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Posted by chmaynard 15 hours ago

How an oil refinery works(www.construction-physics.com)
369 points | 114 comments
tkgally 3 hours ago|
About thirty years ago, I was given a personal tour of an oil refinery in Yokohama, Japan. I was doing freelance translation then for a Japanese oil company. I mentioned to one of my contacts there that I would be interested in actually seeing the sort of equipment I was translating documents about, and they arranged a visit for me.

Two things stand out in my memory:

Even though the refinery was in full operation, we saw no other people as we walked and drove around the facility. The only staff we saw were in the control room, and they didn’t seem very busy.

The other was the almost complete lack of odors. That particular refinery is close to an upscale residential area, and the company had to be careful to keep sulfurous and other gases from escaping in order to avoid complaints and possibly fines. Some of the documentation I was translating then was about their system for detecting and preventing odor releases. As I recall, they had people walk around the perimeter and local neighborhoods regularly, just sniffing for smells from the plant. On the day we were there, I noticed petroleum odors only when we were close to one of the refining towers; otherwise, the only smell was from the nearby Tokyo Bay.

hyraki 1 hour ago|
Sounds about right. I work in the field contracting to a lot of plants and once they are built they don’t need a ton of people there. It’s really if they are doing shutdowns that there are a lot of people.
tolerance 11 hours ago||
Instantly I'm reminded of "That Time I Tried to Buy an Actual Barrel of Crude Oil"

https://news.ycombinator.com/item?id=43761572

https://archive.is/kLFxg

Which leads to "Planet Money Buys Oil"

https://www.npr.org/sections/money/2016/08/26/491342091/plan...

diginova 11 hours ago||
My father actually works at the Jamnagar refinery. I was bought up in there seeing and visiting the refinery as families are allowed for some trips every now and then. I learnt a lot of this process of refining out of curiosity of what my father did and it was just so cool. The refinery in context is the world's largest since more than a decade and seeing it with your own eyes, it feels like a wonder of the world for real. Truly marvellous outcome of perseverance and engineering. Loved to see this blog on the HN homepage, its very well written
spot5010 2 hours ago||
My father worked in the HPCL refinery in Chembur. I got to go visit on Republic day when I was a kid, but they stopped doing visits. He worked in the distillation tower at first, but then moved into diesel desulphurization. I wish it wasn't but its a dangerous job, and he narrowly escaped several accidents, including a horrible naphta fire that took many lives.
throwaway7783 2 hours ago|||
Wow, I contracted in Jamnagar for Reliance building software back in 1999-2000. It was fun building a web interface to report on their IoT (not called IoT back then) devices - sensors, meters and whatnots through a CORBA/C++ interface. That was very advanced for those days.
alephnerd 10 hours ago||
Would love to hear stories about it. Reliance is working on replicating the Jamnagar refinery approach in America [0] now as well.

It's interesting to both see Asian majors and EPCs increasingly dominating the petrochemical chain as well as see an industry that the US used to lead in increasingly become dependent those partners.

What a massive shift in just 25 years.

[0] - https://www.bloomberg.com/news/articles/2026-03-11/reliance-...

caminante 3 hours ago|||
Not really a big deal. The numbers are cumulative. The Reliance Brownsville Texas facility will only process 60 million barrels per year. That's 1% of annual US refining capacity.

> It's interesting to both see Asian majors and EPCs increasingly dominating the petrochemical chain

You really don't want downstream in your backyard, though. The environmental oversight in these countries is...less. Meanwhile, it's a hyper competitive industry with low margins so adding new capacity only works in places with cheap labor and less red tape.

mlinhares 5 hours ago|||
When all you can produce are finance bros this is the result.
ChristopherDrum 6 hours ago||
Here's how a refinery works: https://www.myabandonware.com/game/simrefinery-e65 (built for Chevron, in fact)

And the manual: https://archive.org/details/sim-refinery-tour-book_202006/mo...

t_tsonev 14 hours ago||
The article is quick to point out the huge role of oil in the modern energy mix. It also fails to note that most of the energy ends up us waste heat. The so called "Primary energy fallacy". Other than that, it's a great read.
nerdsniper 13 hours ago||
To me (as someone who has worked on oil rigs, oil pipelines, oil refineries, and chemical plants), crude oil seems far more valuable as a material than as an energy source. It feels like a damned shame that we're still combusting so much of it for heat rather than reserving it for physical materials.

