation unit. *
Steam reforming Steam reforming or steam methane reforming (SMR) is a method for producing syngas (hydrogen and carbon monoxide) by reaction of hydrocarbons with water. Commonly natural gas is the feedstock. The main purpose of this technology is hydrogen product ...
converts natural gas into hydrogen for the hydrotreaters and/or the hydrocracker. * Liquified gas storage vessels store propane and similar gaseous fuels at pressure sufficient to maintain them in liquid form. These are usually spherical vessels or "bullets" (i.e., horizontal vessels with rounded ends). * Amine gas treater, Claus unit, and tail gas treatment convert
hydrogen sulfide Hydrogen sulfide is a chemical compound with the formula . It is a colorless chalcogen-hydride gas, and is poisonous, corrosive, and flammable, with trace amounts in ambient atmosphere having a characteristic foul odor of rotten eggs. The under ...
from
hydrodesulfurization Hydrodesulfurization (HDS) is a catalytic chemical process widely used to remove sulfur (S) from natural gas and from refined petroleum products, such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The purpose of rem ...
into elemental sulfur. The large majority of the 64,000,000 metric tons of sulfur produced worldwide in 2005 was byproduct sulfur from petroleum refining and
natural gas processing Natural-gas processing is a range of industrial processes designed to purify raw natural gas by removing impurities, contaminants and higher molecular mass hydrocarbons to produce what is known as ''pipeline quality'' dry natural gas. Natural gas ...
plants. * Sour water stripper uses steam to remove hydrogen sulfide gas from various wastewater streams for subsequent conversion into end-product sulfur in the Claus unit. *
Cooling towers A cooling tower is a device that rejects waste heat to the atmosphere through the cooling of a coolant stream, usually a water stream to a lower temperature. Cooling towers may either use the evaporation of water to remove process heat and ...
circulate cooling water, boiler plants generates
steam Steam is a substance containing water in the gas phase, and sometimes also an aerosol of liquid water droplets, or air. This may occur due to evaporation or due to boiling, where heat is applied until water reaches the enthalpy of vaporizatio ...
for
steam generators A steam generator is a form of low water-content boiler, similar to a flash steam boiler. The usual construction is as a spiral coil of water-tube, arranged as a single, or monotube, coil. Circulation is once-through and pumped under pressure, ...
, and instrument air systems include pneumatically operated
control valves A control valve is a valve used to control fluid flow by varying the size of the flow passage as directed by a signal from a controller. This enables the direct control of flow rate and the consequential control of process quantities such as pressu ...
and an
electrical substation A substation is a part of an electrical generation, transmission, and distribution system. Substations transform voltage from high to low, or the reverse, or perform any of several other important functions. Between the generating station and ...
. *
Wastewater Wastewater is water generated after the use of freshwater, raw water, drinking water or saline water in a variety of deliberate applications or processes. Another definition of wastewater is "Used water from any combination of domestic, industrial ...
collection and treating systems consist of API separators, dissolved air flotation (DAF) units and further treatment units such as an
activated sludge The activated sludge process is a type of biological wastewater treatment process for treating sewage or industrial wastewaters using aeration and a biological floc composed of bacteria and protozoa. It uses air (or oxygen) and microorganism ...
biotreater to make water suitable for reuse or for disposal. * Solvent refining uses solvent such as
cresol Cresols (also hydroxytoluene or cresylic acid) are a group of aromatic organic compounds. They are widely-occurring phenols (sometimes called ''phenolics'') which may be either natural or manufactured. They are also categorized as methylphenol ...
or
furfural Furfural is an organic compound with the formula C4H3OCHO. It is a colorless liquid, although commercial samples are often brown. It has an aldehyde group attached to the 2-position of furan. It is a product of the dehydration of sugars, as occur ...
to remove unwanted, mainly aromatics from lubricating oil stock or diesel stock. * Solvent dewaxing removes the heavy waxy constituents
petrolatum Petroleum jelly, petrolatum, white petrolatum, soft paraffin, or multi-hydrocarbon, CAS number 8009-03-8, is a semi-solid mixture of hydrocarbons (with carbon numbers mainly higher than 25), originally promoted as a topical ointment for its he ...
from vacuum distillation products. * Storage tanks for storing crude oil and finished products, usually vertical, cylindrical vessels with some sort of vapor emission control and surrounded by an earthen
berm A berm is a level space, shelf, or raised barrier (usually made of compacted soil) separating areas in a vertical way, especially partway up a long slope. It can serve as a terrace road, track, path, a fortification line, a border/ separation ...
to contain spills.


