Refinery & Petroleum Products Quality Specifications, Blending, Mixing, Optimization, Operational Planning, Quality Control & Profitability

Introduction

This course is designed to provide delegates with a detailed and up-to-date overview of refinery and petroleum products quality specifications, blending, mixing, optimization, operational planning, quality control and profitability. It covers the general and organic chemistry and physical and chemical properties of hydrocarbons and petroleum cuts; the petroleum and main non-energy products including the different refinery process technologies; the chemical used in refinery processes; and the product blending, troubleshooting refinery operations and practical problems. During this interactive course, participants will learn the importance of measurement in refinery mass balance and the density measurement require to convert volume to mass; the movement’s qualities and tolerances and the list of frequent movements; the refinery optimization, operations planning, equipment optimization and process optimization; the process operations and the concepts of refinery operational; the planning objectives, planning tools, key crude and product qualities as well as crude and product pricing; and the practical refinery modeling, performance measures and rules of thumb for process engineers.

Objectives

Upon the successful completion of this course, each participant will be able to:-

• Apply and gain an in-depth knowledge on refinery and petroleum products quality specifications, blending, mixing, optimization, operational planning, quality control and profitability
• Discuss general and organic chemistry and physical and chemical properties of hydrocarbons and petroleum cuts
• Identify petroleum and main non-energy products including the different refinery process technologies
• Recognize the chemical used in refinery processes as well as carryout product blending, troubleshooting refinery operations and practical problems
• Discuss the importance of measurement in refinery mass balance and the density measurement require to convert volume to mass
• Calculate and store movement’s qualities and tolerances and provide the list of frequent movements
• Apply refinery optimization, operations planning, equipment optimization and process optimization
• Optimize process operations and identify the concepts of refinery operational
• Carryout planning objectives, planning tools, key crude and product qualities as well as crude and product pricing
• Illustrate practical refinery modeling, performance measures and rules of thumb for process engineers

Training Methodology

Participants to this training course will receive a thorough understanding on the subjects covered by the course outline with the trainer utilising a variety of proven adult learning teaching and facilitation techniques. Course methodology includes professional schematics, videos, case studies surrounding the topic which will enable the participants to have an in-depth understanding of the topic as well as practical skills to implement the learning into real life strategies.

Who Should Attend?

This course provides an overview of all significant aspects and considerations of refinery and petroleum products quality specifications, blending, mixing, optimization, operational planning, quality control and profitability for planning engineers, process engineers, production engineers, scheduling engineers, marketing engineers and estimation engineers. Further, finance managers, commercial managers, estimation managers, section heads, supervisors and refineries/process plant consultants will gain an excellent knowledge from the operational aspects of this course.

Course Outline

General Chemistry

• Basic Material
• Basic Chemical Reaction
• Theory of Gases

Organic Chemistry

• Structure of Organic Compounds
• Reaction of Organic Compounds
• Detail Study of Alkenes
• Alkenes
• Aromatics & Alcohol
• Nitrogen Compounds

Physical & Chemical Properties of Hydrocarbons & Petroleum Cuts

• General Hydrocarbon Classification
• Structure & Properties of Hydrocarbons
• Main Types of Organic Compounds
• Physical & Chemical Properties of Hydrocarbon Mixtures
• Characterization of Petroleum Cuts
• Molar Weight

Volatility:

• TBP & ASTM Distillations
• Mean Average Temperature (Mav)
• Characterization Factor
• Vapor Pressure
• Specific Gravity
• Viscosity
• Critical Properties

Petroleum Products

• Properties, Characteristic & Formulation of Combustible Products
• For Each Chief Product; LPG, Automotive Gasoline, Jet Fuel, Automotive Diesel Fuel, Domestic Fuel Oil & Heavy Fuel Oils, the Following are Developed
• Market Trends – Volatility Characteristics – Combustion Properties
• Under Cold Conditions & Flow -Stability, Storage Behavior

