11 Blending Optimization

Product Blending & Optimization Considerations
Chapters 12 & 14
Updated: January 26, 2016

Copyright 2016 John Jechura (jjechura@mines.edu)
Gases
Polymerization
Sulfur
Plant
Sat Gas
Plant
Gas
LPG
Alkylation
Polymerization
Naphtha
Isomerization
Light Naphtha
Fuel Gas
Butanes
Alkyl
Feed
Gas
Separation &
Stabilizer
Alkylate
Isomerate
Aviation
Gasoline
Automotive
Gasoline
Reformate
Naphtha
Hydrotreating
Heavy
Naphtha
Sulfur
LPG
Solvents
Naphtha
Reforming
Atmospheric
Distillation
Crude
Oil
Jet Fuels
Kerosene
Desalter
Distillate
Hydrocracking
AGO
LVGO
Vacuum
Distillation
Kerosene
Fluidized
Catalytic
Cracking
Gas Oil
Hydrotreating
Cat
Naphtha
Cat
Distillates
Solvents
Distillate
Hydrotreating
Treating &
Blending
Heating Oils
Diesel
Fuel Oil
HVGO
Cycle Oils
Residual
Fuel Oils
DAO
Solvent
Deasphalting
Visbreaking
Vacuum
Residuum
Coker
Naphtha
Heavy
Coker
Gas
Oil
SDA
Bottoms
Asphalts
Naphtha
Distillates
Fuel Oil
Bottoms
Lube Oil
Waxes
Coking
Lubricant
Greases
Solvent
Dewaxing
Waxes
Light Coker
Gas Oil
Coke

Topics
Blending
Blending equations
Specifications / targets
Typical blend stock properties
Optimization
Economics & planning applications
Optimization tools
Linear programming
Non-linear (geometric) programming
Adjusting upstream operations to meet downstream targets

Blending Equations
Volume blending equations
Specific gravity
Olefins content (vol%)
V X
vX
=
V
i
(RVP )mix
1.25
Aromatics content (vol%)
=
X mix
Reid Vapor Pressure (RVP)
Vi (RVP )i
1.25
Octane numbers Simple, by volume

i
Mass blending equations

Sulfur content (wt% or ppm)
Nitrogen content (wt% or ppm)
Nickel & vanadium (ppm)
Carbon residue (CCR, MCRT, )
V X
i oi i
=
X
wX
=
mix
i i
V
i oi
( RON )mix =
Vi ( RON )i
( MON )mix =
Vi ( MON )i
Viscosity
log (log ( mix + c
V log (log (
)) =
V
i
+ 0.7 ) )
Non-Linear Octane Blending Formula

Developed by Ethyl Corporation using a set of 75 & 135 blends
R = R + a1 RJ R J + a2 ( O2 ) O 2 + a3 ( A2 ) A 2
( A2 ) A 2
M = M + b1 MJ M J + b2 ( O2 ) O 2 + b3
100
R+M
"Road" Octane =
75 blends 135 blends
2
a1
0.03224
0.03324
Sensitivity = J R M
a2
0.00101
0.00085
Vi X i
Volume Average= X
a3
0
0
Vi
b1
0.04450
0.04285
Petroleum Refinery Process Economics, 2nd ed. ,
by Robert E. Maples, PennWell Corp., 2000
b2
b3
0.00081
-0.00645
0.00066
-0.00632
6
Typical Gasoline Blend Stock Properties

