Product Blending & Optimization

Considerations

Chapters 12 & 14
Petroleum Refinery Block Flow Diagram

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Topics
Blending
▪ Blending equations
▪ Specifications / targets
▪ Typical blend stock properties
Optimization
▪ Economics & planning applications
▪ Optimization tools
• Linear programming
• Non-linear (geometric) programming
Adjusting upstream operations to meet downstream targets

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Blending

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Blending Equations
Volume blending equations Reid Vapor Pressure (RVP)
▪ Specific gravity
 V (RVP )
1.25

( )
1.25
▪ Aromatics & olefins content (vol%) RVP = i i
mix
V i

X mix =  v i X i =
V X
i i

V i Octane numbers – Simple, by volume

Mass blending equations
( RON )mix = 
Vi ( RON )i
▪ Sulfur & nitrogen content (wt% or V i
ppm)
( MON )mix = 
Vi ( MON )i
▪ Nickel & vanadium (ppm)
V i
▪ Carbon residue (CCR, MCRT, …)
V  X Viscosity
X = w X = i oi i
mix i i V 
i oi log (log (  mix + 0.7 ) ) =
V log (log ( 
i i + 0.7 ) )
V i

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Non-Linear Octane Blending Formula
Developed by Ethyl Corporation using a set of 75 & 135 blends
R = R + a1 RJ − R  J  + a2 (O2 ) − O 2  + a3 ( A2 ) − A 2 
   
 ( A2 ) − A 2 
2

M = M + b1 MJ − M  J  + b2 (O2 ) − O 2  + b3  
   100 
 
R+M
"Road" Octane = 75 blends 135 blends
2
a1 0.03224 0.03324
Sensitivity = J  R − M
a2 0.00101 0.00085
Volume Average = X 
Vi  Xi a3 0 0
V i
b1 0.04450 0.04285
b2 0.00081 0.00066
Petroleum Refinery Process Economics, 2nded. ,
by Robert E. Maples, PennWell Corp., 2000 b3 -0.00645 -0.00632

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Typical Gasoline Blend Stock Properties
No. Component RVP, psi (R+M)/2 MON RON °APl
1 iC4 71.0 92.5 92.0 93.0
2 nC4 52.0 92.5 92.0 93.0
3 iC5 19.4 92.0 90.8 93.2
4 nC5 14.7 72.0 72.4 71.5
5 iC6 6.4 78.8 78.4 79.2
6 LSR gasoline (C5-180°F) 11.1 64.0 61.6 66.4 78.6
7 LSR gasoline isomerized once-through 13.5 82.1 81.1 83.0 80.4
8 HSR gasoline 1.0 60.5 58.7 62.3 48.2
9 Light hydrocrackate 12.9 82.6 82.4 82.8 79.0
10 Hydrocrackate, C5-C6 15.5 87.4 85.5 89.2 86.4
11 Hydrocrackate, C6-190°F 3.9 74.6 73.7 75.5 85.0
12 Hydrocrackate, 190-250°F 1.7 77.3 75.6 79.0 55.5
13 Heavy hydrocrackate 1.1 67.5 67.3 67.6 49.0
14 Coker gasoline 3.6 63.7 60.2 67.2 57.2
15 Light thermal gasoline 9.9 76.8 73.2 80.3 74.0
16 C6+ light thermal gasoline 1.1 72.5 68.1 76.8 55.1
17 FCC gasoline, 200-300°F 1.4 84.6 77.1 92.1 49.5
18 Hydrog. light FCC gasoline, C5+ 13.9 82.1 80.9 83.2 51.5
19 Hydrog. C5-200°F FCC gasoline 14.1 86.5 81.7 91.2 58.1
20 Hydrog. light FCC gasoline, C6+ 5.0 80.2 74.0 86.3 49.3
21 Hydrog. C5+ FCC gasoline 13.1 85.9 80.7 91.0 54.8
22 Hydrog. 300-400°F FCC gasoline 0.5 85.8 81.3 90.2 48.5
23 Reformate, 94 RON 2.8 89.2 84.4 94.0 45.8
24 Reformate, 98 RON 2.2 92.3 86.5 98.0 43.1
25 Reformate, 100 RON 3.2 94.1 88.2 100.0 41.2
26 Aromatic concentrate 1.1 100.5 94.0 107.0
27 Alkylate, C3= 5.7 89.1 87.3 90.8 Table 12.1 Blending Component Values for Gasoline
28 Alkylate, C4= 4.6 96.6 95.9 97.3 70.3 Blending Streams
29 Alkylate, C3=, C4= 5.0 93.8 93.0 94.5 Petroleum Refining Technology & Economics – 5th Ed.
30 Alkylate, C5= 1.0 89.3 88.8 89.7 by James Gary, Glenn Handwerk, & Mark Kaiser, CRC
31 Polymer 8.7 90.5 84.0 96.9 59.5 Press, 2007

