Semester: March 2018

CHE61703 / CHE4513
PETROLEUM ENGINEERING TECHNOLOGY

Name: Student No:

Tutorial 06: Hydrocarbon losses

A small amount in hydrocarbon loss will have a major impact on refinery profitability.
Reducing hydrocarbon (HC) loss is especially critical for refineries in parts of the world with
high fuel prices and varying climatic conditions where lighter ends can be easily escaped.
There are around 50000 storage tanks in United States refineries alone. Existing storage
tanks are fixed roof tanks. To change the existing storage tanks to floating roof tanks could
incur heavy investments.

a. Outline and discuss the various losses that are incurred in the hydrocarbon storage
tanks.

b. Recommend FIVE corrective actions to manage hydrocarbon losses in a refinery.

c. Recommend ONE change to the existing storage tanks to recover the hydrocarbons
and suggest THREE ways to assess the economics of the proposed change.

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Semester: March 2018
CHE61703 / CHE4513
PETROLEUM ENGINEERING TECHNOLOGY

Key solution (open ended).

a.Outline the losses

Flash losses

Occur when the separator or heater treater, operating at higher pressure dumps oil
into the storage tanks, which are at atmospheric pressure.

Working losses

Refer to the vapor released from the changing fluid levels and agitation of tank
contents associated with the circulation of fresh oil through the storage tanks.

Standing losses

Occur with daily and seasonal temperature changes.

b.Recommendation ( any FIVE)

o Fuel gas measurement is accurate to differentiate fuel consumption

from HC loss.
o Flares are metered and monitored.
o Crude oil, feedstock, intermediate, and product densities are kept up to
date in flow meters and tank inventory systems.
o An accounted loss table in the monthly and annual mass balances
exists and that table identifies and attempts to quantify sources of
losses.
o Flaring is minimised except in emergencies. Leaking relief valves are
minimised. Flare-gas recovery systems recover any gas sent to the
flare under normal conditions.
o Detailed procedures are established to minimise flare losses during
shutdowns and startups. Procedures are established to manage
draining of vessels, heat exchangers, pumps, and lines for inspection
and maintenance.
o Tanks are well maintained.
o Sources of HC vented directly to the atmosphere are eliminated.

*Any other similar recommendations accepted

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Semester: March 2018
CHE61703 / CHE4513
PETROLEUM ENGINEERING TECHNOLOGY

c. The losses can be minimized by using vapor recovery units (VRU) which include
the scrubber to remove any condensate and compressor to provide low pressure
suction for the VRU unit.

Assessing VRU Economics (any THREE):

1. Identify possible locations for VRU installation;

2. Quantify the volume of vapor emissions;

3. Determine the value of the recovered emissions;

4. Determine the cost of a VRU project; and

5. Evaluate VRU project economics.