An oil refinery or petroleum refinery is an industrial process plant where petroleum is transformed and refined into products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, liquefied petroleum gas and petroleum naphtha. Petrochemical feedstock like ethylene and propylene can also be produced directly by cracking crude oil without the need of using refined products of crude oil such as naphtha. The crude oil feedstock has typically been processed by an oil production plant. There is usually an oil depot at 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.
Hydrofluoric acid is a solution of hydrogen fluoride (HF) in water. Solutions of HF are colorless, acidic and highly corrosive. It is used to make most fluorine-containing compounds; examples include the commonly used pharmaceutical antidepressant medication fluoxetine (Prozac) and the material PTFE (Teflon). Elemental fluorine is produced from it. It is commonly used to etch glass and silicon wafers.
A boiling liquid expanding vapor explosion is an explosion caused by the rupture of a vessel containing a pressurized liquid that is or has reached a temperature sufficiently higher than its boiling point. Because the boiling point of a liquid rises with pressure, the contents of the pressurized vessel can remain a liquid as long as the vessel is intact. If the vessel's integrity is compromised, the loss of pressure drops the boiling point, which can cause the liquid to convert to gas expanding rapidly. BLEVEs are manifestations of explosive boiling.
The Texas City refinery explosion occurred on March 23, 2005, when a flammable hydrocarbon vapor cloud ignited and violently exploded at the isomerization process unit of the BP oil refinery in Texas City, Texas, killing 15 workers, injuring 180 others and severely damaging the refinery. All the fatalities were contractors working out of temporary buildings located close to the unit to support turnaround activities. Property loss was $200 million. When including costs of repairs, deferred production, fines and settlements, the explosion is the world's costliest refinery accident.
On 25 September 1998 a catastrophic accident occurred at the Esso natural gas plant in Longford, Victoria, Australia. A pressure vessel ruptured resulting in a serious jet fire, which escalated to a conflagration extending to a large part of the plant. Fires lasted two days before they were finally extinguished.
Hydrogen fluoride (fluorane) is an inorganic compound with chemical formula HF. It is a very poisonous, colorless gas or liquid that dissolves in water to yield an aqueous solution termed hydrofluoric acid. It is the principal industrial source of fluorine, often in the form of hydrofluoric acid, and is an important feedstock in the preparation of many important compounds including pharmaceuticals and polymers, e.g. polytetrafluoroethylene (PTFE). HF is also widely used in the petrochemical industry as a component of superacids. Due to strong and extensive hydrogen bonding, it boils at near room temperature, much higher than other hydrogen halides.
Sulfolane (also tetramethylene sulfone, systematic name: 1λ6-thiolane-1,1-dione) is an organosulfur compound, formally a cyclic sulfone, with the formula (CH2)4SO2. It is a colorless liquid commonly used in the chemical industry as a solvent for extractive distillation and chemical reactions. Sulfolane was originally developed by the Shell Oil Company in the 1960s as a solvent to purify butadiene. Sulfolane is a polar aprotic solvent, and it is miscible with water.
The Formosa Plastics propylene explosion was a propylene release and explosion that occurred on October 6, 2005, in the Olefins II Unit at the Formosa Plastics plant in Point Comfort, Texas, United States. The subsequent fire burned for five days.
The Fernald Feed Materials Production Center is a Superfund site located within Crosby Township in Hamilton County, Ohio, as well as Ross Township in Butler County, Ohio, in the United States. It was a uranium processing facility located near the rural town of New Baltimore, about 20 miles (32 km) northwest of Cincinnati, which fabricated uranium fuel cores for the U.S. nuclear weapons production complex from 1951 to 1989. During that time, the plant produced 170,000 metric tons uranium (MTU) of metal products and 35,000 MTU of intermediate compounds, such as uranium trioxide and uranium tetrafluoride.
A refinery owned by Gulf Oil Corporation in Philadelphia, located at Girard Point on the Schuylkill River in South Philadelphia, caught fire on Sunday, August 17, 1975. This incident grew into an 11-alarm fire, not brought under control until 24 hours later, and resulted in the death of eight firefighters of the Philadelphia Fire Department (PFD), injuries to 14 other firefighters, and the loss of four PFD vehicles.