Flow diagram of typical refinery

The image below is a schematic
flow diagram Flow diagram is a collective term for a diagram representing a flow or set of dynamic relationships in a system. The term flow diagram is also used as a synonym for flowchart, and sometimes as a counterpart of the flowchart.Harris. (1999, p. 156 ...
of a typical oil refinery that depicts the various
unit Unit may refer to: Arts and entertainment * UNIT, a fictional military organization in the science fiction television series ''Doctor Who'' * Unit of action, a discrete piece of action (or beat) in a theatrical presentation Music * ''Unit'' (a ...
processes and the flow of intermediate product streams that occurs between the inlet crude oil feedstock and the final end products. The diagram depicts only one of the literally hundreds of different oil refinery configurations. The diagram also does not include any of the usual refinery 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. There are many process configurations other than that depicted above. For example, the
vacuum distillation Vacuum distillation is distillation performed under reduced pressure, which allows the purification of compounds not readily distilled at ambient pressures or simply to save time or energy. This technique separates compounds based on differences i ...
unit may also produce fractions that can be refined into end products such as spindle oil used in the textile industry, light machine oil, motor oil, and various waxes.


Crude oil distillation unit

The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum refineries. The CDU distills the incoming crude oil into various fractions of different boiling ranges, each of which is then processed further in the other refinery processing units. The CDU is often referred to as the ''atmospheric distillation unit'' because it operates at slightly above atmospheric pressure. Below is a schematic flow diagram of a typical crude oil distillation unit. The incoming crude oil is preheated by exchanging heat with some of the hot, distilled fractions and other streams. It is then desalted to remove inorganic salts (primarily sodium chloride). Following the desalter, the crude oil is further heated by exchanging heat with some of the hot, distilled fractions and other streams. It is then heated in a fuel-fired furnace (fired heater) to a temperature of about 398 °C and routed into the bottom of the distillation unit. The cooling and condensing of the distillation tower overhead is provided partially by exchanging heat with the incoming crude oil and partially by either an air-cooled or water-cooled condenser. Additional heat is removed from the distillation column by a pumparound system as shown in the diagram below. As shown in the flow diagram, the overhead distillate fraction from the distillation column is naphtha. The fractions removed from the side of the distillation column at various points between the column top and bottom are called ''sidecuts''. Each of the sidecuts (i.e., the kerosene, light gas oil, and heavy gas oil) is cooled by exchanging heat with the incoming crude oil. All of the fractions (i.e., the overhead naphtha, the sidecuts, and the bottom residue) are sent to intermediate storage tanks before being processed further.


Location of refineries

A party searching for a site to construct a refinery or a chemical plant needs to consider the following issues: * The site has to be reasonably far from residential areas. * Infrastructure should be available for the supply of raw materials and shipment of products to markets. * Energy to operate the plant should be available. * Facilities should be available for waste disposal. Factors affecting site selection for oil refinery: * Availability of land * Conditions of traffic and transportation * Conditions of utilities - power supply, water supply * Availability of labours and resources Refineries that use a large amount of steam and cooling water need to have an abundant source of water. Oil refineries, therefore, are often located nearby navigable rivers or on a seashore, nearby a port. Such location also gives access to transportation by river or by sea. The advantages of transporting crude oil by pipeline are evident, and oil companies often transport a large volume of fuel to distribution terminals by pipeline. A pipeline may not be practical for products with small output, and railcars, road tankers, and barges are used. Petrochemical plants and solvent manufacturing (fine fractionating) plants need spaces for further processing of a large volume of refinery products, or to mix chemical additives with a product at source rather than at blending terminals.


