Technology of Lubrication & Lubricants, Crude Oil Processing, Catalysts in Petroleum Refining and Petrochemical Processes with Mineral Turpentine Oil

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The Book covers the following chapters: Lubrication and Lubricants, Benzene, Ethylene, Monoethylene Glycol, Diethylene Glycol, Triethylene Glycol, Ethylene Oxide, Toluene, Xylene, Petroleum jelly, Bioethanol Production From Sugar Cane Molasses, Production of Bio-ethanol from Molasses by Schizosaccharomyces Species, Petroleum Crude Oils, Crude Oil Processing, Chemicals Based on Methane, Ethane and Higher Paraffins-Based Chemicals, Chemicals Based On Ethylene, Chemicals Based on Propylene, C4 Oleffins and Diolefins- Based Chemicals, Chemicals Based on Benzene, Toluene, and Xylenes, Synthetic Petroleum-Based Polymers, Catalysts in Petroleum Refining and Petrochemical Processes, Petrochemicals Future, Plant Economics of Mineral Turpentine Oil (MTO), Plant Economics of Lubricating Oil (20w40 Grade SN Type), Plant Economics of Oil Re-refining Unit, Plant Economics of Crude Oil Refining.

Preface

Petrochemicals in general are compounds and polymers derived directly or indirectly from petroleum and used in the chemical market. Among the major petrochemical products are plastics, synthetic fibers, synthetic rubber, detergents, and nitrogen fertilizers. Many other important chemical industries such as paints, adhesives, aerosols, insecticides, and pharmaceuticals may involve one or more petrochemical products within their manufacturing steps. The petrochemical industry is a huge field that encompasses many commercial chemicals and polymers.

From these simple intermediates, many important chemicals and polymers are derived through different conversion reactions. The objective of this book is not merely to present the reactions involved in such conversions, but also to relate them to the different process variables and to the type of catalysts used to get a desired product. When plausible, discussions pertinent to mechanisms of important reactions are included. The book, however, is an attempt to offer a simplified treatise for diversified subjects dealing with chemistry, process technology, polymers, and catalysis.

As a starting point, the book reviews the general properties of the rawmaterials. This is followed by the different techniques used to convert these raw materials to the intermediates, which are further reacted to produce the petrochemicals and its uses in commercial fields in lubricants, greases ,petroleum jelly and many others.

When the book is written, the intention is to introduce to the users a simplified approach to a diversified subject dealing with the chemistry and technology of various petroleum and petrochemical process. It reviewed the mechanisms of many reactions as well as the operational parameters (temperature, pressure, residence times, etc.) that directly effect products' yields and composition. To enable the readers to follow the flow of the reactants and products, the processes were illustrated with simplified flow diagrams.

I hope that publishing this book will partially fulfill the objective of continuing the effort in presenting the state of the art in a simple scientific approach.

AUTHOR

Contents

Lubrication and Lubricants

Functions of Lubricants
Lubrication Principles
Tests of Lubricants
Lubricants of Mineral Origin
Synthetic Lubricants

Benzene

Manufacturing Process From Petroleum by
Catalytic Reforming

Ethylene

From Refinery Gas by Thermal Cracking

Monoethylene Glycol

Molecular Formula

Diethylene Glycol

Molecular Formula

Triethylene Glycol

Monoethylene Glycol From Ethylene and Oxygen
Uses
Grades
Toxicity

Ethylene Oxide

Molecular Formula
Properties
Manufacturing Process
From Ethylene and Oxygen
Raw material requirement

Toluene

Properties
Manufacturing Process
From Petroleum by Hydroforming
Raw material requirement

Xylene

Properties of Xylene Isomers
Manufacturing Process
Form Petroleum by Catalytic Reforming or
hydroforming

Petroleum jelly

Physical properties
Comparison with glycerol
Uses
Medical treatment
Skin and hair care
Preventing moisture loss
Hair grooming
Skin lubrication
Product care and protection
Coating
Finishing
Lubrication
Production processes
Tattooing
Explosives
Mechanical, barrier functions
Surface cleansing
Pet care
Clean-up
Properties of Petroleum Jelly
Skin Care
Face Care
Hair Care
Nail Care
Household Needs

Bioethanol Production From Sugar Cane Molasses

Ethanol
Feedstock for bioethanol production
Sucrose-containing feedstocks
Starchy materials
Lignocellulosic biomass
Ethanol from cane molasses
Processes of ethanol production