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Gasoline Blending Considerations
What is available? What are you trying to make?
▪ Amounts ▪ Amount(s)
▪ Properties ▪ Properties
• Appropriate to determine product • Volatility / RVP (maximum)
properties • Octane number (minimum)
▪ Associated costs / values • Drivability Index
• Distillation
o T10 (minimum)
o T50 (range)
o T90 (maximum)
• Composition
o Sulfur (maximum)
o Benzene & total aromatics (maximums)
o Olefins (maximum)
▪ Value

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Gasoline Blend Example – 3 Blend Stocks, 2
Specs
Use 3 blend stocks to make regular gasoline (87 road octane) for both summer (9 psi
RVP) & winter (15 psi RVP)
 R+M 
  = ( 92.5) vnC4 + ( 64.0 ) vLSR + ( 94.1) vRef
 2 
(RVP ) = ( 52.0 ) vnC4 + (11.1) vLSR + ( 3.2 )
1.25 1.25 1.25 1.25
vRef
1 = vnC4 + vLSR + vRef

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Diesel Blending Considerations
Available blend stocks Specification of final product(s)
▪ Amounts ▪ Amount(s)
▪ Properties ▪ Properties
• Appropriate to determine product • Cetane index (minimum)
properties • Flash Point (minimum)
▪ Associated costs / values • Distillation
o T90 (minimum & maximum)
• Cold properties
o Cloud point (minimum)
o Pour point (minimum)
• Composition
o Sulfur (maximum)
o Aromaticity (maximum)
o Carbon residue (maximum)
• Color
▪ Value

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Optimization

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Optimization for Economics & Planning
What should be done rather than what can be done
Optimization
▪ Combines models to…
• Describe operations
• Constraints to operations
▪ Economics added to define costs & benefits to all actions
▪ “Optimal” is best of the “feasible” possibilities
Optimization models tend to be data-driven rather than
mathematical model driven.

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Economics & Planning Applications
Crude oil evaluation Shutdown planning
▪ Incremental value of an opportunity ▪ Multi time periods, must take into
crude compared to base slate account changes in inventories
▪ Take into account change in
Multirefining supply & distribution
products produced
Yearly budgeting
Production planning
Investment studies
Day-to-day operations optimization
Environmental studies
Product blending & pricing
▪ May have opportunity to separately Technology evaluation
purchase blend stocks

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Modeling Hierarchy
unit
operations

single single
plant Process
process model
Simulation

multi-plant refinery
model model
multiple
processes
LP
multi-refinery Simulation
model

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Unit Representations
Simple vector model Delta-Base model
Yield Base
Vector Feed Yield Delta KW Delta API
Feedstock Feed 1.0 -1.0
Butylene -1.0000 Hydrogen -1500
Isobutane -1.2000 C5-180 8.1 1.0 3.6
Product 180-400 28.0 -5.5 11.0
n-Butane 0.1271 Kw -12.1 10.9 1.2
Pentane 0.0680 API -22.0 20.0 4.0
Alkylate 1.5110
"Alky Bottoms 0.1190 Relative Activity 1 1 1 0.5
Tar 0.0096
Utilities
Steam, lb 7.28
Power, kWh 2.45 Relative activities calculated from actual
Cooling Water, M gal 2.48
Fuel, MMBtu 0.69 properties – the Kw & API rows are zero
1  ( −22.0 ) + 1  20.0
API = − = 0.5
For every unit of Butylene consumed, 4.0
must also consume the relative amount Correct base yields to take into account
of isobutane, produce the shown actual properties & relative activities
amounts of products, & use the shown
1  8.1 + 1  1.0 + 0.5  3.6
amounts of utilities C5-180 = = 10.9
1