Safety and environment

The refining process releases a number of different chemicals into the
atmosphere An atmosphere () is a layer of gas or layers of gases that envelop a planet, and is held in place by the gravity of the planetary body. A planet retains an atmosphere when the gravity is great and the temperature of the atmosphere is low. A ...
(see
AP 42 Compilation of Air Pollutant Emission Factors The ''AP 42 Compilation of Air Pollutant Emission Factors'' is a compilation of the US Environmental Protection Agency (EPA)'s emission factor information on air pollution, first published in 1968. , the last edition is the 5th from 2010. Histo ...
) and a notable
odor An odor (American English) or odour (Commonwealth English; see spelling differences) is caused by one or more volatilized chemical compounds that are generally found in low concentrations that humans and animals can perceive via their sense ...
normally accompanies the presence of a refinery. Aside from air pollution impacts there are also wastewater concerns, risks of
industrial accident A work accident, workplace accident, occupational accident, or accident at work is a "discrete occurrence in the course of work" leading to physical or mental occupational injury. According to the International Labour Organization (ILO), more tha ...
s such as fire and explosion, and
noise health effects Noise health effects are the physical and psychological health consequences of regular exposure to consistent elevated sound levels. Noise from traffic, in particular, is considered by the World Health Organization to be one of the worst environm ...
due to
industrial noise Occupational noise is the amount of acoustic energy received by an employee's auditory system when they are working in the industry. Occupational noise, or industrial noise, is often a term used in occupational safety and health, as sustained expos ...
. Many governments worldwide have mandated restrictions on contaminants that refineries release, and most refineries have installed the equipment needed to comply with the requirements of the pertinent environmental protection regulatory agencies. In the United States, there is strong pressure to prevent the development of new refineries, and no major refinery has been built in the country since Marathon's
Garyville, Louisiana Garyville is a census-designated place (CDP) in St. John the Baptist Parish, Louisiana, United States. The population was 2,775 at the 2000 census and 2,123 in 2020. It is part of the New Orleans– Metairie–Kenner Metropolitan Statist ...
facility in 1976. However, many existing refineries have been expanded during that time. Environmental restrictions and pressure to prevent the construction of new refineries may have also contributed to rising fuel prices in the United States. Additionally, many refineries (more than 100 since the 1980s) have closed due to obsolescence and/or merger activity within the industry itself. Environmental and safety concerns mean that oil refineries are sometimes located some distance away from major urban areas. Nevertheless, there are many instances where refinery operations are close to populated areas and pose health risks. In California's
Contra Costa County ) of the San Francisco Bay , subdivision_type = Country , subdivision_name = United States , subdivision_type1 = State , subdivision_name1 = California , subdivision_type2 ...
and
Solano County Solano County () is a county located in the U.S. state of California. As of the 2020 census, the population was 453,491. The county seat is Fairfield. Solano County comprises the Vallejo–Fairfield, CA Metropolitan Statistical Area, which i ...
, a shoreline necklace of refineries, built in the early 20th century before this area was populated, and associated chemical plants are adjacent to urban areas in
Richmond Richmond most often refers to: * Richmond, Virginia, the capital of Virginia, United States * Richmond, London, a part of London * Richmond, North Yorkshire, a town in England * Richmond, British Columbia, a city in Canada * Richmond, Californi ...
, Martinez,
Pacheco Pacheco is a Portuguese and Spanish name which may refer to: General * Alex Pacheco (born 1958), animal rights activist, co-founder of PETA. *Ángel Pacheco (general) (1793-1869), was an Argentine military officer trained by José de San Martín ...
,
Concord Concord may refer to: Meaning "agreement" * Pact or treaty, frequently between nations (indicating a condition of harmony) * Harmony, in music * Agreement (linguistics), a change in the form of a word depending on grammatical features of other ...
, Pittsburg, Vallejo and
Benicia Benicia ( , ) is a waterside city in Solano County, California, located in the North Bay region of the San Francisco Bay Area. It served as the capital of California for nearly thirteen months from 1853 to 1854. The population was 26,997 at th ...
, with occasional accidental events that require "
shelter in place Shelter-in-place (SIP; also known as a shelter-in-place warning, SAME code SPW) is the act of seeking safety within the building one already occupies, rather than evacuating the area or seeking a community emergency shelter. The American Red Cro ...
" orders to the adjacent populations. A number of refineries are located in Sherwood Park, Alberta, directly adjacent to the City of
Edmonton Edmonton ( ) is the capital city of the Canadian province of Alberta. Edmonton is situated on the North Saskatchewan River and is the centre of the Edmonton Metropolitan Region, which is surrounded by Alberta's central region. The city an ...
, which has a population of over 1,000,000 residents.
NIOSH The National Institute for Occupational Safety and Health (NIOSH, ) is the United States federal agency responsible for conducting research and making recommendations for the prevention of work-related injury and illness. NIOSH is part of the ...
criteria for occupational exposure to refined petroleum solvents have been available since 1977.


