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Oil refinery

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Anacortes Refinery,on the north end of March Point southeast ofAnacortes, Washington,United States
Grangemouth Refinery,inScotland
Jamnagar Refinery,the world's largest oil refinery, inGujarat,India

Anoil refineryorpetroleum refineryis anindustrial processplantwherepetroleum(crude oil) is transformed andrefinedinto products such asgasoline(petrol),diesel fuel,asphalt base,fuel oils,heating oil,kerosene,liquefied petroleum gasandpetroleum naphtha.[1][2][3]Petrochemicalfeedstock likeethyleneandpropylenecan also be produced directly bycrackingcrude oil without the need of using refined products of crude oil such as naphtha.[4][5]The crude oil feedstock has typically been processed by anoil production plant.There is usually anoil depotat or near an oil refinery for the storage of incoming crude oil feedstock as well as bulk liquid products. In 2020, the total capacity of global refineries for crude oil was about 101.2 million barrels per day.[6]

Oil refineries are typically large, sprawling industrial complexes with extensivepipingrunning throughout, carrying streams offluidsbetween largechemical processingunits, such asdistillationcolumns. In many ways, oil refineries use many different technologies and can be thought of as types ofchemical plants.Since December 2008, the world's largest oil refinery has been theJamnagar Refineryowned byReliance Industries,located inGujarat,India, with a processing capacity of 1.24 million barrels (197,000 m3) per day.

Oil refineries are an essential part of the petroleum industry'sdownstreamsector.[7]

History[edit]

The Chinese were among the first civilizations to refine oil.[8]As early as the first century, the Chinese were refining crude oil for use as an energy source.[9][8]Between 512 and 518, in the lateNorthern Wei Dynasty,the Chinese geographer, writer and politicianLi Daoyuanintroduced the process of refining oil into various lubricants in his famous workCommentary on the Water Classic.[10][9][8]

Crude oilwas often distilled byPersian chemists,with clear descriptions given in handbooks such as those ofMuhammad ibn Zakarīya Rāzi(c. 865–925).[11]The streets ofBaghdadwere paved withtar,derived from petroleum that became accessible from natural fields in the region. In the 9th century,oil fieldswere exploited in the area around modernBaku,Azerbaijan. These fields were described by theArab geographerAbu al-Hasan 'Alī al-Mas'ūdīin the 10th century, and byMarco Poloin the 13th century, who described the output of those wells as hundreds of shiploads.[12]Arab and Persian chemistsalso distilled crude oil in order to produceflammableproducts for military purposes. ThroughIslamic Spain,distillation became available inWestern Europeby the 12th century.[13]

In theNorthern Song Dynasty(960–1127), a workshop called the "Fierce Oil Workshop", was established in the city of Kaifeng to produce refined oil for the Song military as a weapon. The troops would then fill iron cans with refined oil and throw them toward the enemy troops, causing a fire – effectively the world's first "fire bomb".The workshop was one of the world's earliest oil refining factories where thousands of people worked to produce Chinese oil-powered weaponry.[14]

Prior to the nineteenth century, petroleum was known and utilized in various fashions inBabylon,Egypt,China,Philippines,RomeandAzerbaijan.However, the modern history of the petroleum industry is said to have begun in 1846 when Abraham Gessner ofNova Scotia,Canadadevised a process to produce kerosene from coal. Shortly thereafter, in 1854,Ignacy Łukasiewiczbegan producing kerosene from hand-dug oil wells near the town ofKrosno,Poland.

Romania was registered as the first country in world oil production statistics, according to theAcademy Of World Records.[15][16]

In North America, the first oil well was drilled in 1858 byJames Miller WilliamsinOil Springs, Ontario,Canada.[17]In the United States, the petroleum industry began in 1859 whenEdwin Drakefound oil nearTitusville,Pennsylvania.[18]The industry grew slowly in the 1800s, primarily producing kerosene for oil lamps. In the early twentieth century, the introduction of the internal combustion engine and its use in automobiles created a market for gasoline that was the impetus for fairly rapid growth of the petroleum industry. The early finds of petroleum like those in Ontario andPennsylvaniawere soon outstripped by large oil "booms" inOklahoma,TexasandCalifornia.[19]

Samuel Kierestablished America's first oil refinery in Pittsburgh on Seventh Avenue near Grant Street, in 1853.[20]Polish pharmacist and inventorIgnacy Łukasiewiczestablished an oil refinery inJasło,then part of the Austro-Hungarian Empire (now inPoland) in 1854.