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What is “Linear Programming”?
Word “programming” used here in Terminology
the sense of “planning” ▪ Objective Function – function z to be
maximized
For N independent variables (that
▪ Feasible Vector – set of values x1, x2,
can be zero or positive) maximize
…, xN that satisfies all constraints
z = a01 x1 + a02 x2 + + a0N xN ▪ Optimal Feasible Vector – feasible
vector that maximizes the objective
function
subject to M additional constraints
(all bn positive) Solutions
▪ Will tend to be in the “corners” of
ai 1 x1 + ai 2 x2 + + aiN xN  bi
where the constraints meet
a j1 x1 + a j 2 x2 + + a jN xN  bj
▪ May not have a solution because of
ak 1 x1 + ak 2 x2 + + akN xN = bk incompatible constraints or area
unbounded towards the optimum

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Change Blending Equations to Fit Linear
Form
Sum of blending factors must be removed from the denominator
▪ Volume blending equations
X mix =  vi X i =
V Xi i
 0 = Vi ( X i − X mix )
V i

▪ Mass blending equations

V  X
X = w X = i oi i  0 = Vi   oi ( X i − X mix ) 
mix i i V 
i oi

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Non-Linear Programming
Non-linear blending rules can more closely match the physics of the problem
▪ Example: octane blending models
R = R + 0.03324 RJ − R  J  + 0.00085 (O2 ) − O 2 
 
M = M + 0.04285 MJ − M  J  + 0.00066 ( O2 ) − O 2  − 6.32  10 −7 ( A2 ) − A 2 
   
Guarantees of solutions are more tenuous
▪ Not necessarily at constraints
▪ Discontinuous feasible regions possible

Types of optimization algorithms

▪ Local optimization
• Based on following gradients
o Excel’s Solver based on GRG2

▪ Global optimization
• Randomly search overall region before switching to local optimization technique
o Simulated annealing

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Gasoline Blending Considerations
What is available? What are you trying to make?
▪ Amounts ▪ Amount(s)
▪ Properties ▪ Properties
• Appropriate to determine product • Volatility / RVP (maximum)
properties • Octane number (minimum)
▪ Associated costs / values • Drivability Index
• Distillation
o T10 (minimum)
o T50 (range)
o T90 (maximum)
• Composition
o Sulfur (maximum)
o Benzene & total aromatics (maximums)
o Olefins (maximum)
▪ Value

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Gasoline Blending Example – All Into
Regular
Raw Materials Properties for Blending Calculations
RON MON (R+M)/2 RVP RVP1.25 Aromatics Olefins Benzene
Butane 93.0 92.0 92.5 54 146.4 0.0 0.0 0.00
Straight Run Naphtha 78.0 76.0 77 11.2 20.5 2.2 0.9 0.73
Isomerate 83.0 81.1 82.05 13.5 25.9 1.6 0.1 0.00
Reformate (High Octane) 100.0 88.2 94.1 3.2 4.3 94.2 0.6 1.85
Reformate (Low Benzene) 93.7 84.0 88.85 2.8 3.6 61.1 1.0 0.12
FCC Naphtha 92.1 77.1 84.6 1.4 1.5 35.2 32.6 1.06
Alkylate 97.3 95.9 96.6 4.6 6.7 0.5 0.2 0.00