I understand the ways that economics are very important, and that the economics still currently favor burning a large fraction of the crude oil. But I also know that the right kinds of investments and a bit of luck can often change those economics, and that would be nice to see.

whatever1 12 hours ago|||
We can always make polymers and HydroCarbons in general from other sources if we have energy abundance. We literally can just capture the CO2 we emitted from burning fossil and make it plastics.

Of course this does not make sense in a world where we do not have enough energy to even keep datacenters open.

Edit: To clarify, I do not propose burning fossils to capture CO2 and make plastics. I am a Thermo Laws believer.

ok_computer 2 hours ago|||
Methane >> carbon dioxide as a polyethylene/linear polymers feed stock. Double bonded oxygens are hella higher affinity than four loose hydrogens. Also as pointed out, even in a concentrated combustion effluent stack CO2 is low concentration at atmospheric pressure.

I don’t know about methane as an aromatic/hybridized ring building block. Anything is possible with chemical synthesis but is it energy feasible.

There’s always plant hydrocarbon feed stocks but I think using arable land to make plastics is dumb and also carbon intensive. (I do wear cotton clothing tho because you need to make trade offs).

whatever1 1 hour ago||
Siemens has a collaboration with Porsche are piloting already eFuel production. Cost is super high (think like $10/liter). But thermodynamically feasible.

https://www.siemens-energy.com/global/en/home/press-releases...

adrianN 3 hours ago||||
The problem with carbon capture from air is the low carbon concentration. Try to do the math for how much air you need to process to get even one barrel of oil worth of hydrocarbons from a DAC process.
aethr 1 hour ago||
The answer to this problem as it's currently being pursued is renewable carbon feedstocks. Growing things like canola on marginal land, harvesting it and turning it into biofuels and LCLFs (low carbon liquid fuels) using renewable solar/wind energy.

It's not a solved problem, though. Truly renewable carbon feedstocks have to source their carbon from the air, not the soil, which has to be continually measured. Land selection for carbon feedstock projects has to ensure it doesn't induce land-use change in other locations due to displacing other things like food production, etc. Otherwise the emissions and environmental harm from those downstream effects have to be included in the carbon positive/negative calculations for the project.

sonofhans 7 hours ago|||
That sounds like a hack from late-game Factorio: pollute enough that you can just pull iron filings right out of the air. Everyone wins! Except the meatbags who need to breathe the air …
whatever1 5 hours ago||
Assuming the damn rain does not throw your iron down to the ground before it reaches its destination. But then again you have rivers as a plan B.
marcosdumay 5 hours ago|||
There is way more carbon in the ground as rocks than as oil. If you have plenty of energy, the difference is quite manageable.

Besides, as somebody already pointed out, there is that CO2 on the air that we actually want to get rid of. It's nothing compared to the rocks, and a little harder to get, but getting it first would improve things a lot.

tesseract 22 minutes ago|||
> there is that CO2 on the air that we actually want to get rid of

For this reason I have long been slightly baffled that development of compostable/biodegradable bio-based plastics is such a priority in materials research. Sure, it's interesting in the very long run, but for the foreseeable future, converting atmospheric CO2 (via plants as an initial step) into a long lived, inert material that can just be buried after an initial use seems like a benefit.

ok_computer 2 hours ago|||
The carbon isn’t valuable elementally as much as it is structurally and molecularly. I mean that as aromatic rings and other ready made building blocks that conveniently can be fractionally separated with pressure and temperature conditions in a column as a gross generalization. All of this is energy intensive but much less so than building up from three atom molecules with strong bonds. And much much less energy intensive than separating a trace % molecule from the atmosphere at low atmospheric pressure and translating that to complex molecules.

