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

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

3. 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

5. 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

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

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

11. 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

13. What’s All this Stuff?

14. 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

15. 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

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

18. 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)

20. QUESTIONS ?