Worker health


Background

Modern
petroleum refining An oil refinery or petroleum refinery is an industrial process plant where petroleum (crude oil) is transformed and refined into useful products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, liquefi ...
involves a complicated system of interrelated chemical reactions that produce a wide variety of petroleum-based products. Many of these reactions require precise temperature and pressure parameters.  The equipment and monitoring required to ensure the proper progression of these processes is complex, and has evolved through the advancement of the scientific field of petroleum engineering. The wide array of high pressure and/or high temperature reactions, along with the necessary chemical additives or extracted contaminants, produces an astonishing number of potential health hazards to the oil refinery worker.  Through the advancement of technical chemical and petroleum engineering, the vast majority of these processes are automated and enclosed, thus greatly reducing the potential health impact to workers.  However, depending on the specific process in which a worker is engaged, as well as the particular method employed by the refinery in which he/she works, significant health hazards remain. Although occupational injuries in the United States were not routinely tracked and reported at the time, reports of the health impacts of working in an oil refinery can be found as early as the 1800s. For instance, an explosion in a Chicago refinery killed 20 workers in 1890. Since then, numerous fires, explosions, and other significant events have from time to time drawn the public's attention to the health of oil refinery workers. Such events continue in the 21st century, with explosions reported in refineries in Wisconsin and Germany in 2018. However, there are many less visible hazards that endanger oil refinery workers.


Chemical exposures

Given the highly automated and technically advanced nature of modern petroleum refineries, nearly all processes are contained within engineering controls and represent a substantially decreased risk of exposure to workers compared to earlier times. However, certain situations or work tasks may subvert these safety mechanisms, and expose workers to a number of chemical (see table above) or physical (described below) hazards. Examples of these scenarios include: * System failures (leaks, explosions, etc.). * Standard inspection, product sampling, process turnaround, or equipment maintenance/cleaning activities. Interestingly, even though petroleum refineries utilize and produce chemicals that are known
carcinogen A carcinogen is any substance, radionuclide, or radiation that promotes carcinogenesis (the formation of cancer). This may be due to the ability to damage the genome or to the disruption of cellular metabolic processes. Several radioactive sub ...
s, the literature on cancer rates among refinery workers is mixed. For example,
benzene Benzene is an organic chemical compound with the molecular formula C6H6. The benzene molecule is composed of six carbon atoms joined in a planar ring with one hydrogen atom attached to each. Because it contains only carbon and hydrogen atoms ...
has been shown to have a relationship with
leukemia Leukemia ( also spelled leukaemia and pronounced ) is a group of blood cancers that usually begin in the bone marrow and result in high numbers of abnormal blood cells. These blood cells are not fully developed and are called ''blasts'' or ...
, however studies examining benzene exposure and resultant leukemia specifically in the context of oil refinery workers have come to opposing conclusions.
Asbestos Asbestos () is a naturally occurring fibrous silicate mineral. There are six types, all of which are composed of long and thin fibrous crystals, each fibre being composed of many microscopic "fibrils" that can be released into the atmosphere b ...
-related
mesothelioma Mesothelioma is a type of cancer that develops from the thin layer of tissue that covers many of the internal organs (known as the mesothelium). The most common area affected is the lining of the lungs and chest wall. Less commonly the lining ...
is another particular cancer-carcinogen relationship that has been investigated in the context of oil refinery workers. To date, this work has shown a marginally significant link to refinery employment and mesothelioma. Notably, a meta-analysis which included data on more than 350,000 refinery workers failed to find any statistically significant excess rates of cancer mortality, except for a marginally significant increase in melanoma deaths. An additional US-based study included a follow-up period of 50 years among over 17,000 workers. This study concluded that there was no excess mortality among this cohort as a result of employment. BTX stands for benzene,
toluene Toluene (), also known as toluol (), is a substituted aromatic hydrocarbon. It is a colorless, water-insoluble liquid with the smell associated with paint thinners. It is a mono-substituted benzene derivative, consisting of a methyl group (CH3) ...
,
xylene In organic chemistry, xylene or xylol (; IUPAC name: dimethylbenzene) are any of three organic compounds with the formula . They are derived from the substitution of two hydrogen atoms with methyl groups in a benzene ring; which hydrogens are s ...
. This is a group of common
volatile organic compound Volatile organic compounds (VOCs) are organic compounds that have a high vapour pressure at room temperature. High vapor pressure correlates with a low boiling point, which relates to the number of the sample's molecules in the surrounding air, a ...
s (VOCs) that are found in the oil refinery environment, and serve as a paradigm for more in depth discussion of occupational exposure limits, chemical exposure and surveillance among refinery workers. The most important route of exposure for BTX chemicals is inhalation due to the low boiling point of these chemicals. The majority of the gaseous production of BTX occurs during tank cleaning and fuel transfer, which causes offgassing of these chemicals into the air. Exposure can also occur through ingestion via contaminated water, but this is unlikely in an occupational setting. Dermal exposure and absorption is also possible, but is again less likely in an occupational setting where appropriate personal protective equipment is in place. In the United States, the
Occupational Safety and Health Administration The Occupational Safety and Health Administration'' (OSHA ) is a large regulatory agency of the United States Department of Labor that originally had federal visitorial powers to inspect and examine workplaces. Congress established the agen ...
(OSHA),
National Institute for Occupational Safety and Health The National Institute for Occupational Safety and Health (NIOSH, ) is the United States federal agency responsible for conducting research and making recommendations for the prevention of work-related injury and illness. NIOSH is part of the C ...
(NIOSH), and
American Conference of Governmental Industrial Hygienists The American Conference of Governmental Industrial Hygienists (ACGIH) is a professional association of industrial hygienists and practitioners of related professions, with headquarters in Cincinnati, Ohio. One of its goals is to advance worker pr ...
(ACGIH) have all established
occupational exposure limit An occupational exposure limit is an upper limit on the acceptable concentration of a hazardous substance in workplace air for a particular material or class of materials. It is typically set by competent national authorities and enforced by legi ...
s (OELs) for many of the chemicals above that workers may be exposed to in petroleum refineries. Benzene, in particular, has multiple
biomarker In biomedical contexts, a biomarker, or biological marker, is a measurable indicator of some biological state or condition. Biomarkers are often measured and evaluated using blood, urine, or soft tissues to examine normal biological processes, p ...
s that can be measured to determine exposure. Benzene itself can be measured in the breath, blood, and urine, and metabolites such as
phenol Phenol (also called carbolic acid) is an aromatic organic compound with the molecular formula . It is a white crystalline solid that is volatile. The molecule consists of a phenyl group () bonded to a hydroxy group (). Mildly acidic, it r ...
, ''t'',''t''-muconic acid (''t'',''t''MA) and S-phenylmercapturic acid (''s''PMA) can be measured in urine. In addition to monitoring the exposure levels via these biomarkers, employers are required by OSHA to perform regular blood tests on workers to test for early signs of some of the feared hematologic outcomes, of which the most widely recognized is leukemia. Required testing includes complete blood count with cell differentials and
peripheral blood smear A blood smear, peripheral blood smear or blood film is a thin layer of blood smeared on a glass microscope slide and then stained in such a way as to allow the various blood cells to be examined microscopically. Blood smears are examined in the ...
"on a regular basis". The utility of these tests is supported by formal scientific studies.