Production of Bio-ethanol from Molasses by Schizosaccharomyces Species

Introduction
Materials And Methods
Collection of Samples
Isolation of Schizosaccharomyces
Production of Ethanol from Molasses
Identification of the Microorganisms
Originally Present in Molasses
Inoculation of Molasses by Isolated Yeast
Distillation and Detection of Ethanol
Results And Discussion
Isolation of Schizosaccharomyces
Species
Physical Characteristics of the
Molasses Sample
Microorganisms Originally Present
in Molasses
Production of Ethanol from Raw
Molasses
Production of Ethanol from Molasses
with Different Concentrations of Sucrose
Detection of Ethanol

Petroleum Crude Oils

Composition of Crude Oils
Hydrocarbon Compounds
Alkanes (Paraffins)
Cycloparaffins (Naphthenes)
Aromatic Compounds
Non-hydrocarbon Compounds
Sulfur Compounds
Acidic Sulfur Compounds
Non-acidic Sulfur Compounds
Nitrogen Compounds
Basic Nitrogen Compounds
Non-Basic Nitrogen Compounds
Oxygen Compounds
Acidic Oxygen Compounds
Non-Acidic Oxygen Compounds
Metallic Compounds
Density, Specific Gravity and API Gravity
Salt Content
Sulfur Content
Pour Point
Ash Content

Crude Oil Processing

Physical Separation Processes
Atmospheric Distillation
Vacuum Distillation
Absorption Process
Adsorption Process
Solvent Extraction
Conversion Processes
Thermal Conversion Processes
Coking Processes
Thermal Cracking Reactions
Delayed Coking
Fluid Coking
Viscosity Breaking (Vis-breaking)
Catalytic Conversion Processes
Catalytic Reforming
Reformer Feeds
Reforming Catalysts
Reforming Reactions
From Acetylene and Acetone
From Isobutylene and Formaldehyde (IFP Process)
From Isobutylene and Methylal (Sun Oil Process)
From Propylene (Goodyear Process)

Chemicals Based on Methane

Chemicals Based On Direct Reactions of Methane
Carbon Disulfide (CS)
Uses Of Carbon Disulfide
Hydrogen Cyanide (Hcn)
Chloromethanes
Production of Chloromethanes
Uses of Chloromethanes
SYNTHESIS GAS
CHEMICALS BASED ON SYNTHESIS GAS
AMMONIA (NH)
Uses of Ammonia
Nitric Acid (HNO)
Hydrazine (HN-NH).
Methylalcohol (CHOH)
Production of Methanol
Uses of Methanol
Methyl Chloride (CHCI)
Acetic Acid (CHCOOH)
Methyl Tertiary Butyl Ether ((CH)C-O-CH)
Dimethyl Carbonate (CO(OCH))
Methylamines
Ethylene Glycol

Ethane and Higher Paraffins-Based Chemicals

Ethane Chemicals
Propane Chemicals
Oxidation of Propane
Nitration of Propane (Production of Nitroparaffins)
N-butane Chemicals
Oxidation of N-butane (Acetic Acid and
Acetaldehyde)
Maleic Anhydride:
Aromatics Production
Isobutane Chemicals
Naphtha-based Chemicals
Chemicals From High Molecular Weight
N-paraffins
Oxidation Of Paraffins (Fatty Acids And Fatty
Alcohols)
Chlorination Of N-paraffins (Chloroparaffins)

Chemicals Based On Ethylene

Introduction
Oxidation Of Ethylene
Derivatives of Ethylene Oxide
Ethylene Glycol (CHOHCHOH)
Ethoxylates
Ethanolamines
,-Propanediol
Acetaldehyde (Chcho)
Important Chemicals From Acetaldehyde
Acetic Acid
N-butanol
Oxidative Carbonylation of Ethylene
Chlorination of Ethylene
Vinyl Chloride (Ch=Chcl)
Linear Alcohols

Chemicals Based on Propylene

Oxidation of Propylene
Acrolein (CH=CHCHO)
Uses of Acrolein
Ammoxidation Of Propylene
(Acrylonitrile [CH=CHCN])
Uses of Acrylonitrile
Adiponitrile (NC(CH)CN)
Deriatives and Uses of Propylene Oxide
Propylene Glycol (CHCH(OH)CHOH)
Allyl Alcohol (CH=CHCHOH)
Oxyacylation of Propylene
Chlorination of Propylene
(Allyl Chloride [Ch=Chchcl])
Hydration of Propylene
(Isopropanol [Chchohch])
Properties And Uses of Isopropanol
Acetone Production
Propertles and Uses of Acetone