The first large refinery opened at Ploiești, Romania, in 1856–1857.[15] It was in Ploiesti that, 51 years later, in 1908,Lazăr Edeleanu,a Romanian chemist of Jewish origin who got his Ph.D in 1887 by discovering theAmphetamine,invented, patented and tested on industrial scale the first modern method of liquid extraction for refining crude oil, theEdeleanu process.This increased the refining efficiency compared to purefractional distillationand allowed a massive development of the refining plants. Successively, the process was implemented in France, Germany, U.S. and in a few decades became worldwide spread. In 1910 Edeleanu founded "Allgemeine Gesellschaft für Chemische Industrie" in Germany, which, given the success of the name, changed to Edeleanu GmbH, in 1930. During Nazi's time, the company was bought by the Deutsche Erdöl-AG and Edeleanu, being of Jewish origin, moved back to Romania. After the war, the trademark was used by the successor company EDELEANU Gesellschaft mbH Alzenau (RWE) for many petroleum products, while the company was lately integrated as EDL in thePörner Group. The Ploiești refineries, after being taken over byNazi Germany,were bombed in the 1943Operation Tidal Waveby theAllies,during theOil Campaign of World War II.

Another close contender for the title of hosting the world's oldest oil refinery isSalzbergeninLower Saxony,Germany. Salzbergen's refinery was opened in 1860.

At one point, the refinery inRas Tanura,Saudi Arabiaowned bySaudi Aramcowas claimed to be the largest oil refinery in the world. For most of the 20th century, the largest refinery was theAbadan RefineryinIran.This refinery suffered extensive damage during theIran–Iraq War.Since 25 December 2008, the world's largest refinery complex is theJamnagar RefineryComplex, consisting of two refineries side by side operated byReliance Industries Limitedin Jamnagar, India with a combined production capacity of 1,240,000 barrels per day (197,000 m3/d).PDVSA'sParaguaná Refinery ComplexinParaguaná Peninsula,Venezuela,with a capacity of 940,000 bbl/d (149,000 m3/d) andSK Energy'sUlsaninSouth Koreawith 840,000 bbl/d (134,000 m3/d) are the second and third largest, respectively.

Prior to World War II in the early 1940s, most petroleum refineries in the United States consisted simply of crude oil distillation units (often referred to as atmospheric crude oil distillation units). Some refineries also hadvacuum distillationunits as well asthermal crackingunits such asvisbreakers(viscosity breakers, units to lower theviscosityof the oil). All of the many other refining processes discussed below were developed during the war or within a few years after the war. They became commercially available within 5 to 10 years after the war ended and the worldwide petroleum industry experienced very rapid growth. The driving force for that growth in technology and in the number and size of refineries worldwide was the growing demand for automotive gasoline and aircraft fuel.

In the United States, for various complex economic and political reasons, the construction of new refineries came to a virtual stop in about the 1980s. However, many of the existing refineries in the United States have revamped many of their units and/or constructed add-on units in order to: increase their crude oil processing capacity, increase theoctanerating of their product gasoline, lower thesulfurcontent of their diesel fuel and home heating fuels to comply with environmental regulations and comply with environmental air pollution and water pollution requirements.

Baton Rouge Refinery(the fifth-largest in theUnited States)[21]

United States[edit]

Main article:Petroleum refining in the United States
Refinery, Bayport Industrial Complex, Harris County, Texas

In the 19th century, refineries in the U.S. processed crude oil primarily to recover thekerosene.There was no market for the more volatile fraction, including gasoline, which was considered waste and was often dumped directly into the nearest river. The invention of the automobile shifted the demand to gasoline and diesel, which remain the primary refined products today.[22]

Today, national and state legislation require refineries to meet stringent air and water cleanliness standards. In fact, oil companies in the U.S. perceive obtaining a permit to build a modern refinery to be so difficult and costly that no new refineries were built (though many have been expanded) in the U.S. from 1976 until 2014 when the small Dakota Prairie Refinery in North Dakota began operation.[23]More than half the refineries that existed in 1981 are now closed due to low utilization rates and accelerating mergers.[24]As a result of these closures total US refinery capacity fell between 1981 and 1995, though the operating capacity stayed fairly constant in that time period at around 15,000,000 barrels per day (2,400,000 m3/d).[25]Increases in facility size and improvements in efficiencies have offset much of the lost physical capacity of the industry. In 1982 (the earliest data provided), the United States operated 301 refineries with a combined capacity of 17.9 million barrels (2,850,000 m3) of crude oil each calendar day. In 2010, there were 149 operable U.S. refineries with a combined capacity of 17.6 million barrels (2,800,000 m3) per calendar day.[26]By 2014 the number of refinery had reduced to 140 but the total capacity increased to 18.02 million barrels (2,865,000 m3) per calendar day. Indeed, in order to reduce operating costs and depreciation, refining is operated in fewer sites but of bigger capacity.

In 2009 through 2010, as revenue streams in the oil business dried up and profitability of oil refineries fell due to lower demand for product and high reserves of supply preceding theeconomic recession,oil companies began to close or sell the less profitable refineries.[27]

Operation[edit]

Neste Oilrefinery inPorvoo,Finland

Raw or unprocessed crude oil is not generally useful in industrial applications, although "light, sweet" (low viscosity, lowsulfur) crude oil has been used directly as a burner fuel to produce steam for the propulsion of seagoing vessels. The lighter elements, however, form explosive vapors in the fuel tanks and are therefore hazardous, especially inwarships.Instead, the hundreds of different hydrocarbon molecules in crude oil are separated in a refinery into components that can be used asfuels,lubricants,and feedstocks inpetrochemicalprocesses that manufacture such products asplastics,detergents,solvents,elastomers,andfiberssuch asnylonandpolyesters.

