Refining (also perhaps called by the mathematical term affining) is the process of purification of a (1) substance or a (2) form. The term is usually used of a natural resource that is almost in a usable form, but which is more useful in its pure form. For instance, most types of natural petroleum will burn straight from the ground, but it will burn poorly and quickly clog an engine with residues and by-products. The term is broad, and may include more drastic transformations, such as the reduction of ore to metal (for which see Refining (metallurgy)).
The refining of liquids is often accomplished by distillation or fractionation; this process is useful, for example, for isolating different fractions of petroleum. Gases can be refined in this way as well, by being cooled and/or compressed until they liquefy. Gases and liquids can also be refined by extraction with a selective solvent that dissolves away either the substance of interest, or the unwanted impurities.
Many solids can be refined by growing crystals in a solution of the impure material; the regular structure of the crystal tends to favor the desired material and exclude other kinds of particles.
Chemical reactions are often used to remove impurities of particular types.
Distillation, or classical distillation, is the process of separating the components or substances from a liquid mixture by using selective boiling and condensation, usually inside an apparatus known as a still. Dry distillation is the heating of solid materials to produce gaseous products ; this may involve chemical changes such as destructive distillation or cracking. Distillation may result in essentially complete separation, or it may be a partial separation that increases the concentration of selected components; in either case, the process exploits differences in the relative volatility of the mixture's components. In industrial applications, distillation is a unit operation of practically universal importance, but is a physical separation process, not a chemical reaction. An installation used for distillation, especially of distilled beverages, is a distillery. Distillation includes the following applications:
Zone melting is a group of similar methods of purifying crystals, in which a narrow region of a crystal is melted, and this molten zone is moved along the crystal. The molten region melts impure solid at its forward edge and leaves a wake of purer material solidified behind it as it moves through the ingot. The impurities concentrate in the melt, and are moved to one end of the ingot. Zone refining was invented by John Desmond Bernal and further developed by William G. Pfann in Bell Labs as a method to prepare high-purity materials, mainly semiconductors, for manufacturing transistors. Its first commercial use was in germanium, refined to one atom of impurity per ten billion, but the process can be extended to virtually any solute–solvent system having an appreciable concentration difference between solid and liquid phases at equilibrium. This process is also known as the float zone process, particularly in semiconductor materials processing.
Naphtha is a flammable liquid hydrocarbon mixture. Generally, it is a fraction of crude oil, but it can also be produced from natural gas condensates, petroleum distillates, and the fractional distillation of coal tar and peat. In some industries and regions, the name naphtha refers to crude oil or refined petroleum products such as kerosene or diesel fuel.
An oil refinery or petroleum refinery is an industrial process plant where petroleum is transformed and refined into useful 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.
Fractional distillation is the separation of a mixture into its component parts, or fractions. Chemical compounds are separated by heating them to a temperature at which one or more fractions of the mixture will vaporize. It uses distillation to fractionate. Generally the component parts have boiling points that differ by less than 25 °C (45 °F) from each other under a pressure of one atmosphere. If the difference in boiling points is greater than 25 °C, a simple distillation is typically used. It is used to refine crude oil.
A refinery is a production facility composed of a group of chemical engineering unit processes and unit operations refining certain materials or converting raw material into products of value.
Industrial processes are procedures involving chemical, physical, electrical, or mechanical steps to aid in the manufacturing of an item or items, usually carried out on a very large scale. Industrial processes are the key components of heavy industry.
A visbreaker is a processing unit in an oil refinery whose purpose is to reduce the quantity of residual oil produced in the distillation of crude oil and to increase the yield of more valuable middle distillates by the refinery. A visbreaker thermally cracks large hydrocarbon molecules in the oil by heating in a furnace to reduce its viscosity and to produce small quantities of light hydrocarbons.. The process name of "visbreaker" refers to the fact that the process reduces the viscosity of the residual oil. The process is non-catalytic.