Potential chemical exposure by process


Physical hazards

Workers are at risk of physical injuries due to a large number of high-powered machines in the relatively close proximity of the oil refinery. The high pressure required for many of the chemical reactions also presents the possibility of localized system failures resulting in blunt or penetrating trauma from exploding system components. Heat is also a hazard. The temperature required for the proper progression of certain reactions in the refining process can reach . As with chemicals, the operating system is designed to safely contain this hazard without injury to the worker. However, in system failures, this is a potent threat to workers’ health. Concerns include both direct injury through a heat illness or injury, as well as the potential for devastating burns should the worker come in contact with super-heated reagents/equipment. Noise is another hazard. Refineries can be very loud environments, and have previously been shown to be associated with hearing loss among workers. The interior environment of an oil refinery can reach levels in excess of 90  dB. In the United States, an average of 90 dB is the
permissible exposure limit The permissible exposure limit (PEL or OSHA PEL) is a legal limit in the United States for exposure of an employee to a chemical substance or physical agent such as high level noise. Permissible exposure limits are established by the Occupationa ...
(PEL) for an 8-hour work-day. Noise exposures that average greater than 85 dB over an 8-hour require a
hearing conservation program Hearing conservation programs are designed to prevent hearing loss due to noise. Hearing conservation programs require knowledge about risk factors such as noise and ototoxicity, hearing, hearing loss, protective measures to prevent hearing loss ...
to regularly evaluate workers' hearing and to promote its protection.  Regular evaluation of workers’ auditory capacity and faithful use of properly vetted hearing protection are essential parts of such programs. While not specific to the industry, oil refinery workers may also be at risk for hazards such as vehicle-related accidents, machinery-associated injuries, work in a confined space, explosions/fires,
ergonomic hazard Ergonomic hazards are physical conditions that may pose a risk of injury to the musculoskeletal system. Ergonomic hazards include awkward postures, static postures, high forces, repetitive motion, or short intervals between activities. The risk ...
s, shift-work related sleep disorders, and falls.