Petroleumfossil fuelsare burned in internal combustion engines to provide power forships,automobiles,aircraft engines,lawn mowers,dirt bikes,and other machines. Differentboiling pointsallow thehydrocarbonsto be separated bydistillation.Since the lighter liquid products are in great demand for use in internal combustion engines, a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher-value products.[28]

The oil refinery inHaifa, Israel,is capable of processing about 9 million tons (66 million barrels) ofcrude oila year. Its twocooling towersare landmarks of the city's skyline.

Oil can be used in a variety of ways because it contains hydrocarbons of varyingmolecular masses,forms and lengths such asparaffins,aromatics,naphthenes(orcycloalkanes),alkenes,dienes,andalkynes.[29]While the molecules in crude oil include different atoms such as sulfur and nitrogen, the hydrocarbons are the most common form of molecules, which are molecules of varying lengths and complexity made ofhydrogenandcarbonatoms,and a small number of oxygen atoms. The differences in the structure of these molecules account for their varyingphysicalandchemical properties,and it is this variety that makes crude oil useful in a broad range of several applications.

Once separated and purified of any contaminants and impurities, the fuel or lubricant can be sold without further processing. Smaller molecules such asisobutaneandpropyleneorbutylenescan be recombined to meet specificoctanerequirements by processes such asalkylation,or more commonly,dimerization.The octane grade of gasoline can also be improved bycatalytic reforming,which involves removinghydrogenfrom hydrocarbons producing compounds with higher octane ratings such asaromatics.Intermediate products such asgasoilscan even be reprocessed to break a heavy, long-chained oil into a lighter short-chained one, by various forms ofcrackingsuch asfluid catalytic cracking,thermal cracking,andhydrocracking.The final step in gasoline production is the blending of fuels with different octane ratings,vapor pressures,and other properties to meet product specifications. Another method for reprocessing and upgrading these intermediate products (residual oils) uses adevolatilizationprocess to separate usable oil from the waste asphaltene material.

Oil refineries are large-scale plants, processing about a hundred thousand to several hundred thousandbarrelsof crude oil a day. Because of the high capacity, many of the units operatecontinuously,as opposed to processing inbatches,atsteady stateor nearly steady state for months to years. The high capacity also makesprocess optimizationandadvanced process controlvery desirable.

Major products[edit]

Crude oilis separated into fractions byfractional distillation.The fractions at the top of thefractionating columnhave lowerboiling pointsthan the fractions at the bottom. The heavy bottom fractions are oftencrackedinto lighter, more useful products. All of the fractions are processed further in other refining units.
A breakdown of the products made from a typical barrel of US oil[30]

Petroleum productsare materials derived from crude oil (petroleum) as it is processed inoil refineries.The majority of petroleum is converted to petroleum products, which includes several classes of fuels.[31]

Oil refineries also produce various intermediate products such ashydrogen,light hydrocarbons,reformateandpyrolysis gasoline.These are not usually transported but instead are blended or processed further on-site. Chemical plants are thus often adjacent to oil refineries or a number of further chemical processes are integrated into it. For example, light hydrocarbons aresteam-crackedin anethyleneplant, and the produced ethylene is polymerized to producepolyethene.

To ensure both proper separation and environmental protection, a very low sulfur content is necessary in all but the heaviest products. The crude sulfur contaminant is transformed tohydrogen sulfidevia catalytichydrodesulfurizationand removed from the product stream viaamine gas treating.Using theClaus process,hydrogen sulfide is afterward transformed to elementary sulfur to be sold to the chemical industry. The rather large heat energy freed by this process is directly used in the other parts of the refinery. Often an electrical power plant is combined into the whole refinery process to take up the excess heat.

According to the composition of the crude oil and depending on the demands of the market, refineries can produce different shares of petroleum products. The largest share of oil products is used as "energy carriers", i.e. various grades offuel oilandgasoline.Thesefuelsinclude or can be blended to give gasoline,jet fuel,diesel fuel,heating oil,and heavier fuel oils. Heavier (lessvolatile) fractions can also be used to produceasphalt,tar,paraffin wax,lubricatingand other heavy oils. Refineries also produce otherchemicals,some of which are used inchemical processesto produceplasticsand other useful materials. Since petroleum often contains a few percentsulfur-containing molecules, elemental sulfur is also often produced as a petroleum product.Carbon,in the form ofpetroleum coke,and hydrogen may also be produced as petroleum products. The hydrogen produced is often used as an intermediate product for other oil refinery processes such ashydrocrackingandhydrodesulfurization.[32]

Petroleum products are usually grouped into four categories: light distillates (LPG, gasoline, naphtha), middle distillates (kerosene, jet fuel, diesel), heavy distillates, and residuum (heavy fuel oil, lubricating oils, wax, asphalt). These require blending various feedstocks, mi xing appropriate additives, providing short-term storage, and preparation for bulk loading to trucks, barges, product ships, and railcars. This classification is based on the way crude oil is distilled and separated into fractions.[2]