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Component
iC4
nC4
iC5
nC5
iC6
LSR gasoline (C5-180F)
LSR gasoline isomerized once-through
HSR gasoline
Light hydrocrackate
Hydrocrackate, C5-C6
Hydrocrackate, C6-190F
Hydrocrackate, 190-250F
Heavy hydrocrackate
Coker gasoline
Light thermal gasoline
C6+ light thermal gasoline
FCC gasoline, 200-300F
Hydrog. light FCC gasoline, C5+
Hydrog. C5-200F FCC gasoline
Hydrog. light FCC gasoline, C6+
Hydrog. C5+ FCC gasoline
Hydrog. 300-400F FCC gasoline
Reformate, 94 RON
Reformate, 98 RON
Reformate, 100 RON
Aromatic concentrate
Alkylate, C3=
Alkylate, C4=
Alkylate, C3=, C4=
Alkylate, C5=
Polymer
RVP, psi
71.0
52.0
19.4
14.7
6.4
11.1
13.5
1.0
12.9
15.5
3.9
1.7
1.1
3.6
9.9
1.1
1.4
13.9
14.1
5.0
13.1
0.5
2.8
2.2
3.2
1.1
5.7
4.6
5.0
1.0
8.7
(R+M)/2
92.5
92.5
92.0
72.0
78.8
64.0
82.1
60.5
82.6
87.4
74.6
77.3
67.5
63.7
76.8
72.5
84.6
82.1
86.5
80.2
85.9
85.8
89.2
92.3
94.1
100.5
89.1
96.6
93.8
89.3
90.5
MON
92.0
92.0
90.8
72.4
78.4
61.6
81.1
58.7
82.4
85.5
73.7
75.6
67.3
60.2
73.2
68.1
77.1
80.9
81.7
74.0
80.7
81.3
84.4
86.5
88.2
94.0
87.3
95.9
93.0
88.8
84.0
RON
93.0
93.0
93.2
71.5
79.2
66.4
83.0
62.3
82.8
89.2
75.5
79.0
67.6
67.2
80.3
76.8
92.1
83.2
91.2
86.3
91.0
90.2
94.0
98.0
100.0
107.0
90.8
97.3
94.5
89.7
96.9
APl
78.6
80.4
48.2
79.0
86.4
85.0
55.5
49.0
57.2
74.0
55.1
49.5
51.5
58.1
49.3
54.8
48.5
45.8
43.1
41.2
70.3
59.5
Table 12.1 Blending Component Values for Gasoline Blending Streams

Petroleum Refining Technology & Economics 5th Ed.
by James Gary, Glenn Handwerk, & Mark Kaiser, CRC Press, 2007
Gasoline Blending Considerations

What is available?
What are you trying to make?
Amounts
Amount(s)
Properties
Properties
Appropriate to determine product

properties
Associated costs / values
Volatility / RVP (maximum)

Octane number (minimum)
Drivability Index
Distillation
o
T10 (minimum)
T50 (range)
T90 (maximum)
Composition
o
Sulfur (maximum)
Benzene & total aromatics (maximums)
Olefins (maximum)
Value

Gasoline Blend Example 2 Blend Stocks, 1 Spec

Example, blending LSR only with Reformate
one case 100 RON, other 94 RON
To make Regular or Premium spec,

essentially diluting the Reformate
94 RON Reformate alone cannot bring LSR

up to final spec

Gasoline Blend Example 3 Blend Stocks, 2 Specs

Use 3 blend stocks to make regular gasoline (87 road octane) for both summer (9
psi RVP) & winter (15 psi RVP)
R+M
= ( 92.5) vnC4 + ( 64.0 ) vLSR + ( 94.1) vRef

2
(RVP )
1.25
= ( 71.0 )
1.25
vnC4 + (11.1 )
1.25
vLSR + ( 3.2 )
1.25
vRef
1 = vnC4 + vLSR + vRef

10
Diesel Blending Considerations

Available blend stocks
Specification of final product(s)
Amounts
Amount(s)
Properties
Properties

properties
Cetane index (minimum)

Flash Point (minimum)
Distillation
o
T90 (minimum & maximum)
Cold properties
o
Cloud point (minimum)
Pour point (minimum)
Composition
o
Sulfur (maximum)
Aromaticity (maximum)
Carbon residue (maximum)
Color
Value
11
Optimization for Economics & Planning

What should be done rather than what can be done
Optimization
Combines models to
Describe operations
Constraints to operations
Economics added to define costs & benefits to all actions

Optimal is best of the feasible possibilities
Optimization models tend to be data-driven rather than mathematical model

driven.

13
Economics & Planning Applications

Crude oil evaluation
Incremental value of an opportunity crude compared to base slate
Take into account change in products produced
Production planning
Day-to-day operations optimization
Product blending & pricing
May have opportunity to separately purchase blend stocks
Shutdown planning
Multi time periods, must take into account changes in inventories
Multirefining supply & distribution

Yearly budgeting
Investment studies
Environmental studies
Technology evaluation

14
Modeling Hierarchy
unit
operations
single
process
single
plant
model
multi-plant
model
refinery
model
multiple
processes
multi-refinery
model