Hazard controls

The theory of hierarchy of controls can be applied to petroleum refineries and their efforts to ensure worker safety. Elimination and
substitution Substitution may refer to: Arts and media *Chord substitution, in music, swapping one chord for a related one within a chord progression *Substitution (poetry), a variation in poetic scansion * "Substitution" (song), a 2009 song by Silversun Pic ...
are unlikely in petroleum refineries, as many of the raw materials, waste products, and finished products are hazardous in one form or another (e.g. flammable, carcinogenic). Examples of
engineering controls Engineering controls are strategies designed to protect workers from hazardous conditions by placing a barrier between the worker and the hazard or by removing a hazardous substance through air ventilation. Engineering controls involve a physi ...
include a fire detection/extinguishing system, pressure/chemical sensors to detect/predict loss of structural integrity, and adequate maintenance of piping to prevent hydrocarbon-induced
corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engi ...
(leading to structural failure). Other examples employed in petroleum refineries include the post-construction protection of steel components with
vermiculite Vermiculite is a hydrous phyllosilicate mineral which undergoes significant expansion when heated. Exfoliation occurs when the mineral is heated sufficiently, and commercial furnaces can routinely produce this effect. Vermiculite forms by the we ...
to improve heat/fire resistance. Compartmentalization can help to prevent a fire or other systems failure from spreading to affect other areas of the structure, and may help prevent dangerous reactions by keeping different chemicals separate from one another until they can be safely combined in the proper environment.
Administrative controls Administrative controls are training, procedure, policy, or shift designs that lessen the threat of a hazard to an individual. Administrative controls typically change the behavior of people (e.g., factory workers) rather than removing the actu ...
include careful planning and oversight of the refinery cleaning, maintenance, and turnaround processes. These occur when many of the engineering controls are shut down or suppressed and may be especially dangerous to workers. Detailed coordination is necessary to ensure that maintenance of one part of the facility will not cause dangerous exposures to those performing the maintenance, or to workers in other areas of the plant. Due to the highly flammable nature of many of the involved chemicals, smoking areas are tightly controlled and carefully placed.
Personal protective equipment Personal protective equipment (PPE) is protective clothing, helmets, goggles, or other garments or equipment designed to protect the wearer's body from injury or infection. The hazards addressed by protective equipment include physical, ...
(PPE) may be necessary depending on the specific chemical being processed or produced. Particular care is needed during sampling of the partially-completed product, tank cleaning, and other high-risk tasks as mentioned above. Such activities may require the use of impervious outerwear, acid hood, disposable coveralls, etc. More generally, all personnel in operating areas should use appropriate
hearing Hearing, or auditory perception, is the ability to perceive sounds through an organ, such as an ear, by detecting vibrations as periodic changes in the pressure of a surrounding medium. The academic field concerned with hearing is audit ...
and vision protection, avoid clothes made of flammable material (
nylon Nylon is a generic designation for a family of synthetic polymers composed of polyamides ( repeating units linked by amide links).The polyamides may be aliphatic or semi-aromatic. Nylon is a silk-like thermoplastic, generally made from pet ...
,
Dacron Polyethylene terephthalate (or poly(ethylene terephthalate), PET, PETE, or the obsolete PETP or PET-P), is the most common thermoplastic polymer resin of the polyester family and is used in fibres for clothing, containers for liquids and fo ...
,
acrylic Acrylic may refer to: Chemicals and materials * Acrylic acid, the simplest acrylic compound * Acrylate polymer, a group of polymers (plastics) noted for transparency and elasticity * Acrylic resin, a group of related thermoplastic or thermosett ...
, or blends), and full-length pants and sleeves.