Over 6,000 items are made from petroleum waste by-products, includingfertilizer,floor coverings,perfume,insecticide,petroleum jelly,soap,vitamin capsules.[33]

Chemical processes[edit]

Storage tanks and towers atShell Puget Sound Refinery(Shell Oil Company),Anacortes, Washington
  • Desalterunit washes out salt from the crude oil before it enters the atmospheric distillation unit.[34][35][36]
  • Crude oil distillationunit distills the incoming crude oil into various fractions for further processing in other units. Seecontinuous distillation.[37][38][39][40][41]
  • Vacuum distillationfurther distills the residue oil from the bottom of the crude oil distillation unit. The vacuum distillation is performed at a pressure well below atmospheric pressure.[37][38][39][40][41]
  • Naphthahydrotreaterunit useshydrogento desulfurize naphtha from atmospheric distillation. Naphtha must be desulfurized before sending it to a catalytic reformer unit.[1][42]
  • Catalytic reformerconverts the desulfurizednaphthamoleculesinto higher-octane molecules to producereformate(reformer product). The reformate has higher content of aromatics and cyclic hydrocarbons which is a component of the end-product gasoline or petrol. An important byproduct of a reformer is hydrogen released during the catalyst reaction. The hydrogen is used either in the hydrotreaters or the hydrocracker.[43][44]
  • Distillate hydrotreaterdesulfurizes distillates (such as diesel) after atmospheric distillation. Useshydrogento desulfurize thenaphthafraction from the crude oil distillation or other units within the refinery.[1][42]
  • Fluid catalytic cracker(FCC) upgrades the heavier, higher-boiling fractions from the crude oil distillation by converting them into lighter and lower boiling, more valuable products.[45][3][46]
  • Hydrocrackeruses hydrogen to upgrade heavy residual oils from the vacuum distillation unit by thermally cracking them into lighter, more valuable reduced viscosity products.[47][48]
  • Meroxdesulfurize LPG, kerosene or jet fuel by oxidizingmercaptansto organicdisulfides.
  • Alternative processes for removing mercaptans are known, e.g.doctor sweetening processand caustic washing.
  • Coking units(delayed coker,fluid coker, and flexicoker) process very heavy residual oils into gasoline and diesel fuel, leaving petroleum coke as a residual product.
  • Alkylationunit usessulfuric acidorhydrofluoric acidto produce high-octane components for gasoline blending. The "alky" unit converts light endisobutaneandbutylenesfrom the FCC process intoalkylate,a very high-octane component of the end-product gasoline or petrol.[49]
  • Dimerizationunit convertsolefinsinto higher-octane gasoline blending components. For example,butenescan be dimerized into isooctene which may subsequently be hydrogenated to formisooctane.There are also other uses for dimerization. Gasoline produced through dimerization is highly unsaturated and very reactive. It tends spontaneously to form gums. For this reason, the effluent from the dimerization needs to be blended into the finished gasoline pool immediately or hydrogenated.
  • Isomerizationconverts linear molecules such as normalpentaneto higher-octane branched molecules for blending into gasoline or feed to alkylation units. Also used to convert linear normalbutaneinto isobutane for use in the alkylation unit.
  • Steam reformingconverts natural gas into hydrogen for the hydrotreaters and/or the hydrocracker.
  • Liquified gas storage vessels store propane and similar gaseous fuels at pressure sufficient to maintain them in liquid form. These are usually spherical vessels or "bullets" (i.e., horizontal vessels with rounded ends).
  • Amine gas treater,Claus unit,and tail gas treatment converthydrogen sulfidefromhydrodesulfurizationinto elemental sulfur. The large majority of the 64,000,000 metric tons of sulfur produced worldwide in 2005 was byproduct sulfur from petroleum refining andnatural gas processingplants.[50][51]
  • Sour water stripperuses steam to remove hydrogen sulfide gas from various wastewater streams for subsequent conversion into end-product sulfur in the Claus unit.[36]
  • Cooling towerscirculate cooling water,boiler plantsgeneratessteamforsteam generators,and instrument air systems include pneumatically operatedcontrol valvesand anelectrical substation.
  • Wastewatercollection and treating systems consist ofAPI separators,dissolved air flotation (DAF) unitsand further treatment units such as anactivated sludgebiotreater to make water suitable for reuse or for disposal.[52]
  • Solvent refining uses solvent such ascresolorfurfuralto remove unwanted, mainly aromatics from lubricating oil stock or diesel stock.
  • Solvent dewa xing removes the heavy waxy constituentspetrolatumfrom vacuum distillation products.
  • Storage tanks for storing crude oil and finished products, usually vertical, cylindrical vessels with some sort of vapor emission control and surrounded by an earthenbermto contain spills.

