Upon completion of this course, participants will be able to:

• Analyze the relationship between crude oil properties (assay) and optimal product yields.
• Apply linear programming (LP) concepts to optimize refinery feed and product blends.
• Develop and execute optimization strategies for key units (e.g., FCC, Hydrocracker, Reformer).
• Calculate and manage key economic metrics such as Gross Margin and Processing Gain.
• Evaluate the impact of market price fluctuations on the optimal unit operating severity.
• Identify and address process constraints (bottlenecks) that limit yield potential.
• Implement real-time optimization (RTO) and advanced process control (APC) techniques.
• Design and manage the optimal final product blending strategy to meet specifications and margin targets.

• Refinery Process Engineers and Optimization Specialists.
• Refinery Planners and Schedulers (Crude and Blending).
• Advanced Process Control (APC) Engineers.
• Technologists and Consultants in refining operations.
• Refinery Managers and Economists responsible for margin performance.
• Senior Operators involved in unit operational strategy.

• Scenarios: Running an optimization scenario based on a new crude slate and current product prices.
• Case Studies: Analysis of refinery margin improvement projects and key unit revamps.
• Group Activities: Developing an optimization plan for a specific refinery unit (e.g., FCC severity adjustment).
• Individual Exercises: Calculating the economic incentive for a yield shift.
• Discussions on the integration of LP planning models with RTO systems.

Unit 1: Refinery Economics and Optimization Drivers

• Defining refinery margin, gross margin, and net profit drivers.
• The impact of crude oil selection (feed slate) on final product yields and quality.
• Understanding the relationship between product specifications and market value (pricing differentials).
• Introduction to Linear Programming (LP) models for integrated refinery optimization.

Unit 2: Optimization of Primary Conversion Units

• Optimization of Crude Distillation Unit (CDU) cut-points and furnace severity.
• Strategies for maximizing light product yield in the Fluid Catalytic Cracking (FCC) unit.
• Optimizing severity and catalyst management in the Catalytic Reformer for high-octane gasoline.
• Hydrocracker and Hydrotreater optimization for residue upgrading and sulfur removal.

Unit 3: Constraints and Bottleneck Management

• Identifying physical, contractual, and environmental constraints (e.g., cooling capacity, tank limits).
• Techniques for economic balancing of intermediate product streams (e.g., naphtha, heavy oil).
• Managing utility consumption (steam, power, hydrogen) as a profitability constraint.
• Process monitoring and troubleshooting for unit performance deviation.

Unit 4: Advanced Control and Yield Improvement Tools

• The role of Advanced Process Control (APC) in maintaining optimal operating points.
• Fundamentals of Real-Time Optimization (RTO) and model predictive control (MPC).
• Utilizing process simulation software to model yield improvements (link to HYSYS).
• Data analytics and machine learning applications in predictive yield optimization.

Unit 5: Product Blending and Margin Maximization

• Principles of optimal gasoline, diesel, and fuel oil blending to meet multiple specifications.
• Using LP blending models to minimize giveaway and maximize high-value component usage.
• Economic analysis of blending component valuation and transfer pricing.
• Developing a dynamic optimization strategy responsive to daily market changes.