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Operators
control the refining processes using hi-tech computers located in control centers situated throughout the
refinery.
Heat and catalysts are used to convert the heavier oils to lighter products using three "cracking" methods:
fluid catalytic cracking (FCC), hydrocracking (Isomax), and coking (or thermal-cracking).
The Fluid Catalytic Cracker (FCC) uses high temperature and catalyst to crack 86,000 barrels (3.6 million
gallons) each day of heavy gas oil mostly into gasoline. Hydrocracking uses catalysts to react gas oil and
hydrogen under high pressure and high temperature to make both jet fuel and gasoline.
Also, about 58,000 barrels (2.4 million gallons) of lighter gas oil is converted daily in two Isomax Units, using
this hydrocracking process.
We blend most of the products from the FCC and the Isomaxes directly into transportation fuels, i.e.,
gasoline, diesel and jet fuel. We burn the lightest molecules as fuel for the refinery's furnaces, thus
conserving natural gas and minimizing waste.
In the Delayed Coking Unit (Coker), 98,000 barrels a day of low-value residuum is converted (using the
coking, or thermal-cracking process) to high-value light products, producing petroleum coke as a by-product.
The large residuum molecules are cracked into smaller molecules when the residuum is held in a coke drum
at a high temperature for a period of time. Only solid coke remains and must be drilled from the coke drums.
Modifications to the refinery during its 2003 Clean Fuels Project increased residuum volume going to the
Coker Unit. The project increased coke handling capacity and replaced the 150 metric-ton coke drums with
new 300 metric-ton drums to handle the increased residuum volume.
The Coker typically produces more than 6,000 tons a day of petroleum coke, which is sold for use as fuel or
in cement manufacturing.
Combining
While the cracking processes break most of the gas oil into gasoline and jet fuel, they also break off some
pieces that are lighter than gasoline. Since Pascagoula Refinery's primary focus is on making transportation
fuels, we recombine 14,800 barrels (622,000 gallons) each day of lighter components in two Alkylation Units.
This process takes the small molecules and recombines them in the presence of sulfuric acid catalyst to
convert them into high octane gasoline.
The gasoline process streams in the refinery that have a fairly low octane rating are sent to a Reforming Unit
where their octane levels are boosted. These reforming units employ precious-metal catalysts - platinum and
rhenium and thereby get the name "rheniformers." In the reforming process, hydrocarbon molecules are
"reformed" into high octane gasoline components. For example, methyl cyclohexane is reformed into
toluene.
The reforming process actually removes hydrogen from low-octane gasoline. The hydrogen is used
throughout the refinery in various cracking (hydrocracking) and treating (hydrotreating) units.
Our refinery operates three catalytic reformers, where we rearrange and change 71,000 barrels (about 3
million gallons) of gasoline per day to give it the high octane cars need.
Product testing
Blending
A final and critical step is the blending of our products. Gasoline, for example, is blended from treated
components made in several processing units. Blending and Shipping Area operators precisely combine
these to ensure that the blend has the right octane level, vapor pressure rating and other important
specifications. All products are blended in a similar fashion.
Quality Control
In the refinerys modernly-equipped Laboratory, chemists and technicians conduct quality assurance tests
on all finished products, including checking gasoline for proper octane rating. Techron Chevrons patented
performance booster, is added to gasoline at the companys marketing terminals, one of which is located at
the Pascagoula Refinery.