Process
Simulation
LP
Simulation
15
Unit Representations
Simple vector model
Feedstock
Butylene
Isobutane
Product
n-Butane
Pentane
Alkylate
"Alky Bottoms
Tar
Utilities
Steam, lb
Power, kWh
Cooling Water, M gal
Fuel, MMBtu
Delta-Base model
Yield
Vector
Feed
Hydrogen
C5-180
180-400
Kw
API
-1.0000
-1.2000
0.1271
0.0680
1.5110
0.1190
0.0096
Feed
1.0
-12.1
-22.0
1
Relative Activity
7.28
2.45
2.48
0.69
Base
Yield
Delta KW Delta API
-1.0
-1500
8.1
1.0
3.6
28.0
-5.5
11.0
10.9
1.2
20.0
4.0
1
0.5
Relative activities calculated from actual properties the

Kw & API rows are zero
1 ( 22.0 ) + 1 20.0
API =
=
0.5
4.0
For every unit of Butylene
consumed, must also consume the

relative amount of isobutane,
Correct base yields to take into account actual properties
produce the shown amounts of
& relative activities
products, & use the shown amounts
of utilities
=
C5-180

1 8.1 + 1 1.0 + 0.5 3.6

= 10.9
1
16
What is Linear Programming?

Word programming used here in the
sense of planning
For N independent variables (that can be

zero or positive) maximize
z= a01 x1 + a02 x2 + + a0N xN
subject to M additional constraints (all bn

positive)
ai 1 x1 + ai 2 x2 + + aiN xN bi
a j1 x1 + a j 2 x2 + + a jN xN bj
ak 1 x1 + ak 2 x2 + + akN xN =
bk

Terminology
Objective Function function z to be
maximized
Feasible Vector set of values x1, x2, ,
xN that satisfies all constraints
Optimal Feasible Vector feasible vector
that maximizes the objective function
Solutions
Will tend to be in the corners of where
the constraints meet
May not have a solution because of
incompatible constraints or area
unbounded towards the optimum
17
Change Blending Equations to Fit Linear Form

Volume blending equations
=
X mix
vi X i
=
V X
V
i
=
0
V ( X
i
X mix )
Mass blending equations

V X
i oi i
X
wX
=
=
mix
i i
V
i oi
0
=

V ( X X )
i
oi
mix
18
Non-Linear Programming
Non-linear blending rules can more closely match the physics of the problem
Example: octane blending models
R = R + 0.03324 RJ R J + 0.00085 ( O2 ) O 2
M = M + 0.04285 MJ M J + 0.00066 ( O2 ) O 2 6.32 10 7 ( A2 ) A 2
Guarantees of solutions are more tenuous

Not necessarily at constraints
Discontinuous feasible regions possible
Types of optimization algorithms

Local optimization
Based on following gradients
o
Excels Solver based on GRG2
Global optimization
Randomly search overall region before switching to local optimization technique
o
Simulated annealing

19
Gasoline Blending Considerations

Available blend stocks
Specification of final product(s)
Amounts
Amount(s)
Properties
Properties

properties
Volatility / RVP (max)

Octane number (min)
Drivability Index
Distillation
o
T10 (min)
T50 (range)
T90 (max)
Composition
o
Sulfur (max)
Benzene & total aromatics (max)
Olefins (max)
Value
21
Gasoline Blending Example All Into Regular

