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The oil products generated by the aforementioned devices are typically not suitable for direct commercial use. To meet industry standards and performance requirements, additional processing is often necessary. This includes blending with other oils, adding performance-enhancing additives, and further refining to eliminate impurities that may affect quality, stability, or usability. Common contaminants in crude oil include sulfur-, nitrogen-, and oxygen-containing compounds, as well as waxes and gums. These impurities can cause unpleasant odors, dark discoloration, equipment corrosion, and poor storage properties. To address these issues, several refining techniques are commonly employed.
Acid refining involves treating the oil with sulfuric acid to remove sulfur compounds, nitrogen compounds, and gums. Alkaline refining, on the other hand, uses a caustic soda solution to eliminate oxygenates and sulfides, while also neutralizing any residual acid from the previous step. These two methods are often used together, forming what is known as acid-base refining. Deodorization is another important process, especially for fuels derived from high-sulfur crude oil. It involves removing foul-smelling mercaptans using a catalyst, lye, and air oxidation to prevent the formation of sticky residues that hinder storage and handling.
Hydrogenation is a critical process where hydrogen is introduced under high pressure and temperature (300–425°C) in the presence of a catalyst. This helps remove sulfur, nitrogen, and oxygen compounds, as well as metal impurities, thereby improving the oil’s stability, corrosiveness, and flammability. Dewaxing is essential for aviation kerosene and diesel, as waxes can crystallize at low temperatures, leading to clogged pipelines and reduced flow. Molecular sieves are often used for this purpose, and dewaxing may also be required during lubricating oil production to improve its low-temperature performance.
White clay refining is typically the final stage in the refining process, where harmful substances are adsorbed by clay composed mainly of silica and alumina. Lubricating oils, which are primarily distilled from crude oil, require careful refinement to maintain their key properties: viscosity, stability, and lubricity. The main goal of lubricant production is to remove undesirable components such as gums, asphaltenes, sulfur-, nitrogen-, and oxygen-containing compounds, waxes, and polycyclic aromatic hydrocarbons. These impurities negatively impact the oil's color, stability, and viscosity.
Solvent refining is widely used in lubricant production, where solvents like furfural and phenol are employed to separate unwanted components based on their solubility. Solvent dewaxing, often referred to as ketone-benzene dewaxing, involves using mixed solvents such as toluene and methyl ethyl ketone to dissolve and remove paraffin wax, ensuring better low-temperature performance and easier filtration. Overall, the refining process is a complex but crucial step in transforming raw crude oil into high-quality, usable petroleum products.