Regulations


United States

Worker health and safety in oil refineries is closely monitored at a national level by both the
Occupational Safety and Health Administration The Occupational Safety and Health Administration'' (OSHA ) is a large regulatory agency of the United States Department of Labor that originally had federal visitorial powers to inspect and examine workplaces. Congress established the agen ...
(OSHA) and
National Institute for Occupational Safety and Health The National Institute for Occupational Safety and Health (NIOSH, ) is the United States federal agency responsible for conducting research and making recommendations for the prevention of work-related injury and illness. NIOSH is part of the C ...
(NIOSH). In addition to federal monitoring,
California California is a state in the Western United States, located along the Pacific Coast. With nearly 39.2million residents across a total area of approximately , it is the most populous U.S. state and the 3rd largest by area. It is also the m ...
's CalOSHA has been particularly active in protecting worker health in the industry, and adopted a policy in 2017 that requires petroleum refineries to perform a "Hierarchy of Hazard Controls Analysis" (see above "Hazard controls" section) for each process safety hazard. Safety regulations have resulted in a below-average injury rate for refining industry workers. In a 2018 report by the
US Bureau of Labor Statistics The Bureau of Labor Statistics (BLS) is a unit of the United States Department of Labor. It is the principal fact-finding agency for the U.S. government in the broad field of labor economics and statistics and serves as a principal agency of ...
, they indicate that petroleum refinery workers have a significantly lower rate of occupational injury (0.4 OSHA-recordable cases per 100 full-time workers) than all industries (3.1 cases), oil and gas extraction (0.8 cases), and petroleum manufacturing in general (1.3 cases). Below is a list of the most common regulations referenced in petroleum refinery safety citations issued by OSHA: * Flammable and Combustible Liquids () * The Hazard Communication (HazCom) standard () * Permit-Required Confined Spaces () * Hazardous (Classified) Locations () * The Personal Protective Equipment (PPE) standard () * The Control of Hazardous Energy (Lockout/Tagout) standard ()


Corrosion

Corrosion of metallic components is a major factor of inefficiency in the refining process. Because it leads to equipment failure, it is a primary driver for the refinery maintenance schedule. Corrosion-related direct costs in the U.S. petroleum industry as of 1996 were estimated at US$3.7 billion.Corrosion Costs and Preventive Strategies in the United States
, a publication of
NACE International The Association for Materials Protection and Performance (AMPP), is a professional association focused on the protection of assets and performance of materials. AMPP was created when NACE International and SSPC the Society for Protective Coat ...
.
Corrosion occurs in various forms in the refining process, such as pitting corrosion from water droplets, embrittlement from hydrogen, and stress corrosion cracking from sulfide attack.
From a materials standpoint, carbon steel is used for upwards of 80 percent of refinery components, which is beneficial due to its low cost.
Carbon steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, coba ...
is resistant to the most common forms of corrosion, particularly from hydrocarbon impurities at temperatures below 205 °C, but other corrosive chemicals and environments prevent its use everywhere. Common replacement materials are
low alloy steel Alloy steel is steel that is alloyed with a variety of elements in total amounts between 1.0% and 50% by weight to improve its mechanical properties. Alloy steels are broken down into two groups: low alloy steels and high alloy steels. The differe ...
s containing
chromium Chromium is a chemical element with the symbol Cr and atomic number 24. It is the first element in group 6. It is a steely-grey, lustrous, hard, and brittle transition metal. Chromium metal is valued for its high corrosion resistance and hard ...
and
molybdenum Molybdenum is a chemical element with the symbol Mo and atomic number 42 which is located in period 5 and group 6. The name is from Neo-Latin ''molybdaenum'', which is based on Ancient Greek ', meaning lead, since its ores were confused with lead ...
, with
stainless steels Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's res ...
containing more chromium dealing with more corrosive environments. More expensive materials commonly used are
nickel Nickel is a chemical element with symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel is a hard and ductile transition metal. Pure nickel is chemically reactive but large pieces are slow t ...
,
titanium Titanium is a chemical element with the symbol Ti and atomic number 22. Found in nature only as an oxide, it can be reduced to produce a lustrous transition metal with a silver color, low density, and high strength, resistant to corrosion i ...
, and
copper Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pink ...
alloys. These are primarily saved for the most problematic areas where extremely high temperatures and/or very corrosive chemicals are present. Corrosion is fought by a complex system of monitoring, preventative repairs, and careful use of materials. Monitoring methods include both offline checks taken during maintenance and online monitoring. Offline checks measure corrosion after it has occurred, telling the engineer when equipment must be replaced based on the historical information they have collected. This is referred to as preventative management. Online systems are a more modern development and are revolutionizing the way corrosion is approached. There are several types of online corrosion monitoring technologies such as linear polarization resistance, electrochemical noise and electrical resistance. Online monitoring has generally had slow reporting rates in the past (minutes or hours) and been limited by process conditions and sources of error but newer technologies can report rates up to twice per minute with much higher accuracy (referred to as real-time monitoring). This allows process engineers to treat corrosion as another process variable that can be optimized in the system. Immediate responses to process changes allow the control of corrosion mechanisms, so they can be minimized while also maximizing production output.R.D. Kane, D.C. Eden, and D.A. Eden, Innovative Solutions Integrate Corrosion Monitoring with Process Control, Mater. Perform., Feb 2005, p 36–41. In an ideal situation having on-line corrosion information that is accurate and real-time will allow conditions that cause high corrosion rates to be identified and reduced. This is known as predictive management. Materials methods include selecting the proper material for the application. In areas of minimal corrosion, cheap materials are preferable, but when bad corrosion can occur, more expensive but longer-lasting materials should be used. Other materials methods come in the form of protective barriers between corrosive substances and the equipment metals. These can be either a lining of refractory material such as standard
Portland cement Portland cement is the most common type of cement in general use around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. It was developed from other types of hydraulic lime in England in the early 19t ...
or other special acid-resistant cement that is shot onto the inner surface of the vessel. Also available are thin overlays of more expensive metals that protect cheaper metal against corrosion without requiring much material.