Raw M aterials
Properties for Blending Calculations

RON
Butane
Straight Run Naphtha
Isomerate
Reformate (High Octane)
Reformate (Low Benzene)
FCC Naphtha
Alkylate
MON
93.0
78.0
83.0
100.0
93.7
92.1
97.3
92.0
76.0
81.1
88.2
84.0
77.1
95.9
(R+M)/2
92.5
77
82.05
94.1
88.85
84.6
96.6
Cost & Availability
Butane
Isomerate
FCC Naphtha
Alkylate
Products
Cost
($/gal)
0.85
2.05
2.20
2.80
2.75
2.60
2.75
0
0
0
0
0
0
0
Lower
Premium
Maximum
Available
30,000
35,000
0
60,000
0
70,000
40,000
RVP1.25
146.4
20.5
25.9
4.3
3.6
1.5
6.7
Aromatics
0.0
2.2
1.6
94.2
61.1
35.2
0.5
Olefins
0.0
0.9
0.1
0.6
1.0
32.6
0.2
Benzene
0.00
0.73
0.00
1.85
0.12
1.06
0.00
Premium
0
0
0
0
0
0
0
Upper
87
0.0
0.0
0.0
91
0.0
0.0
0.0
Octane
RVP
RVP1.25
Benzene
Octane
RVP
RVP1.25
Benzene
Regular
30,000
35,000
0
60,000
0
70,000
40,000
Minimum
Slack
30,000
35,000
0
60,000
0
70,000
40,000
Maximum
Slack
Minimum
Required
1
1
Maximum
Allowed
1,000,000
1
$1
$1
$0
$646,251
$557,251
$89,000
Lower Slack
234,999
457,000
5,741,488
210,750
-1
-3
25
0
Upper Slack
765,000
4,948,000
1,195,675
47,750
1
11
-14
0
Total
30,000
35,000
0
60,000
0
70,000
40,000
0
0
0
0
0
0
0
Price & Production Requirements
110
15.0
29.5
1.1
110
15.0
29.5
1.1
Product Calculations
Volumes & Properties
Produced
RON
MON
(R+M)/2
RVP
RVP1.25
Benzene
54
11.2
13.5
3.2
2.8
1.4
4.6
Usage
Minimum
Required
Lower & Upper Limits on Properties
Regular
RVP
Regular
Premium
Price
($/gal)
2.75
2.85
Cost & Revenue

Revenue ($)
Cost($)
Profit ($)
$646,250
$557,250
$89,000
Linear-Form Product Constraints

Regular
235,000
93.02
84.87
88.9
12.9
24.43
0.90
Premium

0
83.24
81.59
82.4
28.0
64.46
0.48
Total
235,000
Regular
Premium
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
22
Gasoline Blending Example Only Regular (Optimized)

Raw M aterials

RON
Butane
Isomerate
FCC Naphtha
Alkylate
MON
93.0
78.0
83.0
100.0
93.7
92.1
97.3
92.0
76.0
81.1
88.2
84.0
77.1
95.9
(R+M)/2
92.5
77
82.05
94.1
88.85
84.6
96.6
Cost & Availability
Butane
Isomerate
FCC Naphtha
Alkylate
Products
Cost
($/gal)
0.85
2.05
2.20
2.80
2.75
2.60
2.75
0
0
0
0
0
0
0
Lower
Premium
Maximum
Available
30,000
35,000
0
60,000
0
70,000
40,000
RVP1.25
146.4
20.5
25.9
4.3
3.6
1.5
6.7
Aromatics
0.0
2.2
1.6
94.2
61.1
35.2
0.5
Olefins
0.0
0.9
0.1
0.6
1.0
32.6
0.2
Benzene
0.00
0.73
0.00
1.85
0.12
1.06
0.00
Premium
0
0
0
0
0
0
1
Upper
87
0.0
0.0
0.0
91
0.0
0.0
0.0
Octane
RVP
RVP1.25
Benzene
Octane
RVP
RVP1.25
Benzene
Regular
30,000
35,000
0
12,628
0
70,000
39,999
Minimum
Slack
30,000
35,000
0
12,628
0
70,000
40,000
Maximum
Slack
Minimum
Required
1
1
Maximum
Allowed
1,000,000
1
$3
$2
$1
$515,976
$424,607
$91,369
Lower Slack
187,626
120,652
5,538,708
123,111
0
0
30
0
Upper Slack
812,373
4,194,760
0
83,278
0
19
0
1
Total
30,000
35,000
0
12,628
0
70,000
40,000
0
0
0
47,372
0
0
0
110
15.0
29.5
1.1
110
15.0
29.5
1.1
Produced
RON
MON
(R+M)/2
RVP
RVP1.25
Benzene
54
11.2
13.5
3.2
2.8
1.4
4.6
Usage
Minimum
Required
Regular
RVP
Regular
Premium
Price
($/gal)
2.75
2.85
Cost & Revenue

Revenue ($)
Cost($)
Profit ($)
$515,973
$424,605
$91,368

Regular
187,627
91.25
84.03
87.6
15.0
29.52
0.66
Premium

1
91.75
90.25
91.0
15.0
29.52
0.19
Total
187,628
Regular
Premium
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
23
Gasoline Blending Example Only Premium (Optimized)

