Process Optimization & Slop Oil Reduction( Fahad Khan)
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Transcript of Process Optimization & Slop Oil Reduction( Fahad Khan)
A R L
Process Optimization & Slop Oil Reduction
2nd Plant Maintenance & OperationsConference 2014
Muhammad Fahad KhanEngineer Operations
• Challenge
• Slop Oil & its Sources
• Main Sources Detail
• Flash Point Calculator
• Achievements
• Q&A
Content of PresentationsA R L
“Approximately 8500 barrels per month of slop oil is re-processed. Roughly reprocessing cost is 2$ / bbl. If we reduce it to 5000 barrels per month, we can reduce the cost by approximately 7000$ a month”
ChallengeA R L
SLOP OIL ???
Main Sources :
Process Units’ Sample Points
Desalter / JET Filters Drain
Process Units’ start up & Shut down
Upsets at Process Units
Vacuum Creating System
Slop Oil & its SourcesA R L
Process Unit Sample PointsA R L
CLOSE SAMPLING SYSTEM
REDUCE SAMPLING POINT DISTANCE
Distance b/w source and sample point
Slop Oil & SourcesCalculationsA R L
FLASH POINT CALCULATOR
FLASH OF COMPONENT “SLOP" 49 C
QUANTITY OF COMPONENT “SLOP" 550 BBLS
FLASH OF COMPONENT “Blended HSD" 72 C
QUANTITY OF COMPONENT "Blended HSD" 170 BBLS
FLASH OF COMPONENT BLEND 54 C
Slop Oil & Sources
Main Sources :
Units’ Sample Points
Desalter/ JET Filters Drain
Units’ start up Shut down
Upsets at units
Vacuum Creating System
Main Sources DetailA R L
Slop Oil & SourcesCalculationsA R L
FLASH POINT CALCULATOR
FLASH OF COMPONENT “SLOP" 38 C
QUANTITY OF COMPONENT “SLOP" 75 BBLS
FLASH OF COMPONENT "Blended HSD" 72 C
QUANTITY OF COMPONENT "Blended HSD" 65 BBLS
FLASH OF COMPONENT BLEND 54 C
Slop Oil & Sources
Main Sources :
Units’ Sample Points
Desalter/ JET Filters Drain
Units’ start up Shut down
Upsets at units
Vacuum Creating System
Main Sources DetailA R L
Slop Oil & Sources
Main Sources :
Units’ Sample Points
Desalter/ JET Filters Drain
Units’ start up Shut down
Upsets at units
Vacuum Creating System
Main Sources DetailA R L
Slop Oil & Sources
Main Sources :
Units’ Sample Points
Desalter/ JET Filters Drain
Units’ start up Shut down
Upsets at units
Vacuum Creating System
Main Sources DetailA R L
OVER HEAD VESSEL
TO SLOP TANK FOR RE-PROCESSING
Sampling Testing
Blending with HSD
Vacuum Creating System Heavy Crude Unit (HCU)
1525 bbls / month
A R L
Slop Oil & SourcesSlop Oil Results
Results of HCU Slop Oil From V-008
Sr. No
RESULTSSp.
GravityColor
(ASTM)Flash Point
( C )C.P( C )
P. P (C )
1 0.821 0.5 45 <-18 <-18
2 0.824 0.5 42 <-18 <-18
3 0.820 0.5 42 <-18 <-18
4 0.844 1.0 48 -9 -15
5 0.842 1.0 49 -9 -14
A R L
Slop Oil & SourcesCalculationsA R L
FLASH POINT CALCULATOR
FLASH OF COMPONENT “SLOP" 48 C
QUANTITY OF COMPONENT “SLOP" 1525 BBLS
FLASH OF COMPONENT "Blended HSD" 72 C
QUANTITY OF COMPONENT "Blended HSd" 550 BBLS
FLASH OF COMPONENT BLEND 54 C
Slop Oil & SourcesSlop Oil Results
Results of Lummus Vacuum Separator / Tk-38
Sr. No
RESULTS
Sp. Gravity Color (ASTM) Flash Point ( C ) C.P ( C ) P. P (C )
1 0.838 0.5 56 <-18 <-18
2 0.842 0.5 55 -15 -18
3 0.835 0.5 58 <-18 <-18
4 0.825 0.5 60 <-18 <-18
5 0.831 0.5 46 <-18 <-18
6 0.837 1.0 47 <-18 <-18
7 0.833 1.0 51 <-18 <-18
8 0.829 0.5 51 <-18 <-18
9 0.845 0.5 57 2 -9
A R L
Slop Oil & SourcesCalculationsA R L
FLASH POINT CALCULATOR
FLASH OF COMPONENT “SLOP" 48 C
QUANTITY OF COMPONENT “SLOP" 4210 BBLS
FLASH OF COMPONENT "Blended HSD" 72 C
QUANTITY OF COMPONENT "Blended HSD" 1400 BBLS
FLASH OF COMPONENT BLEND 54 C
Slop Oil & Sources
Main Sources :
Units’ Sample Points
Desalter/ JET Filters Drain
Units’ start up Shut down
Upsets at units
Vacuum Creating System
Main Sources DetailA R L
Achievements
SLOP OIL RECOVERY DETAILS
DETAILS SLOP OIL (TOTAL)
SLOP OIL(Remaining)
SLOP OIL(Recovered)
HSD Required
(for blending)
TOTAL BLEND
Lummus (VCS) 4210 0 4210 1400 5610
HCU (VCS) 1525 0 1525 550 2075
Jp-1 Filter Repacking 75 0 75 65 140
SAMPLING Points &Pump Drainages 3300 2750 550 170 720
TOTAL9110 2750 6360 2185 8545
A R L
6360 bbls of Slop Oil recovered.
Reduction in SLOP OIL Re-Processing Cost reduced for 6360 bbls/month.
Blending of Recovered Oil with HSD, meeting Quality Standards.
One time profit of 6360 bbls excess HSD Production with out processing.
A R L Achievements (cont.)