Main Non-Energy Products

• Bitumen
• The Different Types of Bitumen; Pure, Outbacks, Polymer Modified, Emulsion, etc
• Lubricants
• Function of Lubricants
• Composition of Lubricants
• Base Oils & Additives
• Formulation
• Engine Oils Industrial Oils

Different Refinery Process Technologies

• Parameters to be Monitored & Controlled in Different Processes & Their Use in Maintaining Product Specification

Chemical Used in Refinery Processes

• Nature of Chemical
• Optimization Usage
• Chemical Hazards & Prevention
• Safe Storage of the Chemicals
• Petroleum Product Specification and Testing

Product Blending

• Reid Vapor Pressure
• Octane Blending
• Blending for Other Properties
• Case Study Problem: Gasoline Blending
• Case Study Problem: Diesel & Jet Fuel Blending

Troubleshooting Refinery Operations

• Crude Distillation
• Delayed Coking Cycles
• Delayed Coking Process
• Amine Regeneration & Scrubbing
• Sulfur Recovery
• Alkylation
• Fluid Catalytic Cracking Units
• FCCU Product Fractionation
• Saving Energy at Reduced Feed Rates

Refinery Mass Balance

• Importance of Measurement
• Accurate Crude Inputs are Critical
• Fuel Measurement can be a Large, Unexpected Source of Error
• Density Measurement Required to Convert Volume to Mass
• Refinery Evaluates Systems for Mass Balance Improvements
• The Theory of Coriolis-Based Direct Mass Measurement

Material Movements

• VM-PA Calculates & Stores Movement’s Quantities
• Calculate Movement Quantities and Tolerances
• Transfers can have a “Complete/Incomplete” Status
• Provides the User with a List of Frequent Movements

Refinery Optimization

• Definitions & Basic Optimization Tools
• Breakeven Analysis
• Graphical Solutions
• Numerical Methods

• Incremental Method
• Linear Programming (LP)
• Quadratic Programming (QP)
• Non-Linear Optimization Techniques
• Global & Local Optima

Optimizing Operations Planning

• Linear Programs (LP) & Non-Linear Models
• Optimizing Unit Performance
• Scheduling

Equipment Optimization

• Heaters/Pumps/Compressors/Heat Exchangers
• Critical Parameter Monitoring for Maximum Utilization & Optimization for each Specific Equipment
• Resources Optimization like Catalyst/Chemicals/Utilities
• Operation

Process Optimization

• IOW
• Key Process Parameter Monitoring & Controlling for Maximum Utilization & Optimization for each Area Process
• Conversions Losses & Yield Monitoring
• Interactions of the Key Parameters Between Processes
• Improving Unit Reliability
• Reducing Refinery Losses, Energy Conservation
• Reducing Flare/Slop Process
• Key Parameters for Optimization
• Crude Unit Cut Points
• Reformer Severity
• FCC Conversion
• Other Key Parameters
• Integrating Unit Performance
• Utilities

Concepts of Refinery Operational Profitability

• Gross Refining Margin (GRM)
• Net Refining Margin
• Contribution Margin

Planning Objectives

• Production Plans (Unit Operating Goals, Blending Operations)
• Feedstock Selection
• Feasibility
• Optimality (Minimum Cost, Maximum Profit)
• Optimal Product Mix
• Marginal Economics
• Investment Opportunities
• Planning versus Scheduling
• Modeling Tools (Simple Stock Balances (Spreadsheet), Linear Programming (LP’s), Feasibility, Linear Relationships, Non-Linear Programming (NLP’s), Feasibility, Local Optima, Distributed Error Recursion & Integer Programming)
• Model Types (Blending, Single Refinery, Multi-Refinery and Distribution & Time Period)

Key Crude & Product Qualities

• Sulfur & Gravity
• Other Properties
• Environmental Regulations

Practical Refinery Modeling

• Constructing a Simple LP
• The Real World is Non-Linear (The Pooling Problem, Delta-Base Modeling & Convexity Constraints)
• Marginal Values or Shadow Prices
• Crude Ranking & Evaluation
• Weight versus Volume Basis