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A typical fluid catalytic cracking unit in a petroleum refinery. 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, alkene gases, and other petroleum products.
Petroleum refinery in Anacortes, Washington, United States. Petroleum refining processes are the chemical engineering processes and other facilities used in petroleum refineries (also referred to as oil refineries) to transform crude oil into useful products such as liquefied petroleum gas (LPG), gasoline or petrol, kerosene, jet fuel, diesel oil and fuel oils.
On average, U.S. petroleum refineries produce about 19 to 20 gallons of gasoline, 11 to 13 gallons of distillate fuel diesel fuel and 3 to 4 gallons of jet fuel from each 42 gallon (152 liters) barrel of crude oil. The product ratio depends upon the processing in an oil refinery and the crude oil assay. [19]
Catalytic reforming is a chemical process used to convert naphthas from crude oil into liquid products called reformates, which are premium "blending stocks" for high-octane gasoline. The process converts low-octane linear hydrocarbons (paraffins) into branched alkanes (isoparaffins) and cyclic naphthenes , which are then partially ...
Since crude oil generally contains only 10-40% of hydrocarbon constituents in the gasoline range, refineries typically use an FCCU to convert high molecular weight hydrocarbons into smaller and more volatile compounds, which are then converted into liquid gasoline-size hydrocarbons. Byproducts of the FCC process also include other low molecular ...
The main product of the Fischer–Tropsch process, synthetic crude oil, requires additional refining to produce fuel products such as diesel fuel or gasoline. This refining typically adds additional costs, causing some industry leaders to label the economics of commercial-scale Fischer–Tropsch processes as challenging. [9]
The hot crude oil is then passed into a distillation column that allows the separation of the crude oil into different fractions depending on the difference in volatility. The pressure at the top is maintained at 1.2–1.5 atm [ 2 ] so that the distillation can be carried out at close to atmospheric pressure, and therefore it is known as the ...
'Sour' crude oil has high natural sulphur content (at least 0.5%). [7] Extra treatment is required in the refining process; [6] impurities are removed to refine the crude into gasoline. [9] Due to the greater cost associated, it is more commonly refined into fuel oil and diesel - less valuable outputs than products of sweet crude oil. [9]