Raw M aterials

RON
Butane
Isomerate
FCC Naphtha
Alkylate
MON
93.0
78.0
83.0
100.0
93.7
92.1
97.3
92.0
76.0
81.1
88.2
84.0
77.1
95.9
(R+M)/2
92.5
77
82.05
94.1
88.85
84.6
96.6
Cost & Availability
Butane
Isomerate
FCC Naphtha
Alkylate
Products
Cost
($/gal)
0.85
2.05
2.20
2.80
2.75
2.60
2.75
0
0
0
0
0
0
0
Lower
Premium
Maximum
Available
30,000
35,000
0
60,000
0
70,000
40,000
RVP1.25
146.4
20.5
25.9
4.3
3.6
1.5
6.7
Aromatics
0.0
2.2
1.6
94.2
61.1
35.2
0.5
Premium
30,000
17,433
0
60,000
0
32,959
40,000
Total
30,000
17,433
0
60,000
0
32,959
40,000
Olefins
0.0
0.9
0.1
0.6
1.0
32.6
0.2
Benzene
0.00
0.73
0.00
1.85
0.12
1.06
0.00
0
0
0
0
0
0
0
Upper
87
0.0
0.0
0.0
91
0.0
0.0
0.0
Octane
RVP
RVP1.25
Benzene
Octane
RVP
RVP1.25
Benzene
Regular
Minimum
Slack
30,000
17,433
0
60,000
0
32,959
40,000
Maximum
Slack
Minimum
Required
Maximum
Allowed
0
17,567
0
0
0
37,041
0
110
15.0
29.5
1.1
110
15.0
29.5
1.1
Regular
Premium
Price
($/gal)
2.75
2.85
1
1
1
1,000,000
$514,115
$424,930
$89,186
$514,118
$424,932
$89,186
Cost & Revenue

Revenue ($)
Cost($)
Profit ($)
$3
$2
$0

Regular
Produced
RON
MON
(R+M)/2
RVP
RVP1.25
Benzene
54
11.2
13.5
3.2
2.8
1.4
4.6
Usage
Minimum
Required
Regular
RVP
1
90.90
83.10
87.0
15.0
29.52
1.10
Premium
180,391
94.67
87.33
91.0
15.0
29.52
0.88

Total
180,392
Regular
Premium
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Lower Slack
0
0
30
1
180,390
0
5,325,125
158,662
Upper Slack
0
23
0
0
819,609
3,427,436
0
39,769
24
Gasoline Blending Example Combined (Optimized)

Raw M aterials

RON
Butane
Isomerate
FCC Naphtha
Alkylate
MON
93.0
78.0
83.0
100.0
93.7
92.1
97.3
92.0
76.0
81.1
88.2
84.0
77.1
95.9
(R+M)/2
92.5
77
82.05
94.1
88.85
84.6
96.6
Cost & Availability
Butane
Isomerate
FCC Naphtha
Alkylate
Products
Cost
($/gal)
0.85
2.05
2.20
2.80
2.75
2.60
2.75
0
0
0
0
0
0
0
Lower
Premium
Maximum
Available
30,000
35,000
0
60,000
0
70,000
40,000
Aromatics
0.0
2.2
1.6
94.2
61.1
35.2
0.5
Regular
17,925
35,000
0
43,599
0
24,226
0
Premium
12,075
0
0
16,401
0
45,774
40,000
Total
30,000
35,000
0
60,000
0
70,000
40,000
Olefins
0.0
0.9
0.1
0.6
1.0
32.6
0.2
Benzene
0.00
0.73
0.00
1.85
0.12
1.06
0.00
Upper
87
0.0
0.0
0.0
91
0.0
0.0
0.0
Octane
RVP
RVP1.25
Benzene
Octane
RVP
RVP1.25
Benzene
Minimum
Slack
30,000
35,000
0
60,000
0
70,000
40,000
Maximum
Slack
Minimum
Required
1
1
Maximum
Allowed
1,000,000
1,000,000
$325,613
$285,199
$40,414
$657,675
$557,250
$100,425
0
0
0
0
0
0
0
110
15.0
29.5
1.1
110
15.0
29.5
1.1
Produced
RON
MON
(R+M)/2
RVP
RVP1.25
Benzene
RVP1.25
146.4
20.5
25.9
4.3
3.6
1.5
6.7
Usage
Minimum
Required
Regular
54
11.2
13.5
3.2
2.8
1.4
4.6
RVP
Regular
Premium
Price
($/gal)
2.75
2.85
Cost & Revenue

Revenue ($)
Cost($)
Profit ($)
$332,063
$272,051
$60,011

Regular
120,750
91.00
83.00
87.0
15.0
29.52
1.09
Premium
114,250
95.15
86.85
91.0
10.6
19.05
0.69