There needs to be more appreciation for the laws of thermodynamics when discussing technology. Everything is not a 1-dimensional reduced abstraction.

throw0101c 13 hours ago|||
> It also fails to note that most of the energy ends up us waste heat.

I've heard the statistic that 40% of the total oil pumped out of the ground just to transporting oil. We use almost half just to move it to and fro before even using it.

Is this accurate?

dmurray 10 hours ago|||
This can't be accurate.

Let's say a barrel of oil travels 15,000 km from Saudi Arabia to Texas, gets refined, gets shipped another 10,000 km to Europe, then the last 1,000 km overland by truck.

This reasonably well sourced Reddit post [0] says big oil tankers burn 0.1% of their fuel per 1,000 km, smaller ones a bit more. Say 0.2% on aggregate, that's 5% for the whole journey, 10% because the ship is empty half the time.

From the same source, a truck burns about 3% per 1,000 km. This seems too high: for a 40,000 kg loaded truck that's less than 1 kmpl or 2.5 mpg. But let's believe it, double it for empty journeys, and we still only get 16%.

I used very conservative estimates here: surely most oil doesn't travel anywhere near that far.

Alternative thought experiment: look at the traffic on the highway. If this were true, even neglecting oil burnt for heating or electricity or aviation, you'd expect 40% of the vehicles to be tanker trucks.

[0] https://www.reddit.com/r/explainlikeimfive/comments/2jozd7/e...

sokoloff 10 hours ago|||
> you'd expect 40% of the vehicles to be tanker trucks.

I’d expect tanker trucks to carry far more fuel than the typical vehicle.

mschuster91 7 hours ago|||
> Say 0.2% on aggregate, that's 5% for the whole journey, 10% because the ship is empty half the time.

Fuel saves from slow steaming and being empty are massive.

> If this were true, even neglecting oil burnt for heating or electricity or aviation, you'd expect 40% of the vehicles to be tanker trucks.

The US has a lot of domestic pipelines [1], and a lot of the remainder is done by train [2] because trains are the most efficient way to transport bulk goods over extremely long distances.

[1] https://www.bts.gov/geography/geospatial-portal/us-petroleum...

[2] https://www.aar.org/wp-content/uploads/2018/07/AAR-US-Rail-C...

jml7c5 10 hours ago||||
I suspect this is confusion between the statistic that 40% of global shipping traffic is transportation of fossil fuels.

https://qz.com/2113243/forty-percent-of-all-shipping-cargo-c...

porknubbins 4 hours ago||||
Say a tanker truck has a roughly 300 gallon fuel tank and a 10,000 gallon payload tank (per google). Thats roughly 3% loss to cross a lot of the US, which is by no means insignificant but assuming ships are not any worse and the pipeline to the ship is minimal, around a manageable 6% loss.
0cf8612b2e1e 7 hours ago||||
I also don’t have a source, but I have heard that 15% of global energy is dedicated to handling petroleum (extracting, transporting, refining) which feels like a plausible number.
foota 10 hours ago||||
This doesn't math out to me just based on what I know of energy consumption numbers.
matkoniecz 10 hours ago||||
Sounds really dubious to me. Tankers and pipelines are really efficient.

I would not believe it at all without source.

Maybe someone got confused by "transportation" altogether being major consumer?

testing22321 11 hours ago|||
It must be way higher if you really got into it

i.e. A friend that works on rigs is flown to and from rigs from anywhere on earth every month, then choppers out to the rig and back. Same for everyone that works on the rigs.

matkoniecz 10 hours ago||
And? Given how much typical oil rig produces this would not be a serious part of its production.
tmellon2 13 hours ago||
[flagged]
shhsshs 13 hours ago||
As someone with no real-world petrochemistry experience, but much gaming experience, I was very surprised how familiar the crude oil processing diagram looks. Factorio and GregTech are two prime examples of fairly realistic oil processing lines (probably as accurate as any game would reasonably try to be).
FumblingBear 12 hours ago|
I was thinking the same thing! Having played through Factorio and a fair amount of GregTech really reframed my viewpoint on energy production that a huge part of the benefit of fossil fuels is the byproducts, not just raw energy output.
triceratops 12 hours ago||
All the more reason to save fossil fuels instead of burning them for energy.
protocolture 4 hours ago||
>triceratops

Hurry up and become crude oil.

yread 11 hours ago||
I find it amazing how "naphtha" can mean crude oil, diesel, kerosene, gasoline or kind of white spirit.

