process optimization & slop oil reduction( fahad khan)

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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

Process Unit Sample PointsA R L

CLOSE SAMPLING SYSTEM

REDUCE SAMPLING POINT DISTANCE

Distance b/w source and sample point

Process Unit Sample Points

Blending with HSD

550 bbls / month

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(CONT’D)A R L

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


Main Sources DetailA R L

TO HSD TANK

TO SLOP

JET Filters Drain

75 bbls /month

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FLASH OF COMPONENT "Blended HSD" 72 C



Slop Oil & Sources

Main Sources :




Upsets at units



OVER HEAD VESSEL

TO SLOP TANK FOR RE-PROCESSING

Sampling Testing

Blending with HSD

Vacuum Creating System Heavy Crude Unit (HCU)

1525 bbls / month

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(Cont.)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

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QUANTITY OF COMPONENT "Blended HSd" 550 BBLS


HOT WELL

STORAGE TANK

LUMMUS SLOP REDUCTION

4210 bbls / month

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LUMMUS SLOP REDUCTIONA R L

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

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Slop Oil & Sources

Main Sources :




Upsets at units



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

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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.)

NO QUESTIONS ???

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THANKS FOR ASKING

process optimization & slop oil reduction( fahad khan)

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