Total
235,000
Regular
Premium
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Lower Slack
120,749
0
3,564,521
131,888
114,249
0
2,176,967
78,862
Upper Slack
879,250
2,777,250
0
937
885,750
2,170,750
1,195,675
46,813
25
Gasoline Blending Example Lower RVP & Benzene

Raw M aterials

RON
Butane
Isomerate
FCC Naphtha
Alkylate
MON
93.0
78.0
83.0
100.0
93.7
92.1
97.3
92.0
76.0
81.1
88.2
84.0
77.1
95.9
(R+M)/2
92.5
77
82.05
94.1
88.85
84.6
96.6
Cost & Availability
Butane
Isomerate
FCC Naphtha
Alkylate
Products
Cost
($/gal)
0.85
2.05
2.20
2.80
2.75
2.60
2.75
0
0
0
0
0
0
0
Lower
Premium
Maximum
Available
30,000
35,000
0
60,000
0
70,000
40,000
RVP1.25
146.4
20.5
25.9
4.3
3.6
1.5
6.7
Aromatics
0.0
2.2
1.6
94.2
61.1
35.2
0.5
Olefins
0.0
0.9
0.1
0.6
1.0
32.6
0.2
Benzene
0.00
0.73
0.00
1.85
0.12
1.06
0.00
Premium
0
0
0
0
0
0
0
Upper
87
0.0
0.0
0.0
91
0.0
0.0
0.0
Octane
RVP
RVP1.25
Benzene
Octane
RVP
RVP1.25
Benzene
Regular
8,187
28,305
0
0
0
60,824
40,000
Minimum
Slack
8,188
28,305
0
0
0
60,824
40,000
Maximum
Slack
21,812
6,695
0
60,000
0
9,176
0
Minimum
Required
1
1
Maximum
Allowed
1,000,000
1,000,000
$3
$3
$0
$377,621
$333,127
$44,493
Lower Slack
137,315
0
2,140,540
85,136
0
0
16
1
Upper Slack
862,684
3,158,261
0
0
999,999
19
0
0
Total
8,188
28,305
0
0
0
60,824
40,000
110
9.0
15.6
0.62
110
9.0
15.6
0.62
Produced
RON
MON
(R+M)/2
RVP
RVP1.25
Benzene
54
11.2
13.5
3.2
2.8
1.4
4.6
Usage
Minimum
Required
Regular
RVP
Regular
Premium
Price
($/gal)
2.75
2.85
Cost & Revenue

Revenue ($)
Cost($)
Profit ($)
$377,618
$333,125
$44,493

Regular
137,316
90.76
83.24
87.0
9.0
15.59
0.62
Premium

1
95.03
86.97
91.0
9.0
15.59
0.62
Total
137,317
Regular
Premium
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
26
Gasoline Blending Example Low Benzene Reformate

Raw M aterials

RON
Butane
Isomerate
FCC Naphtha
Alkylate
MON
93.0
78.0
83.0
100.0
93.7
92.1
97.3
92.0
76.0
81.1
88.2
84.0
77.1
95.9
(R+M)/2
92.5
77
82.05
94.1
88.85
84.6
96.6
Cost & Availability
Butane
Isomerate
FCC Naphtha
Alkylate
Products
Cost
($/gal)
0.85
2.05
2.20
2.80
2.75
2.60
2.75
0
0
0
0
0
0
0
Lower
Premium
Maximum
Available
30,000
35,000
0
0
65,400
70,000
40,000
Aromatics
0.0
2.2
1.6
94.2
61.1
35.2
0.5
Regular
13,552
35,000
0
0
53,656
70,000
35,854
Premium
1,355
0
0
0
11,744
0
4,146
Total
14,907
35,000
0
0
65,400
70,000
40,000
Olefins
0.0
0.9
0.1
0.6
1.0
32.6
0.2
Benzene
0.00
0.73
0.00
1.85
0.12
1.06
0.00
Minimum
Slack
14,907
35,000
0
0
65,400
70,000
40,000
Maximum
Slack
15,093
0
0
0
0
0
0
Minimum
Required
1
1
Maximum
Allowed
1,000,000
1,000,000
Upper
87
0.0
0.0
0.0
91
0.0
0.0
0.0
Octane
RVP
RVP1.25
Benzene
Octane
RVP
RVP1.25
Benzene
$49,147
$44,848
$4,299
$621,318
$556,271
$65,048
110
9.0
15.6
0.62
110
9.0
15.6
0.62
Produced
RON
MON
(R+M)/2
RVP
RVP1.25
Benzene
RVP1.25
146.4
20.5
25.9
4.3
3.6
1.5
6.7
Usage
Minimum
Required
Regular
54
11.2
13.5
3.2
2.8
1.4
4.6
RVP
Regular
Premium
Price
($/gal)
2.75
2.85
Cost & Revenue