Cost & Availability Usage

Cost Minimum Maximum Minimum Maximum
($/gal) Required Available Regular Premium Total Slack Slack
Butane 0.85 0 30,000 30,000 0 30,000 30,000 0
Straight Run Naphtha 2.05 0 35,000 35,000 0 35,000 35,000 0
Isomerate 2.20 0 0 0 0 0 0 0
Reformate (High Octane) 2.80 0 60,000 60,000 0 60,000 60,000 0
Reformate (Low Benzene) 2.75 0 0 0 0 0 0 0
FCC Naphtha 2.60 0 70,000 70,000 0 70,000 70,000 0
Alkylate 2.75 0 40,000 40,000 0 40,000 40,000 0

Products Lower & Upper Limits on Properties Price & Production Requirements
Price Minimum Maximum
Lower Upper ($/gal) Required Allowed
Regular Octane 87 110 Regular 2.75 1 1,000,000
RVP 0.0 15.0 Premium 2.85 1 1
RVP1.25 0.0 29.5
Benzene 0.0 1.1
Premium Octane 91 110 Cost & Revenue
RVP 0.0 15.0 Revenue ($) $646,250 $1 $646,251
RVP1.25 0.0 29.5 Cost($) $557,250 $1 $557,251
Benzene 0.0 1.1 Profit ($) $89,000 $0 $89,000

Product Calculations Linear-Form Product Constraints

Volumes & Properties Lower Slack Upper Slack
Regular Premium Total Regular Volume 234,999 765,000
Produced 235,000 0 235,000 Vol*Octane 457,000 4,948,000
RON 93.02 83.24 Vol*RVP1.25 5,741,488 1,195,675
MON 84.87 81.59 Vol*Benzene 210,750 47,750
(R+M)/2 88.9 82.4 Premium Volume -1 1
RVP 12.9 28.0 Vol*Octane -3 11
RVP1.25 24.43 64.46 Vol*RVP1.25 25 -14
Benzene 0.90 0.48 Vol*Benzene 0 0

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Gasoline Blending Example – Only Regular
(Optimized)
Raw Materials Properties for Blending Calculations
RON MON (R+M)/2 RVP RVP1.25 Aromatics Olefins Benzene
Butane 93.0 92.0 92.5 54 146.4 0.0 0.0 0.00
Straight Run Naphtha 78.0 76.0 77 11.2 20.5 2.2 0.9 0.73
Isomerate 83.0 81.1 82.05 13.5 25.9 1.6 0.1 0.00
Reformate (High Octane) 100.0 88.2 94.1 3.2 4.3 94.2 0.6 1.85
Reformate (Low Benzene) 93.7 84.0 88.85 2.8 3.6 61.1 1.0 0.12
FCC Naphtha 92.1 77.1 84.6 1.4 1.5 35.2 32.6 1.06
Alkylate 97.3 95.9 96.6 4.6 6.7 0.5 0.2 0.00

Cost & Availability Usage

Cost Minimum Maximum Minimum Maximum
($/gal) Required Available Regular Premium Total Slack Slack
Butane 0.85 0 30,000 30,000 0 30,000 30,000 0
Straight Run Naphtha 2.05 0 35,000 35,000 0 35,000 35,000 0
Isomerate 2.20 0 0 0 0 0 0 0
Reformate (High Octane) 2.80 0 60,000 12,628 0 12,628 12,628 47,372
Reformate (Low Benzene) 2.75 0 0 0 0 0 0 0
FCC Naphtha 2.60 0 70,000 70,000 0 70,000 70,000 0
Alkylate 2.75 0 40,000 39,999 1 40,000 40,000 0

Products Lower & Upper Limits on Properties Price & Production Requirements
Price Minimum Maximum
Lower Upper ($/gal) Required Allowed
Regular Octane 87 110 Regular 2.75 1 1,000,000
RVP 0.0 15.0 Premium 2.85 1 1
RVP1.25 0.0 29.5
Benzene 0.0 1.1
Premium Octane 91 110 Cost & Revenue
RVP 0.0 15.0 Revenue ($) $515,973 $3 $515,976
RVP1.25 0.0 29.5 Cost($) $424,605 $2 $424,607
Benzene 0.0 1.1 Profit ($) $91,368 $1 $91,369

