Training on Petroleum Refining Operations and Process Optimization

Module 1: Crude Oil Properties and Refining Overview

• Crude oil composition: hydrocarbons, sulfur, metals, and acidity.

• Key properties: API gravity, sulfur content, distillation curve, and viscosity.

• Refining complexity: hydroskimming, cracking, and coking refineries.

• Case Study/Hands-on Exercise: Analyze crude assay data for two different crude oils, comparing yields and product quality potential.

Module 2: Crude Distillation and Atmospheric/Vacuum Units

• Atmospheric distillation unit (ADU): separation into naphtha, kerosene, diesel, gas oil, and residue.

• Vacuum distillation unit (VDU): further separation of atmospheric residue.

• Key operating parameters and product quality control.

• Case Study/Hands-on Exercise: Simulate the impact of changing crude slate on ADU product yields and optimize cut points.

Module 3: Conversion Processes – Catalytic Cracking and Hydrocracking

• Fluid Catalytic Cracking (FCC): converting gas oil to gasoline and LPG.

• Hydrocracking: producing high-quality diesel and jet fuel.

• Catalyst management and process optimization.

• Case Study/Hands-on Exercise: Optimize FCC operating conditions to maximize gasoline yield while meeting product specifications.

Module 4: Reforming and Isomerization for Octane Improvement

• Catalytic reforming: converting naphtha to high-octane reformate.

• Isomerization: converting normal paraffins to isoparaffins.

• Hydrogen management in the refinery.

• Case Study/Hands-on Exercise: Determine the optimal reformer severity to meet gasoline octane targets while balancing hydrogen production.

Module 5: Hydrotreating and Sulfur Removal

• Hydrodesulfurization (HDS) for gasoline, diesel, and other streams.

• Meeting ultra-low sulfur diesel (ULSD) and Tier 3 gasoline specifications.

• Hydrogen consumption and catalyst life management.

• Case Study/Hands-on Exercise: Design a hydrotreater operating plan to produce ULSD from high-sulfur straight-run diesel.

Module 6: Residue Upgrading – Coking and Asphalt Production

• Delayed coking: converting vacuum residue to lighter products and petroleum coke.

• Asphalt and bitumen production.

• Economics of residue upgrading vs. fuel oil production.

• Case Study/Hands-on Exercise: Evaluate the economics of installing a coker versus selling vacuum residue as fuel oil.

Module 7: Product Blending and Quality Management

• Gasoline blending: octane, vapor pressure, and sulfur limits.

• Diesel blending: cetane, cold flow, and sulfur.

• Automated blending systems and quality giveaways.

• Case Study/Hands-on Exercise: Develop a gasoline blending recipe using available components (reformate, FCC gasoline, alkylate, butane) to meet specifications at minimum cost.

Module 8: Refinery Linear Programming (LP) Optimization

• Introduction to LP models for refinery optimization (e.g., PIMS, Haverly).

• Defining crude slates, process unit constraints, and product values.

• Running LP scenarios for crude selection and product slate optimization.

• Case Study/Hands-on Exercise: Use a simplified LP model to select the optimal crude slate and operating mode to maximize refinery margin given product prices.

Module 9: Energy Efficiency and Utilities Management

• Refinery energy consumption: furnaces, steam, and electricity.

• Heat integration and pinch analysis.

• Managing utilities: steam, cooling water, power, and hydrogen.

• Case Study/Hands-on Exercise: Identify energy-saving opportunities in a refinery using heat integration principles and calculate potential savings.

Module 10: Refinery Supply Chain Integration and Economics

• Linking refinery operations with crude supply and product logistics.

• Managing refinery inventory: crude tanks, intermediate storage, and product tanks.

• Turnarounds, maintenance planning, and their supply chain impact.

• Case Study/Hands-on Exercise: Develop an integrated crude procurement and refinery operating plan for a quarter, balancing crude costs, refinery constraints, and product demand.