Revenue ($)
Cost($)
Profit ($)
$572,172
$511,423
$60,749

Regular
208,062
91.10
82.90
87.0
9.0
15.59
0.51
Premium
17,244
94.51
87.49
91.0
9.0
15.59
0.08

Total
225,307
Regular
Premium
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Volume
Vol*Octane
Vol*RVP1.25
Vol*Benzene
Lower Slack
208,061
0
3,243,372
106,189
17,243
0
268,815
1,409
Upper Slack
791,938
4,785,436
0
22,810
982,756
327,645
0
9,282
27
Cutpoint Economics
Adjust upstream cutpoints to meet needs in the downstream blending
Heavy LSRvalue as blending component
versus Reformer feed
Heavy Naphthavalue as Reformer feed
versus kerosene blend stock
Heavy Kerosenevalue as kerosene blend
stock versus diesel blend stock
Heavy Dieselvalue as diesel blend stock
versus FCC feed
Heavy Gas Oilvalue as FCC feed versus
resid/asphalt production or coker feed
The refinery LP can determine the optimum

cut point for each of these given any set of constraints
29
Cutpoints To Meet Operating Economies

TBP Cut Points (F) for Various Crude Oil Fractions
Cut
IBP
EP
LSR
90
90
80
180
190
220
330
330
380
420
480
520
610
800
1050+
180
190
220
380
330
330
520
480
520
650
610
610
800
1050
Naphtha
Kerosene
Diesel
Gas Oil
VGO
Resid

Processing Use
Min LSR cut

Normal LSR cut
Max LSR cut
Max reforming cut
Max jet fuel
Min reforming cut
Max kerosene cut
Max Jet A cut
Max gasoline
Max diesel cut
Max jet fuel cut
Min diesel cut
Cat cracker feed

Cat cracker feed
Coker feed, asphalt
30
Optimize FCC Gasoline Distillation

Frame the analysis
What is the value of the molecules in the stream
above?
What is the value of the molecules in the stream
below?
What upstream unit operations affect the stream
value?
What downstream unit operations affect the
stream value?
What unit specific operations affect the stream
value?
What product blending constraints affect the
stream value?
Ref: http://www.refinerlink.com/blog/Truly_Optimize_FCC_Gasoline_Distillation
31
Optimize FCC Gasoline Distillation

Value to the stream above?
Value to the stream below?
Upstream unit affects?

Downstream unit affects?
Unit specific affects?
Product blending constraints?
LCN
May have sub-optimal amount of olefins:
Alkylation unit downstream have capacity for the
olefins?
Type of alky unit? Sulfuric Alky can take more
C5= olefins; HF Alky limited by strength concerns
Time of year? Alky economics better during
summer
When distillate more valuable than gasoline minimize
the LCN/HCN cut point to maximize distillate
production from HCN contributions
Degree of hydrotreating possible to give low sulfur

content in final product
Destination of LCN?
Gasoline Hydrotreater & then to blend pool
Selective Hydrogenation Unit & then to
Reformer
High olefin content will increase hydrogen
requirements in downstream hydrotreaters
Subtle constraints such as olefin content and octane
value will be influenced by a combination of riser and
distillation targets.
Cat-to-oil ratio affects product mix, thus distillation
strategies.
Usually routed to gasoline need to olefins, sulfur,
and aromatics
HCN
When distillate more valuable than gasoline minimize
the LCN/HCN cut point to maximize distillate
production from HCN
Diesel prices higher than gasoline, minimize HCN end

point & still make diesel flash limit
If LCO is routed to a Hydrocracker HCN end point can
be adjusted to make jet flash limit.
HCN endpoint can also be used to optimize heavy fuel
oil blending when LCO is used as a cutter
Degree of hydrotreating possible to give low sulfur
content in final product
If routed to Gasoline Hydrotreater may reduce end
point to better make gasoline sulfur specs
If routed to Jet Hydrotreater then make-up hydrogen
constraints may limit end point
Fractionator draw constraints may be handled by

adjusting FCC reactor conditions & yields
When routing to gasoline, use HCN endpoint to adjust

gasoline sulfur, endpoint, and aromatics.
When routing to jet, use HCN IBP to meet jet flash &
endpoint to manage jet freeze & smoke point.
When routing to diesel, use IBP to manage diesel
flash
Ref: http://www.refinerlink.com/blog/Truly_Optimize_FCC_Gasoline_Distillation