The Shell plant explosion in Norco, Louisiana refers to two explosions that occurred in the community in 1973 and 1988. The incident in 1973 occurred when a sixteen-year-old, Leroy Jones, was cutting grass for Helen Washington, who was taking a nap on her porch in the Diamond community. The plant released a plume of gas. A spark from the lawnmower ignited the plume of gas and the flames that resulted engulfed Leroy Jones and Helen Washington. The second explosion occurred in 1988. An early morning explosion from the plant killed seven Shell workers, destroyed homes in the Diamond community, and released 159 million pounds (72 kt) of chemical waste into the atmosphere. Residents still suffer from early illnesses and deaths as a result of the toxic fumes. Citizens have fought Shell Oil since the 1973 explosion. On June 11, 2002, the Concerned Citizens of Norco finished open discussions and negotiations with Shell Oil. The settlement created two programs, the Property Purchase Program and the Home Improvement Program. These programs allow the citizens to either sell their property to Shell at fair price or benefit from programs aimed at improving the Diamond community.
An alkylation unit (alky) is one of the conversion processes used in petroleum refineries. It is used to convert isobutane and low-molecular-weight alkenes (primarily a mixture of propene and butene) into alkylate, a high octane gasoline component. The process occurs in the presence of an acid such as sulfuric acid (H2SO4) or hydrofluoric acid (HF) as catalyst. Depending on the acid used, the unit is called a sulfuric acid alkylation unit (SAAU) or hydrofluoric acid alkylation unit (HFAU). In short, the alky produces a high-quality gasoline blending stock by combining two shorter hydrocarbon molecules into one longer chain gasoline-range molecule by mixing isobutane with a light olefin such as propylene or butylene from the refinery's fluid catalytic cracking unit (FCCU) in the presence of an acid catalyst.
The Williams Olefins Plant explosion occurred on June 13, 2013 at a petrochemical plant located in Geismar, an unincorporated and largely industrial area 20 miles (32 km) southeast of Baton Rouge, Louisiana. Two workers were killed and 114 injured. The U.S. Occupational Safety and Health Administration (OSHA) and the U.S. Chemical Safety and Hazard Investigation Board (CSB) launched investigations to determine how and why the heat exchanger failed. The Chemical Safety Board concluded that a standby heat exchanger had filled with hydrocarbon. This heat exchanger was isolated from its pressure relief; shortly after the heat exchanger was heated with hot water, the hydrocarbon flashed to vapor, ruptured the heat exchanger, and exploded.
The 2010 Tesoro Anacortes Refinery disaster was an industrial accident that occurred at the Tesoro Anacortes Refinery in Anacortes, Washington on April 2, 2010. Seven workers received fatal burns in an explosion and ensuing fire when a heat exchanger violently ruptured after a maintenance restart.
The Gallup Refinery, also known as the Ciniza Refinery, was an American oil refinery. The facility is located in northwestern New Mexico along Interstate 40, approximately 20 miles east of the city center of Gallup and near the town of Jamestown, New Mexico. The facility occupies 880 acres in McKinley County and employed approximately 220 employees as of March 2019. The facility processed approximately 26,000 barrels of crude oil per day and produced gasoline, diesel, heavy fuel oil, and propane.
An explosion at the ARCO Chemical (ACC) Channelview, Texas petrochemical plant killed 17 people and injured five others on July 5, 1990. It was one of the deadliest industrial disasters in the history of the Greater Houston area.
On April 26, 2018, an explosion and subsequent fire occurred at the Husky Energy Oil Refinery in Superior, Wisconsin. An initial explosion was reported at 10:00 AM and was extinguished close to noon, however a piece of debris had hit a storage tank containing asphalt, which ignited after spilling across the refinery, sending a thick plume of black smoke into the air. Thirty-six people, including 11 refinery employees, were sent to local hospitals, but there were ultimately no fatalities. Residents 3 miles to the east and west of the refinery, 2 miles to the north, and 10 miles to the south were evacuated from their homes temporarily due to concerns of both the toxicity of the smoke affecting those who lived south of the refinery and concerns regarding the plant's hydrofluoric acid tank causing further damage.