EDIT: oh and it comes from Akkadian! how many Akkadian words do you know?

TheJoeMan 6 hours ago|
And RP-1 Rocket Fuel and Jet-A Jet Fuel are both Kerosene!
didgetmaster 9 hours ago||
I remember driving by a refinery years ago and it had two or three towers with big flames that were just burning off waste gas. This seemed wasteful to me. If it can burn, then it seems like it could be used for something productive.

Do they still just burn off that gas?

sushibowl 8 hours ago||
Usually, when refineries flare something like that it's because what they are burning is not suitable for use, and making it suitable would cost more than the product would sell for.

Often methane as a by-product of oil production is flared, because the amount is small enough that it's not worth setting up processing plants and supply chains for. Other times, the fluid is heavily contaminated by e.g. sulfur compounds, and would be costly to purify. Still other times the production of the fluid is unreliable or intermittent, and cannot sustain a continuous production process.

Although, flare gas recovery systems exist nowadays to make use of these waste gases, commonly for local power production for the refinery itself.

deepsun 8 hours ago|||
That's why plastic bags are so cheap -- ethanol is a byproduct, but you earn more if you discard it and sell only oil.

But the burned up ethanol would be perfectly suitable for products.

Nowadays there are some regulations to prevent that, so they may sell up ethanol at negative prices sometimes.

UPDATE: Ethene, not ethanol.

nayuki 7 hours ago||
You wrote ethanol (C₂H₆O), but do you mean ethylene/ethene (C₂H₄)? Polyethylene (PE) is a very common plastic, such as HDPE, LDPE, PET.
deepsun 7 hours ago||
You're right, sorry, I thought of ethene.

Like here is a good review https://youtu.be/325HdQe4WM4

beerandt 7 hours ago|||
Yea while $ viability is true, it's better to think of as

1) using some potentially useful products as fuel to burning off things you don't want and

2) the buffer to keep non-steady inflows in a suitable ready condition for steady-state processing. (When real world steady-state is less than ideal.)

Number 2 is really what dominates the equation, as shutting in gas sources or even just turning off pipelines is incredibly more complicated than just an 'off' switch.

And turning back on is even more complicated. In the case of wells, once you shut in, turning back on may never result in the same level of production as before.

the-grump 8 hours ago|||
It's usually a small amount of waste, and handling gas is very different from distillate.

You'd need to either liquify that gas or collect it to a pipeline in order to make it useful. I remember reading that modern refineries make use of the gases instead of flaring them though I'm not sure how.

JohnKemeny 8 hours ago|||
They flare to quickly burn off excess gases as a safety mechanism rather than anything else. Venting gas into the air would be much worse.
noisy_boy 55 minutes ago||
Can't that burning be converted into energy like boiling water to turn a turbine to generate energy? Or not worth the payoff?
chasd00 8 hours ago||
the way it was explained to me is if you see the flares then something is wrong. It may not be catastrophic or anything serious but something isn't going according to plan. Because you're right, why burn it off when you can sell it?
beerandt 7 hours ago||
It generally means something is out of balance, which doesn't necessarily mean something is wrong. Usually not.

But if something is wrong, yea you can bet they will be burning off with big flares.

rolph 3 hours ago||
Fractional distillation

https://en.wikipedia.org/wiki/Fractional_distillation

Fractionating column

https://en.wikipedia.org/wiki/Fractionating_column

noer 13 hours ago|
If you're interested in how the oil industry as a whole operates and why, Oil 101 is an interesting read.
gf263 5 hours ago||
By Morgan Downey?
balderdash 11 hours ago||
Highly recommend
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