Flow diagram of typical refinery[edit]

The image below is a schematicflow diagramof a typical oil refinery that depicts the variousunitprocesses and the flow of intermediate product streams that occurs between the inlet crude oil feedstock and the final end products. The diagram depicts only one of the literally hundreds of different oil refinery configurations. The diagram also does not include any of the usual refinery facilities providing utilities such as steam, cooling water, and electric power as well as storage tanks for crude oil feedstock and for intermediate products and end products.[1][53][54][55]

Schematic flow diagram of a typical oil refinery

There are many process configurations other than that depicted above. For example, thevacuum distillationunit may also produce fractions that can be refined into end products such as spindle oil used in the textile industry, light machine oil, motor oil, and various waxes.

Crude oil distillation unit[edit]

The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum refineries. The CDU distills the incoming crude oil into various fractions of different boiling ranges, each of which is then processed further in the other refinery processing units. The CDU is often referred to as theatmospheric distillation unitbecause it operates at slightly above atmospheric pressure.[1][2][39] Below is a schematic flow diagram of a typical crude oil distillation unit. The incoming crude oil is preheated by exchanging heat with some of the hot, distilled fractions and other streams. It is then desalted to remove inorganic salts (primarily sodium chloride).

Following the desalter, the crude oil is further heated by exchanging heat with some of the hot, distilled fractions and other streams. It is then heated in a fuel-fired furnace (fired heater) to a temperature of about 398 °C and routed into the bottom of the distillation unit.

The cooling and condensing of the distillation tower overhead is provided partially by exchanging heat with the incoming crude oil and partially by either an air-cooled or water-cooled condenser. Additional heat is removed from the distillation column by a pumparound system as shown in the diagram below.

As shown in the flow diagram, the overhead distillate fraction from the distillation column is naphtha. The fractions removed from the side of the distillation column at various points between the column top and bottom are calledsidecuts.Each of the sidecuts (i.e., the kerosene, light gas oil, and heavy gas oil) is cooled by exchanging heat with the incoming crude oil. All of the fractions (i.e., the overhead naphtha, the sidecuts, and the bottom residue) are sent to intermediate storage tanks before being processed further.

Schematic flow diagram of a typical crude oil distillation unit as used in petroleum crude oil refineries

Location of refineries[edit]

A party searching for a site to construct a refinery or a chemical plant needs to consider the following issues:

  • The site has to be reasonably far from residential areas.
  • Infrastructure should be available for the supply of raw materials and shipment of products to markets.
  • Energy to operate the plant should be available.
  • Facilities should be available for waste disposal.

Factors affecting site selection for oil refinery:

  • Availability of land
  • Conditions of traffic and transportation
  • Conditions of utilities – power supply, water supply
  • Availability of labours and resources

Refineries that use a large amount of steam and cooling water need to have an abundant source of water. Oil refineries, therefore, are often located nearby navigable rivers or on a seashore, nearby a port. Such location also gives access to transportation by river or by sea. The advantages of transporting crude oil by pipeline are evident, and oil companies often transport a large volume of fuel to distribution terminals by pipeline. A pipeline may not be practical for products with small output, and railcars, road tankers, and barges are used.

Petrochemical plants and solvent manufacturing (fine fractionating) plants need spaces for further processing of a large volume of refinery products, or to mix chemical additives with a product at source rather than at blending terminals.

Safety and environment[edit]

Fire-extinguishing operations after theTexas City refinery explosion

The refining process releases a number of different chemicals into theatmosphere(seeAP 42 Compilation of Air Pollutant Emission Factors) and a notableodornormally accompanies the presence of a refinery. Aside from air pollution impacts there are also wastewater concerns,[52]risks ofindustrial accidentssuch as fire and explosion, andnoise health effectsdue toindustrial noise.[56]

Many governments worldwide have mandated restrictions on contaminants that refineries release, and most refineries have installed the equipment needed to comply with the requirements of the pertinent environmental protection regulatory agencies. In the United States, there is strong pressure to prevent the development of new refineries, and no major refinery has been built in the country sinceMarathon'sGaryville, Louisianafacility in 1976. However, many existing refineries have been expanded during that time. Environmental restrictions and pressure to prevent the construction of new refineries may have also contributed to rising fuel prices in the United States.[57]Additionally, many refineries (more than 100 since the 1980s) have closed due to obsolescence and/or merger activity within the industry itself.[58]

Environmental and safety concerns mean that oil refineries are sometimes located some distance away from major urban areas. Nevertheless, there are many instances where refinery operations are close to populated areas and pose health risks.[59][60]In California'sContra Costa CountyandSolano County,a shoreline necklace of refineries, built in the early 20th century before this area was populated, and associated chemical plants are adjacent to urban areas inRichmond,Martinez,Pacheco,Concord,Pittsburg,VallejoandBenicia,with occasional accidental events that require "shelter in place"orders to the adjacent populations. A number of refineries are located inSherwood Park, Alberta,directly adjacent to the City ofEdmonton,which has a population of over 1,000,000 residents.[61]

