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What is a Refinery?
REFINING
REFINERY PRIFITABILITY
FUNCTIONAL OBJECTIVES-MARGIN
FUNCTIONAL OBJECTIVES
Complexity of a Refinery
The combination of refining processes and operations employed (complexity) varies from one refinery to another.
Environmental stipulations
CEI
Ceiba
29.8
0.57
0.88
0.82
API
29.5 24.1 22.1 19.8 27.3 38.7 36.2 23.2 36.7 28.2 31.6 29.4 32.8 34.1
%S
0.26 3.36 0.13 0.77 0.65 0.14 1.44 0.19 0.27 0.44 0.34 0.25 1.07 0.15
Origin
Equatorial Guinea Qatar Australia Brazil Angola Nigeria Iran Argentina Cameroon Angola Cameroon Nigeria Oman Nigeria
SPG
0.88 0.91 0.92 0.94 0.89 0.83 0.84 0.91 0.84 0.89 0.87 0.88 0.86 0.85
TAN
0.81 0.78 0.75 0.74 0.72 0.72 0.71 0.69 0.65 0.64 0.61 0.59 0.59 0.53
PROFITABLE CRUDE
Depends on :
- Configuration of Refinery what are the units present - Metallurgy of refinery particularly columns, piping to take care of acidic / corrosive crude
Processing Puzzle
HAC Corrosion
HAC corrosion
Prevention Methods
The supply / manufacturing economist can determine the precise value of the eligible crudes for his refinery.
This is highly complex, since the value of a crude depends on the facilities and markets of the Oil Company. Processing opportunity crude oils has been recognized by the refining industry as a viable method for improving refinery profitability.
Doba Crude 4.7 TAN Brent Price US$50 per barrel Discount = (4.7-0.07)*0.051*50 = $11.81/bbl
The extra cost of processing high TAN crude is in the range $1.15 /bbl,
The cost of crude accounts for about 9095% of the total running costs of refineries, so it is very attractive for refineries to process opportunity crude, especially high TAN crude.
Blending Process
Most world-wide Oil Refineries have a core business that can be separated into four distinct processes: Receive, Produce, Blend, and Distribute.
The purpose of the blending process is to obtain petroleum products from refined components that meet certain quality specifications on time for distributing to the market place by ship or pipeline. The objective is to find the combinations of blending recipes that make the best use of the components.
Description of Blending
The quantities and qualities of the component rundowns and product requirements are known on a daily basis. In reality the rundown of all continuous. components to finished tanks is
Also blending from component tanks to product tanks and dispatch from product tanks cannot be performed instantaneously.
Blending Constraints
Each component rundown must go to exactly one component tank every day. (This component rundown schedule is decided upon a priori.) The daily qualities of each component tank are determined by combining the qualities of the component tank on the previous day with any rundown into the component tank on the corresponding day. Each quality is determined by a blend rule (which for some qualities is non-linear ). Each component and product tank has a maximum and minimum level which must not be violated on any day. Each product lifting must be able to be made from one (or more) product tank(s) on the appropriate day and satisfy all quality specifications associated with the product. Minimize the amount of giveaway in products lifted
Giveaway is defined as the quality of a product being lifted minus the product specification.
For example a product lifted with an Octane of 92.3 where the Octane specification for that product is 91.3 has 1.0 unit Octane giveaway.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
LPG Straight RUN NAPHTHA Euro III/IV MS AVIATION TURBINE FUEL SUPERIOR KEROSENE OIL EURO III/IV HIGH SPEED DIESEL JUTE BATCHING OIL(C&P) FURNACE OIL CARBON CLACK FEED STOCK BITUMEN LUBE OIL BASE STOCKS
Blending MS components
Reformate ex U-22 gasoline is received in the MS tank whose dip is comparatively low. Circulate the tank after receiving these components with the help of one of the pumps for at least 6-8 hours (min). It is sampled (TMB) and tested in the laboratory. After knowing the base RON & RVP, if RON is less than the required spec 91.3 , then calculated amount of reformate ex Tank is added to boost RON to get 91.3 octane. According to the specification the MS must have orange colour. So add orange dye in the tank itself by bucket, followed by tank recirculation. Allow the tank to settle for at least 4 hours. Take sample (TMB) and send Laboratory for test.
Blending MS components
After knowing the base RON & RVP, If the octane no. becomes higher than 91.3 RON add some treated gasoline or Low S C5-90 cut is added for lowering RON. But in no case the total percentage of VB gasoline in MS blend should exceed ten. Allow the tank to settle for at least 4 hours after recirculation. Take sample (TMB) and send Laboratory for test.
S 145 max
118 106 120 60 121 105
Give Away in RON and Sulphur. The give away may be corrected by back blending Light Naphtha (C5-70) streams of RON 70 and S 250 ppm. MS-Naphtha price differential Rs 5500/MT
4.37956E-07 0.081
1 2
Naphtha upgradation in MT/ unit RON/ MT of actual MS production--> Average price Differential RS/MT between MS-BS II and Naphtha -> Margin improvement: RS /MT/ UNIT RON---------------------------------->
0.007 -5500 37
Quality
91.70 105.00
15000.0 15000.0
GRM Improvement through QGA correction of 5 batches of MS works out as 1.6 lakhs.
S 340 max
252
254 274 233 246 252
Cetane No. Rec. at 360 Flash 0C Point 51.4 min 95.5 min 37 min
51.8
51.8 51.8 51.8 51.8 51.8
95.7
95.7 95.7 95.7 95.7 95.7
39.5
38 39 42 40 39.7
Give Away in Sulphur and Flash Point. The give Away may be corrected by blending with Heavy naphtha Flash Point 8 deg C, Recovery 100%, Sulphur 500 ppm HSD-Naphtha price differential Rs 4000/MT, RS/MT/unit Flash 6.79
TOTAL/AV
766
3489853
0.8232
36441
51.5
Product
HSD-BS3
Manufacturin Actual g spec Average Cost of QGA as per QGA w.r.t Dispatch blend Manufact uring (R/R) spec Rs/MT/Unit 93.00 30000.0 0.08144 2.70 30000.0 6.79746 Total QGA w.r.t Manufacturing spec
Quality
252.00 39.7
GRM Improvement through QGA correction of 5 batches of HSD works out as 8 lakhs.
Haldia Refinery
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