C4 Oleffins and Diolefins- Based Chemicals

Introduction
Chemicals From N-butenes
Oxidation of Butenes
Acetic Acid CHCOH

Chemicals Based on Benzene, Toluene, and Xylenes

Reactions and Chemicals of Benzene
Reactions and Chemicals of Toluene
Oxidation of Toluene
Caprolactam Production
Phenol from Benzoic Acid
Terephthalic Acid from Benzoic Acid
Chlorination of Toluene
Nitration of Toluene
Carbonylation of Toluene
Chemicals From Xylenes
Terephthalic Acid (Hoocc6h4cooh)

Synthetic Petroleum-Based Polymers

Introduction
Thermoplastics And Engineering Resins
Polyethylene
Low-Density Polyethylene
High-Density Polyethylene
Linear Low-Density Polyethylene
Properties and Uses of Polyethylenes
Polypropylene
Copolymerization
Properties and Uses of Polypropylene
Properties and Uses of Polyvinyl Chloride
Properties and Uses of Styrene Polymers
Nylon Resins
Thermoplastic Polyesters
Polycarbonates
Properties and Uses of Polycarbonates
Polyether Sulfones
Properties and Uses of Aromatic Polyether Sulfones
Poly(phenylene) Oxide
Polyacetals
Thermosetting Plastics
Polyurethanes
Properties and Uses of Polyurethanes
Epoxy Resins
Properties and Uses of Epoxy Resins
Unsaturated Polyesters
Phenol-formaldehyde Resins
Properties and Uses of Phenolic Resins
Amino Resins (Aminoplasts)
Urea-Formaldehyde and Urea-Melamine Resins
Properties and Uses of Aminoplasts
Polycyanurates
Synthetic Rubber
Butadiene Polymers And Copolymers
Properties and Uses of Polybutadiene
Styrene-Butadiene Rubber (SBR)
Nitrile Rubber (Nbr)
Polyisoprene
Properties and Uses of Polyisoprene
Polychloroprene (Neoprene Rubber)
Butyl Rubber
Ethylene-propylene Rubber
Transpolypentamer
Thermoplastic Elastomers
Synthetic Fibers
Polyester Fibers
Polyethylene Terephthalate Production
Properties and Uses of Polyesters
Polyamides (Nylon Fibers)
Nylon (Polyhexamethyleneadipate)
Nylon (Polycaproamide)
Nylon (Polylaurylamide)
Nylon (Polybutyramide)
Nylon (Polyundecanylamide)
Other Nylon Polymers
Properties and Uses of Nylons
Acrylic And Modacrylic Fibers
Properties and Uses of Polyacrylics
Carbon Fibers (Graphite Fibers)
Polypropylene Fibers

Catalysts in Petroleum Refining and Petrochemical Processes

Introduction
Homogeneous and Heterogeneous Catalysts
Catalyst Morphology and Activity
Catalysts for Petroleum Refining
Cracking Catalysts
Reforming Catalysts
Hydrotreating Catalysts
Catalysts For Petrochemicals Industry
Catalysts For Synthesis Gas
Hydrogenation Catalysts
Hydrocarbon Oxidation Catalysts
Polymerization Catalysts
Recent Advances in Industrial Catalysis
Dual-Function Catalysts
Super-Active Metal Catalysts
Supported-Ziegler Catalysts
Advances in Homogeneous Catalysis
Role of Polymers in Catalysis

Petrochemicals Future

Integrated Petrochemicals Complex
Natural Gas As Petrochemical Feedstock
Impact Of Heavy Feedstocks
On Petro-chemicals
Ecology And The Energy Crisis
Coal As An Alternative To Oil
Energy Crisis and the Industrial Fuels
Natural Fuels
Synthetic Fuels
Hydrogen: Fuel for tomorrow
Trends in Petrochemical Industry
Development in Cracking Technology
Olefins Vs Paraffins
Prospect for Propylene
Size of Plant
Biomass: Renewable Resource for Petrochemicals
Waste Disposal

Plant Economics of Mineral Turpentine Oil (MTO)

Plant & Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

Plant Economics of Lubricating Oil (20w40 Grade Sn-Type)

Plant & Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

Plant Economics of Oil Re-refining Unit

Plant & Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

Plant Economics of Crude Oil Refining

Plant & Machinery
Fixed Capital
Raw Materials
Total Working Capital/Month
Total Capital Investment
Turn Over/Annum

List of Tables

Table : Properties and uses of various types of greases

Table : Specification for Commercial Grades of Benzene

Table : Typical specification for polymer-grade ethylene

Table : Specifications of Technical Grades of

Ethylene Glycol

Table : Specification for Technical Grade Diethylene

Glycol and Triethylene Glycol

Table : Commercial specifications of Industrial Xylene

Table : Type of feedstock

Table : Physical properties of Ethanol

Table : Different feedstock for bioethanol production and their comparative production potential.