NIOSHcriteria foroccupational exposureto refined petroleum solvents have been available since 1977.[62]

Worker health[edit]

Background[edit]

Modernpetroleum refininginvolves a complicated system of interrelated chemical reactions that produce a wide variety of petroleum-based products.[63][64]Many of these reactions require precise temperature and pressure parameters.[65]The equipment and monitoring required to ensure the proper progression of these processes is complex, and has evolved through the advancement of the scientific field ofpetroleum engineering.[66][67]

The wide array of high pressure and/or high temperature reactions, along with the necessary chemical additives or extracted contaminants, produces an astonishing number of potential health hazards to the oil refinery worker.[68][69]Through the advancement of technical chemical and petroleum engineering, the vast majority of these processes are automated and enclosed, thus greatly reducing the potential health impact to workers.[70]However, depending on the specific process in which a worker is engaged, as well as the particular method employed by the refinery in which he/she works, significant health hazards remain.[71]

Although occupational injuries in the United States were not routinely tracked and reported at the time, reports of the health impacts of working in an oil refinery can be found as early as the 1800s. For instance, an explosion in a Chicago refinery killed 20 workers in 1890.[72]Since then, numerous fires, explosions, and other significant events have from time to time drawn the public's attention to the health of oil refinery workers.[73]Such events continue in the 21st century, with explosions reported in refineries in Wisconsin and Germany in 2018.[74]

However, there are many less visible hazards that endanger oil refinery workers.

Chemical exposures[edit]

Given the highly automated and technically advanced nature of modern petroleum refineries, nearly all processes are contained within engineering controls and represent a substantially decreased risk of exposure to workers compared to earlier times.[70]However, certain situations or work tasks may subvert these safety mechanisms, and expose workers to a number of chemical (see table above) or physical (described below) hazards.[75][76]Examples of these scenarios include:

  • System failures (leaks, explosions, etc.).[77][78]
  • Standard inspection, product sampling, process turnaround, or equipment maintenance/cleaning activities.[75][76]

A 2021systematic reviewassociated working in thepetrochemical industrywith increased risk of various cancers, such asmesothelioma.It also found reduced risks of other cancers, such asstomachandrectal.The systematic review did mention that several of the associations were not due to factors directly related to the petroleum industry, rather were related to lifestyle factors such assmoking.Evidence for adverse health effects for nearby residents was also weak, with the evidence primarily centering around neighborhoods indeveloped countries.[79]

BTXstands for benzene,toluene,xylene.This is a group of commonvolatile organic compounds(VOCs) that are found in the oil refinery environment, and serve as a paradigm for more in depth discussion of occupational exposure limits, chemical exposure and surveillance among refinery workers.[80][81]

The most important route of exposure for BTX chemicals is inhalation due to the low boiling point of these chemicals. The majority of the gaseous production of BTX occurs during tank cleaning and fuel transfer, which causes offgassing of these chemicals into the air.[82]Exposure can also occur through ingestion via contaminated water, but this is unlikely in an occupational setting.[83]Dermal exposure and absorption is also possible, but is again less likely in an occupational setting where appropriate personal protective equipment is in place.[83]

In the United States, theOccupational Safety and Health Administration(OSHA),National Institute for Occupational Safety and Health(NIOSH), andAmerican Conference of Governmental Industrial Hygienists(ACGIH) have all establishedoccupational exposure limits(OELs) for many of the chemicals above that workers may be exposed to in petroleum refineries.[84][85][86]

Occupational exposure limits forBTXchemicals
OSHAPEL (8-hour TWA) CalOSHAPEL (8-hour TWA) NIOSHREL (10-hour TWA) ACGIHTLV (8-hour TWA)
Benzene 10ppm 1 ppm 0.1 ppm 0.5 ppm
Toluene 200 ppm 10 ppm 100 ppm 20 ppm
Xylene 100 ppmx 100 ppm 100 ppm 100 ppm
Sources:[87][88][89][84][90]

Benzene, in particular, has multiplebiomarkersthat can be measured to determine exposure. Benzene itself can be measured in the breath, blood, and urine, and metabolites such asphenol,t,t-muconic acid(t,tMA) and S-phenylmercapturic acid (sPMA) can be measured in urine.[91]In addition to monitoring the exposure levels via these biomarkers, employers are required by OSHA to perform regular blood tests on workers to test for early signs of some of the feared hematologic outcomes, of which the most widely recognized is leukemia. Required testing includescomplete blood count with cell differentialsandperipheral blood smear"on a regular basis".[92]The utility of these tests is supported by formal scientific studies.[93]

Potential chemical exposure by process[edit]

