1. Refinery Basics
John Kulluk Ph.D.
Torrance Fire Department
&
Robert Distaso PE – 714/573-6253
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
Splitter
Gasoline
Distilling
Reformer
Jet Fuel
Hydrotreating
Hydrotreating
Distillate Fuel
Alky
CCU
Flasher
Visbreaker
Leffler, 1985
Residual
Fuel

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

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

11. Other Hazardous Materials
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Sulfur
Hydrofluoric Acid (HF)
Sulfuric Acid (H2SO4)
Ammonia (NH3)
Sodium Hypochlorite
Radioactive Materials
Chlorine
Amines
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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.:
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Atmospheric
Vacuum
Hydrotreating (uses excess hydrogen)
• Breaking apart molecules to make smaller ones, e.g.:
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catalytic cracking
hydrocracking
• Joining molecules to make bigger ones, e.g.:
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Reforming - alkylation that lengthens the hydrocarbon
chain
Reforming - cyclic that generates hydrogen

15. Physical Hazards
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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
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Protection
Safety Goggles or Faceshield
Fire-Resistant Clothing

18. Process Hazards
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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 ?