Continuous distillation, a form of distillation, is an ongoing separation in which a mixture is continuously fed into the process and separated fractions are removed continuously as output streams. Distillation is the separation or partial separation of a liquid feed mixture into components or fractions by selective boiling and condensation. The process produces at least two output fractions. These fractions include at least one volatile distillate fraction, which has boiled and been separately captured as a vapor condensed to a liquid, and practically always a bottoms fraction, which is the least volatile residue that has not been separately captured as a condensed vapor.
Hydrodesulfurization (HDS), also called hydrotreatment or hydrotreating, is a catalytic chemical process widely used to remove sulfur (S) from natural gas and from refined petroleum products, such as gasoline or petrol, jet fuel, kerosene, diesel fuel, and fuel oils. The purpose of removing the sulfur, and creating products such as ultra-low-sulfur diesel, is to reduce the sulfur dioxide emissions that result from using those fuels in automotive vehicles, aircraft, railroad locomotives, ships, gas or oil burning power plants, residential and industrial furnaces, and other forms of fuel combustion.
Natural-gas processing is a range of industrial processes designed to purify raw natural gas by removing contaminants such as solids, water, carbon dioxide (CO2), hydrogen sulfide (H2S), mercury and higher molecular mass hydrocarbons (condensate) to produce pipeline quality dry natural gas for pipeline distribution and final use. Some of the substances which contaminate natural gas have economic value and are further processed or sold. Hydrocarbons that are liquid at ambient conditions: temperature and pressure (i.e., pentane and heavier) are called natural-gas condensate (sometimes also called natural gasoline or simply condensate).
A delayed coker is a type of coker whose process consists of heating a residual oil feed to its thermal cracking temperature in a furnace with multiple parallel passes. This cracks the heavy, long chain hydrocarbon molecules of the residual oil into coker gas oil and petroleum coke.
The BPRefinery (Kent) was an oil refinery on the Isle of Grain in Kent. It was commissioned in 1953 and had a maximum processing capacity of 11 million tonnes of crude oil per year. It was decommissioned in August 1982.
Automotive oil recycling involves the recycling of used oils and the creation of new products from the recycled oils, and includes the recycling of motor oil and hydraulic oil. Oil recycling also benefits the environment: increased opportunities for consumers to recycle oil lessens the likelihood of used oil being dumped on lands and in waterways. For example, one gallon of motor oil dumped into waterways has the potential to pollute one million gallons of water.
Petroleum refining processes are the chemical engineering processes and other facilities used in petroleum 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.
Petroleum naphtha is an intermediate hydrocarbon liquid stream derived from the refining of crude oil with CAS-no 64742-48-9. It is most usually desulfurized and then catalytically reformed, which rearranges or restructures the hydrocarbon molecules in the naphtha as well as breaking some of the molecules into smaller molecules to produce a high-octane component of gasoline.
William Gardner Pfann was an inventor and materials scientist with Bell Labs. Pfann is known for his development of zone melting which is essential to the semiconductor industry. As stated in an official history of Bell Labs, "Timely invention of zone refining by W.G.Pfann ... was a major contribution that helped bring the impurities in germanium and silicon under control."
A separation process is a method that converts a mixture or a solution of chemical substances into two or more distinct product mixtures, a scientific process of separating two or more substance in order to obtain purity. At least one product mixture from the separation is enriched in one or more of the source mixture's constituents. In some cases, a separation may fully divide the mixture into pure constituents. Separations exploit differences in chemical properties or physical properties between the constituents of a mixture.
Petroleum refining in the United States in 2013 produced 18.9 million barrels per day of refined petroleum products, more than any other country. Although the US was the world's largest net importer of refined petroleum products as recently as 2008, the US became a net exporter in 2010, and in 2014 was the largest exporter and the largest net exporter of refined petroleum. As of January 2019, there were 135 operating refineries in the US, distributed among 30 states.
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