Process Potential chemical exposure[94] Common health concerns[95]
Solvent extractionand dewa xing Phenol[96] Neurologic symptoms, muscle weakness, skin irritation.
Furfural[97] Skin irritation
Glycols Central nervous system depression, weakness, irritation of the eyes, skin, nose, throat.
Methyl ethyl ketone[98] Airway irritation, cough, dyspnea, pulmonary edema.
Thermal cracking Hydrogen sulfide[99] Irritation of the respiratory tract, headache, visual disturbances, eye pain.
Carbon monoxide[100] Electrocardiogram changes, cyanosis, headache, weakness.
Ammonia[101] Respiratory tract irritation, dyspnea, pulmonary edema, skin burns.
Catalytic cracking Hydrogen sulfide[99] Irritation of the respiratory tract, headache, visual disturbances, eye pain.
Carbon monoxide[100] Electrocardiogram changes, cyanosis, headache, weakness.
Phenol[96] Neurologic symptoms, muscle weakness, skin irritation.
Ammonia[101] Respiratory tract irritation, dyspnea, pulmonary edema, skin burns.
Mercaptan[102][103] Cyanosis and narcosis, irritation of the respiratory tract, skin, and eyes.
Nickel carbonyl[104] Headache, teratogen, weakness, chest/abdominal pain, lung and nasal cancer.
Catalytic reforming Hydrogen sulfide[99] Irritation of the respiratory tract, headache, visual disturbances, eye pain.
Benzene[105] Leukemia, nervous system effects, respiratory symptoms.
Isomerization Hydrochloric acid Skin damage, respiratory tract irritation, eye burns.
Hydrogen chloride Respiratory tract irritation, skin irritation, eye burns.
Polymerization Sodium hydroxide[106] Irritation of the mucous membranes, skin, pneumonitis.
Phosphoric acid Skin, eye, respiratory irritation.
Alkylation Sulfuric acid Eye and skin burns, pulmonary edema.
Hydrofluoric acid Bone changes, skin burns, respiratory tract damage.
Sweetening and treating Hydrogen sulfide[99] Irritation of the respiratory tract, headache, visual disturbances, eye pain.
Sodium hydroxide[106] Irritation of the mucous membranes, skin, pneumonitis.
Unsaturated gas recovery Monoethanolamine(MEA) Drowsiness, irritation of the eyes, skin, and respiratory tract.
Diethanolamine(DEA) Corneal necrosis, skin burns, irritation of the eyes, nose, throat.
Amine treatment Monoethanolamine(MEA) Drowsiness, irritation of the eyes, skin, and respiratory tract.
Diethanolamine(DEA) Corneal necrosis, skin burns, irritation of the eyes, nose, throat.
Hydrogen sulfide[99] Irritation of the respiratory tract, headache, visual disturbances, eye pain.
Carbon dioxide Headache, dizziness, paresthesia, malaise,tachycardia.
Saturated gas extraction Hydrogen sulfide[99] Irritation of the respiratory tract, headache, visual disturbances, eye pain.
Carbon dioxide[107] Headache, dizziness, paresthesia, malaise, tachycardia.
Diethanolamine Corneal necrosis, skin burns, irritation of the eyes, nose, throat.
Sodium hydroxide[106] Irritation of the mucous membranes, skin, pneumonitis.
Hydrogen production Carbon monoxide[100] Electrocardiogram changes, cyanosis, headache, weakness.
Carbon dioxide[107] Headache, dizziness, paresthesia, malaise, tachycardia.

Physical hazards[edit]

Workers are at risk of physical injuries due to a large number of high-powered machines in the relatively close proximity of the oil refinery. The high pressure required for many of the chemical reactions also presents the possibility of localized system failures resulting in blunt or penetrating trauma from exploding system components.[108]

Heat is also a hazard. The temperature required for the proper progression of certain reactions in the refining process can reach 1,600 °F (870 °C).[70]As with chemicals, the operating system is designed to safely contain this hazard without injury to the worker. However, in system failures, this is a potent threat to workers' health. Concerns include both direct injury through aheat illness or injury,as well as the potential for devastating burns should the worker come in contact with super-heated reagents/equipment.[70]

Noise is another hazard. Refineries can be very loud environments, and have previously been shown to be associated with hearing loss among workers.[109]The interior environment of an oil refinery can reach levels in excess of 90dB.[110][56]In the United States, an average of 90 dB is thepermissible exposure limit(PEL) for an 8-hour work-day.[111]Noise exposures that average greater than 85 dB over an 8-hour require ahearing conservation programto regularly evaluate workers' hearing and to promote its protection.[112]Regular evaluation of workers' auditory capacity and faithful use ofproperly vetted hearing protectionare essential parts of such programs.[113]

While not specific to the industry, oil refinery workers may also be at risk for hazards such asvehicle-related accidents,machinery-associated injuries, work in a confined space, explosions/fires,ergonomic hazards,shift-work related sleep disorders,and falls.[114]

Hazard controls[edit]

The theory ofhierarchy of controlscan be applied to petroleum refineries and their efforts to ensure worker safety.