See also

*
Acid gas Acid gas is a particular typology of natural gas or any other gas mixture containing significant quantities of hydrogen sulfide (H2S), carbon dioxide (CO2), or similar acidic gases. A gas is determined to be acidic or not after it is mixed with w ...
*
H-Bio H-Bio is an oil-refining processes which involves converting vegetable oil into high-quality diesel via hydrogenation. Hydrogenation is a chemical reaction, in which a substance is treated with Hydrogen, thus resulting in a new product. In H-Bio, ...
*
AP 42 Compilation of Air Pollutant Emission Factors The ''AP 42 Compilation of Air Pollutant Emission Factors'' is a compilation of the US Environmental Protection Agency (EPA)'s emission factor information on air pollution, first published in 1968. , the last edition is the 5th from 2010. Histo ...
*
API oil-water separator An application programming interface (API) is a way for two or more computer programs to communicate with each other. It is a type of software interface, offering a service to other pieces of software. A document or standard that describes how ...
*
Biorefinery A biorefinery is a refinery that converts biomass to energy and other beneficial byproducts (such as chemicals). The International Energy Agency Bioenergy Task 42 defined biorefining as "the sustainable processing of biomass into a spectrum of bio ...
*
Ethanol fuel Ethanol fuel is ethyl alcohol, the same type of alcohol found in alcoholic beverages, used as fuel. It is most often used as a motor fuel, mainly as a biofuel additive for gasoline. The first production car running entirely on ethanol was t ...
* Butanol fuel *
Gas flare A gas flare, alternatively known as a flare stack, flare boom, ground flare, or flare pit is a gas combustion device used in places such as petroleum refineries, chemical plants and natural gas processing plants, oil or gas extraction sites hav ...
*
Industrial wastewater treatment Industrial wastewater treatment describes the processes used for treating wastewater that is produced by industries as an undesirable by-product. After treatment, the treated industrial wastewater (or effluent) may be reused or released to a s ...
* K factor crude oil refining *
List of oil refineries This is a list of oil refineries. '' Oil & Gas Journal'' publishes a worldwide list of refineries annually in a country-by-country tabulation that includes for each refinery: location, crude oil daily processing capacity, and the size of each proce ...
*
Natural-gas processing Natural-gas processing is a range of industrial processes designed to purify raw natural gas by removing impurities, contaminants and higher molecular mass hydrocarbons to produce what is known as ''pipeline quality'' dry natural gas. Natural gas ...

National Occupational Research Agenda Oil and gas Extraction Council
*
Nelson complexity index The Nelson complexity index (NCI) is a measure to compare the secondary conversion capacity of a petroleum refinery with the primary distillation capacity. The index provides an easy metric for quantifying and ranking the complexity of various r ...
*
Sour gas Sour gas is natural gas or any other gas containing significant amounts of hydrogen sulfide (H2S). Natural gas is usually considered sour if there are more than 5.7 milligrams of H2S per cubic meter of natural gas, which is equivalent to approxim ...
*
Atmospheric distillation of crude oil Refining of crude oils essentially consists of primary separation processes and secondary conversion processes. The petroleum refining process is the separation of the different hydrocarbons present in the crude oil into useful fractions and the con ...


References


Bibliography

*


External links


Interactive map of UK refineries

Searchable United States Refinery Map




- history of Oljeön,
Sweden Sweden, formally the Kingdom of Sweden,The United Nations Group of Experts on Geographical Names states that the country's formal name is the Kingdom of SwedenUNGEGN World Geographical Names, Sweden./ref> is a Nordic countries, Nordic c ...

Fueling Profits: Report on Industry Consolidation
(publication of the Consumer Federation of America)
Price Spikes, Excess Profits and Excuses
(publication of the Consumer Federation of America) {{DEFAULTSORT:Oil Refinery Chemical processes Chinese inventions Distillation Northern Wei Song dynasty Occupational safety and health