Process Development & Refinery Overview
Sunday 20/7/2025
Location: Process Development Division – Jordan Petroleum Refinery Company
Introduction
On this training day, we were introduced to a new division within the refinery: the Process
Development and Quality Control Division. The session aimed to give us a comprehensive
understanding of the refinery structure, its production processes, expansion history, and how
petroleum derivatives are refined and monitored through different operational units.
Refinery Structure
The engineer began by explaining that the refinery is composed of four main departments:
1. Operations & Loading
o Divided into Operations 1, 2, and 3
o Includes electrical and mechanical engineers
o Also contains the fire safety unit
2. Maintenance
3. Engineering Department
o Includes mechanical design engineers
o Teams are organized into groups such as Project Team, etc.
o Responsible for design, development, and project implementation
4. Process Development & Quality Control
o Includes the Laboratory Department and the Process Development
Department (today’s host)
Operational Divisions Explained
Operations 1
Zone 1: Contains production units
Zone 2: Includes storage tanks, asphalt units, and treatment units
Operations 2
Zone 6:
o Atmospheric distillation units
o Naphtha reforming units
o Gasoline upgrading units
o LPG recovery units
Zone 4:
o Utility services: steam, air, etc.
Operations 3
Zone 7:
o Hydrogen cracking unit
o Hydrogen production unit
o Nitrogen production unit
o Vacuum distillation
o Wastewater treatment
🔹 Note: The API (American Petroleum Institute) Gravity is used as an indicator of crude oil's
specific gravity and quality.
Refining Process Overview
🔄 Step-by-Step Flow from Crude Oil to Final Product
1. Blending Stage
o Crude oil is blended to achieve a suitable API gravity that matches the
distillation units’ operating range.
2. Atmospheric Distillation Units
o At the top (overhead):
Naphtha, LPG, and Benzene
o At the side:
Kerosene
o At the bottom:
Atmospheric Residue → sent to the Vacuum Distillation Units
3. Vacuum Distillation
o Produces:
VHGO (Vacuum Gas Oil)
Fuel Oil (used in industrial boilers and plants)
4. Kerosene
o Sent to a chemical treatment unit (kerosene treatment)
5. Diesel
o Goes directly to storage without further treatment
6. Naphtha Processing
o LPG is first separated
The remaining naphtha and benzene are sent to the Deputanizer (distillation
o
column)
o Output:
Light Naphtha → sent to the Hydrogen Production Unit (Plug Flow
Reactor)
Heavy Naphtha → sent to the Gasoline Reforming Unit
7. LPG Recovery
o LPG is recovered from both:
Naphtha processing
Gasoline reforming
Processing of VHGO
VHGO is sent to two different upgrading units:
1. FCC (Fluid Catalytic Cracking):
Produces benzene and LPG which need additional treatment
2. HC (Hydrogen Cracking):
Produces kerosene and diesel
The diesel meets Euro V standards (high-quality sulfur-free diesel)
Refinery Expansion Timeline
The engineer also explained the refinery’s four major expansion phases, which took place over
the decades since its establishment in the 1960s. These expansions enhanced capacity, efficiency,
and environmental compliance.
Monitoring & Control
We were also introduced to the use of:
Process flow diagrams (PFDs) and piping & instrumentation diagrams (P&IDs)
Digital control systems (DCS) for monitoring the performance of production units
Real-time monitoring of pressure, temperature, flow rates, and unit outputs
Conclusion
Today’s session with the Process Development Division offered a comprehensive insight into
how crude oil is transformed into valuable petroleum products. We now have a clearer
understanding of how each unit operates, how materials flow between them, and how the
refinery ensures efficiency and safety at every stage. The depth of explanation from the engineer
allowed us to see the full picture—from raw crude intake to market-ready products.