32
Gasoline Blending Modify Upstream Operations

How much gasoline can be produced by blending Reformate+LSR with respect to
the Reformers severity?

33
General Gasoline Blending Considerations

Reduce RVP giveaway
Blend nC4, not iC4.
iC4 has higher vapor pressure than nC4
iC4 has more value as alkylation feedstock
Reduce Octane giveaway

Setting constant reformer severity target hydrogen & octane balance highly dynamic
constraints
Blending low octane components to reduce octane giveaway maybe theres just too
much high octane blendstock?
http://www.refinerlink.com/blog/Redefining_Gasoline_RVP_Giveaway
http://www.refinerlink.com/blog/Top_3_Refinery_Octane_Blending_Mistakes/
34
General Gasoline Blending Considerations

Many blending problems require fixes to upstream operations
RVP
Poor depropanizer operation allowing propane into the butane pool?
Proper splitting in Deisobutanizer & isostrippers?
Octane
Correct cut points between heavy naphtha & kerosene?
Reduce reformer severity?
o
May not be possible if hydrogen needed.
Batch operating reformer severity?

o
Would provide balance between octane enhancement & volume to blending
Reducing reformer feed rates

Selling high octane components
http://www.refinerlink.com/blog/Redefining_Gasoline_RVP_Giveaway
http://www.refinerlink.com/blog/Top_3_Refinery_Octane_Blending_Mistakes/
35

11 Blending Optimization

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Product Blending & Optimization Considerations

Updated: January 26, 2016

Updated: January 26, 2016

Adjusting upstream operations to meet downstream targets

Updated: January 26, 2016

Aromatics content (vol%)

Reid Vapor Pressure (RVP)

Octane numbers Simple, by volume

Mass blending equations

Non-Linear Octane Blending Formula

Typical Gasoline Blend Stock Properties

Table 12.1 Blending Component Values for Gasoline Blending Streams

Gasoline Blending Considerations

What are you trying to make?

Appropriate to determine product

Associated costs / values

Volatility / RVP (maximum)

Benzene & total aromatics (maximums)

Updated: January 26, 2016

Gasoline Blend Example 2 Blend Stocks, 1 Spec

To make Regular or Premium spec,

94 RON Reformate alone cannot bring LSR

Updated: January 26, 2016

Gasoline Blend Example 3 Blend Stocks, 2 Specs

= ( 92.5) vnC4 + ( 64.0 ) vLSR + ( 94.1) vRef

1 = vnC4 + vLSR + vRef

Updated: January 26, 2016

Diesel Blending Considerations

Specification of final product(s)

Appropriate to determine product

Associated costs / values

Cetane index (minimum)

T90 (minimum & maximum)

Cloud point (minimum)

Pour point (minimum)

Carbon residue (maximum)

Optimization for Economics & Planning

Economics added to define costs & benefits to all actions

Optimization models tend to be data-driven rather than mathematical model

Updated: January 26, 2016

Economics & Planning Applications

Multirefining supply & distribution

Updated: January 26, 2016

Updated: January 26, 2016

Relative activities calculated from actual properties the

For every unit of Butylene

consumed, must also consume the

Updated: January 26, 2016

1 8.1 + 1 1.0 + 0.5 3.6

What is Linear Programming?

For N independent variables (that can be

z= a01 x1 + a02 x2 + + a0N xN

subject to M additional constraints (all bn

Updated: January 26, 2016

Change Blending Equations to Fit Linear Form

Mass blending equations

Updated: January 26, 2016

M = M + 0.04285 MJ M J + 0.00066 ( O2 ) O 2 6.32 10 7 ( A2 ) A 2

Guarantees of solutions are more tenuous

Types of optimization algorithms

Excels Solver based on GRG2

Updated: January 26, 2016

Gasoline Blending Considerations

Specification of final product(s)