Orange County Fire Authority Refinery Basics John Kulluk Ph.D. Torrance Fire Department & Robert Distaso PE – 714/573-6253 Orange County Fire Authority

Refining Means. . . 1. To reduce to a pure state, to remove impurities 2. To improve or perfect

Refinery Process Flow Chart Sulfur Gas Plant Fuel Gas Isom Distilling Splitter Gasoline Reformer Jet Fuel Hydrotreating Distillate Fuel Hydrotreating Alky CCU Flasher Residual Fuel Visbreaker Leffler, 1985

Other Refinery Units Steam Generation Wastewater Treatment Hydrogen Generation Power Generation (e.g., cogen) Air Separation Plant Loading/Unloading - Railcar, Trucks, etc. Storage (high pressure hydrocarbon, crude oil, intermediates) Floating-Roof Tanks - 150‘ diameter is common Spherical Tanks - 50‘ are common Horton Spheroid (refrigerated) Steam-Heated Tanks for “Heavier” Products Self-Contained Firewater Supply Firewater Pumps

What is Crude Oil? Mixture of organic carbon chain molecules Impurities include sulfur and nitrogen compounds Some metals and salts too

Components such as . . . Straight-Chain Hydrocarbons Olefins Cyclic H/C Aromatics (Benzene, toluene, xylenes) Mercaptans Hydrogen Sulfide (H2S) Greases Propane LPG

Other Hazardous Materials Sulfur Hydrofluoric Acid (HF) Sulfuric Acid (H2SO4) Ammonia (NH3) Sodium Hypochlorite Radioactive Materials Chlorine Amines MEK Sulfur Dioxide (SO2) Heavy Metal Catalysts Sour Water Caustic (fresh/spent) Alcohol Asbestos

What’s All this Stuff?

What Goes on at a Refinery. . .? Separation of components by distillation, e.g.: Atmospheric Vacuum Hydrotreating (uses excess hydrogen) Breaking apart molecules to make smaller ones, e.g.: catalytic cracking hydrocracking Joining molecules to make bigger ones, e.g.: Reforming - alkylation that lengthens the hydrocarbon chain Reforming - cyclic that generates hydrogen

Physical Hazards High Pressure/Temperature Steam Oil/Gas-Fired Furnaces Acoustic High Voltage (4160V, 480V, 13.2 kV) Falling Hazards Confined Space Hazards Cranes/Lifting Hazards Hot Work Hazards Acid Exposure Toxic Vapors Radiation Flammability Hazards

Common PPE Requirements Hardhat Hardsoled / Hardtoe Shoes Safety Glasses with Side Protection Safety Goggles or Faceshield Fire-Resistant Clothing

Process Hazards Emergency Flare Atmospheric Pressure Relief High Temperature (up to 2000oF) Low Temperature (e.g., Brittle Fracture) High Pressure (up to 3000 psig) Low Pressure (e.g., vacuum)

QUESTIONS ?