Stream Routing Optimisation Using Rigorous Refinery-Wide Simulation

Refineries are becoming more complex with more conversion units and more frequent integration with petrochemical units. Product demands and prices are increasingly volatile. Crude quality is becoming poorer while product specifications are becoming tighter. There are fundamental changes in product demand patterns such as falling demand for fuel oil and increasing demand for diesel over gasoline. These changes increase the opportunity for refinery optimisation while making it more difficult. Simple empirical LP models are generally used to optimise refinery operations. These models do not accurately reflect the full impact of changing the routing of streams within a refinery. They include only a few of the feed and product qualities and operating parameters which are needed to do a complete analysis. This paper presents the results of a study carried out at an Asian refinery to optimise the routing of intermediate products. The study was carried out using a complete first principles refinery model built using KBC's industry leading simulator, Petro-SIM. The results of the study were implemented on the refinery leading to implemented benefits of millions of dollars per annum.