Eliminationandsubstitutionare unlikely in petroleum refineries, as many of the raw materials, waste products, and finished products are hazardous in one form or another (e.g. flammable, carcinogenic).[94][115]

Examples ofengineering controlsinclude afire detection/extinguishing system,pressure/chemical sensors to detect/predict loss of structural integrity,[116]and adequate maintenance of piping to prevent hydrocarbon-inducedcorrosion(leading to structural failure).[77][78][117][118]Other examples employed in petroleum refineries include the post-construction protection of steel components withvermiculiteto improve heat/fire resistance.[119]Compartmentalizationcan help to prevent a fire or other systems failure from spreading to affect other areas of the structure, and may help prevent dangerous reactions by keeping different chemicals separate from one another until they can be safely combined in the proper environment.[116]

Administrative controlsinclude careful planning and oversight of the refinery cleaning, maintenance, and turnaround processes. These occur when many of the engineering controls are shut down or suppressed and may be especially dangerous to workers. Detailed coordination is necessary to ensure that maintenance of one part of the facility will not cause dangerous exposures to those performing the maintenance, or to workers in other areas of the plant. Due to the highly flammable nature of many of the involved chemicals, smoking areas are tightly controlled and carefully placed.[75]

Personal protective equipment(PPE) may be necessary depending on the specific chemical being processed or produced. Particular care is needed during sampling of the partially-completed product, tank cleaning, and other high-risk tasks as mentioned above. Such activities may require the use of impervious outerwear, acid hood, disposable coveralls, etc.[75]More generally, all personnel in operating areas should use appropriatehearingandvision protection,avoid clothes made of flammable material (nylon,Dacron,acrylic,or blends), and full-length pants and sleeves.[75]

Regulations[edit]

United States[edit]

Worker health and safety in oil refineries is closely monitored at a national level by both theOccupational Safety and Health Administration(OSHA) andNational Institute for Occupational Safety and Health(NIOSH).[120][121]In addition tofederalmonitoring,California'sCalOSHAhas been particularly active in protecting worker health in the industry, and adopted a policy in 2017 that requires petroleum refineries to perform a "Hierarchy of Hazard Controls Analysis" (see above "Hazard controls" section) for eachprocess safetyhazard.[122]Safety regulations have resulted in a below-average injury rate for refining industry workers. In a 2018 report by theUS Bureau of Labor Statistics,they indicate that petroleum refinery workers have a significantly lower rate of occupational injury (0.4 OSHA-recordable cases per 100 full-time workers) than all industries (3.1 cases), oil and gas extraction (0.8 cases), and petroleum manufacturing in general (1.3 cases).[123]

Below is a list of the most common regulations referenced in petroleum refinery safety citations issued by OSHA:[124]

Corrosion[edit]

Refinery ofSlovnaftinBratislava
Oil refinery in Iran

Corrosion of metallic components is a major factor of inefficiency in the refining process. Because it leads to equipment failure, it is a primary driver for the refinery maintenance schedule. Corrosion-related direct costs in the U.S. petroleum industry as of 1996 were estimated at US$3.7 billion.[118][125]

Corrosion occurs in various forms in the refining process, such as pitting corrosion from water droplets, embrittlement from hydrogen, and stress corrosion cracking from sulfide attack.[126]From a materials standpoint, carbon steel is used for upwards of 80 percent of refinery components, which is beneficial due to its low cost.Carbon steelis resistant to the most common forms of corrosion, particularly from hydrocarbon impurities at temperatures below 205 °C, but other corrosive chemicals and environments prevent its use everywhere. Common replacement materials arelow alloy steelscontainingchromiumandmolybdenum,withstainless steelscontaining more chromium dealing with more corrosive environments. More expensive materials commonly used arenickel,titanium,andcopperalloys. These are primarily saved for the most problematic areas where extremely high temperatures and/or very corrosive chemicals are present.[127]

Corrosion is fought by a complex system of monitoring, preventative repairs, and careful use of materials. Monitoring methods include both offline checks taken during maintenance and online monitoring. Offline checks measure corrosion after it has occurred, telling the engineer when equipment must be replaced based on the historical information they have collected. This is referred to as preventative management.

Online systems are a more modern development and are revolutionizing the way corrosion is approached. There are several types of online corrosion monitoring technologies such as linear polarization resistance,electrochemical noiseand electrical resistance. Online monitoring has generally had slow reporting rates in the past (minutes or hours) and been limited by process conditions and sources of error but newer technologies can report rates up to twice per minute with much higher accuracy (referred to as real-time monitoring). This allows process engineers to treat corrosion as another process variable that can be optimized in the system. Immediate responses to process changes allow the control of corrosion mechanisms, so they can be minimized while also maximizing production output.[117]In an ideal situation having on-line corrosion information that is accurate and real-time will allow conditions that cause high corrosion rates to be identified and reduced. This is known as predictive management.

Materials methods include selecting the proper material for the application. In areas of minimal corrosion, cheap materials are preferable, but when bad corrosion can occur, more expensive but longer-lasting materials should be used. Other materials methods come in the form of protective barriers between corrosive substances and the equipment metals. These can be either a lining of refractory material such as standardPortland cementor other special acid-resistant cement that is shot onto the inner surface of the vessel. Also available are thin overlays of more expensive metals that protect cheaper metal against corrosion without requiring much material.[128]

See also[edit]

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