Table : Main components of cane black strap molasses

Table : Microbiological analysis of sugarcane

molasses

Table : Production of ethanol and pH value from raw molasses

Table : Production of ethanol and pH value from molasses with different concentrations of sucrose

Table : Heating values of methane and heavier hydrocarbons present in natural gas

Table : Typical analysis of some crude oils

Table : Approximate ASTM boiling point ranges for

crude oil fractions

Table: Types of petroleum cokes and their end uses

Table : Major thermoplastic polymers

Table : Important properties of polyethylenes

Table : Properties of Polypropylene

Table : Properties of polycarbonates compared with

some thermoplastics

Table : Selected properties of some elastomers

Table : Important properties of polyesters

Table : Melting points of various nylons and the

monomer formula

Table : Physical properties of fiber-grade

polypropylene

Table : Characteristics of Typical Catalysts used in Petroleum Refining.

Table : Important Catalytic Processes of Refining

and Petrochemical Industry

Table : Major Catalysts in use in IPCL Plants

Table : Industrially Important Free-Racial

Polymerization Catalysts

Table : Ziegler-Type Catalysts used in Polymer

Manufacture

Table : HOPE Catalysts.

Table : Miscellaneous Catalysts used In Polymer

Industry.

Table : Relative Cost of Ethylene Production from

Various Feedstocks

Table : Octane Number of Aromatics.

Table : Calorific Value of Fuels.

Table : Comparative Cost of Production of Various

Fuels.

Table : Sources of Hydrogen.

Table : Yield Pattern from a High Severe Cracking

Furnace.

Table : Comparative Study of Propane and

Propylene Routes to Acrylonitriie

List of figures

Fig Fluid film formation in bearing

Fig : Ethanol structure

Fig : Sugar refinery process

Fig.: Enzymatic hydrolysis of starch to glucose.

Fig. : Flow chart of ethanol production from cereal

grains.

Fig. Culture characteristics of Schizosacc-

haromyces species

Fig. Microscopic appearance of Schizosacc-

haromyces species using Gram stain technique

Fig. KMnOH+ before addition of sample (a),

Reduction of KMnOH+ to colourless after

addition of sample (b)

Fig. KCrOH+before addition of

sample (a), KCrOH+after addition change

into colour (b)

Fig. Iodine reagent before addition sample (a),

addition of sample and heating, colour of iodine

change into blue colour (b) and when cooling in water

and added NaOH, the reaction formed yellow colour

precipitate

called iodo-form (c)

Fig Flow diagram of atmospheric and vacuum

distillation units: (,) heat exchangers; () desalter,

(,) heater; () distillation column, () overhead

condenser, (-) pump around streams, () vacuum

distillation heater; () vacuum tower.

Fig Important chemicals based on methane,

synthesis gas, ammonia, and methanol.

Fig A block flow diagram showing the combined

reforming for methanol synthesis.

Fig The Haldor Topsoe and Nippon Kasei

process for producing formaldehyde: () blower,

() heat exchanger, () reactor, () steam boiler,

() absorber, (,) coolers, () incinerator, () heat

recovery, () methanol evaporator, () boiler

feed water.

Fig Major chemicals based on ethylene.

Fig Important chemicals based on propylene.

Fig . Important chemicals based on benzene.

Fig . The reaction scheme for o-xylene to phthalonitrile

Fig The Union Carbide Unipol process for producing

Fig The Union Carbide gas-phase process for gh

producing polypropylene: () reactor, () centri-

fugal compressor, () heat exchanger, () product

discharge tank (unreacted gas separated from product),

() impact reactor, () compressor, () heat exchanger,

() discharge tank (copolymer separated from reacted

gas).

Fig Polyvinyl chloride

Fig The European Vinyls Corp. process for

producing polyvinyl chloride using suspension polymeri-

zation : () reactor, () blow-down vessels (to

separate unreacted monomer), () stripping column,

() reacted monomer recovery, () slurry centrifuge,

() slurry drier.

Figure The Lummus Crest Inc. process for

producing polystyrene: () reactor, () holding

tank (Polystyrene beads and water), () centrifuge,

() pneumatic drier, () conditioning tank, () screening of

beads, (,) lubrication and blending, () shipping product.

Figure The comparative thickness for the same

degree of insulation (dry conditions).

Figure A process for producing ,-polyisoprene

(>%) by a continuous solution polymerization.

Figure The Inventa AG Process for

producing polyethylene-terephthala

Figure The Inventa-Fisher process for producing

nylon from caprolactam: () Melting station, (, )

polymerization reactors, () extruder, () intermediate

vessel, () extraction column, (,) extraction

columns, () cooling silo.

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