Product Calculations Linear-Form Product Constraints

Volumes & Properties Lower Slack Upper Slack
Regular Premium Total Regular Volume 187,626 812,373
Produced 187,627 1 187,628 Vol*Octane 120,652 4,194,760
RON 91.25 91.75 Vol*RVP1.25 5,538,708 0
MON 84.03 90.25 Vol*Benzene 123,111 83,278
(R+M)/2 87.6 91.0 Premium Volume 0 0
RVP 15.0 15.0 Vol*Octane 0 19
RVP1.25 29.52 29.52 Vol*RVP1.25 30 0
Benzene 0.66 0.19 Vol*Benzene 0 1

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Gasoline Blending Example – Only
Premium (Optimized)
Raw Materials Properties for Blending Calculations
RON MON (R+M)/2 RVP RVP1.25 Aromatics Olefins Benzene
Butane 93.0 92.0 92.5 54 146.4 0.0 0.0 0.00
Straight Run Naphtha 78.0 76.0 77 11.2 20.5 2.2 0.9 0.73
Isomerate 83.0 81.1 82.05 13.5 25.9 1.6 0.1 0.00
Reformate (High Octane) 100.0 88.2 94.1 3.2 4.3 94.2 0.6 1.85
Reformate (Low Benzene) 93.7 84.0 88.85 2.8 3.6 61.1 1.0 0.12
FCC Naphtha 92.1 77.1 84.6 1.4 1.5 35.2 32.6 1.06
Alkylate 97.3 95.9 96.6 4.6 6.7 0.5 0.2 0.00

Cost & Availability Usage

Cost Minimum Maximum Minimum Maximum
($/gal) Required Available Regular Premium Total Slack Slack
Butane 0.85 0 30,000 0 30,000 30,000 30,000 0
Straight Run Naphtha 2.05 0 35,000 0 17,433 17,433 17,433 17,567
Isomerate 2.20 0 0 0 0 0 0 0
Reformate (High Octane) 2.80 0 60,000 0 60,000 60,000 60,000 0
Reformate (Low Benzene) 2.75 0 0 0 0 0 0 0
FCC Naphtha 2.60 0 70,000 0 32,959 32,959 32,959 37,041
Alkylate 2.75 0 40,000 0 40,000 40,000 40,000 0

Products Lower & Upper Limits on Properties Price & Production Requirements
Price Minimum Maximum
Lower Upper ($/gal) Required Allowed
Regular Octane 87 110 Regular 2.75 1 1
RVP 0.0 15.0 Premium 2.85 1 1,000,000
RVP1.25 0.0 29.5
Benzene 0.0 1.1
Premium Octane 91 110 Cost & Revenue
RVP 0.0 15.0 Revenue ($) $3 $514,115 $514,118
RVP1.25 0.0 29.5 Cost($) $2 $424,930 $424,932
Benzene 0.0 1.1 Profit ($) $0 $89,186 $89,186

Product Calculations Linear-Form Product Constraints

Volumes & Properties Lower Slack Upper Slack
Regular Premium Total Regular Volume 0 0
Produced 1 180,391 180,392 Vol*Octane 0 23
RON 90.90 94.67 Vol*RVP1.25 30 0
MON 83.10 87.33 Vol*Benzene 1 0
(R+M)/2 87.0 91.0 Premium Volume 180,390 819,609
RVP 15.0 15.0 Vol*Octane 0 3,427,436
RVP1.25 29.52 29.52 Vol*RVP1.25 5,325,125 0
Benzene 1.10 0.88 Vol*Benzene 158,662 39,769

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Gasoline Blending Example – Combined
(Optimized)
Raw Materials Properties for Blending Calculations
RON MON (R+M)/2 RVP RVP1.25 Aromatics Olefins Benzene
Butane 93.0 92.0 92.5 54 146.4 0.0 0.0 0.00
Straight Run Naphtha 78.0 76.0 77 11.2 20.5 2.2 0.9 0.73
Isomerate 83.0 81.1 82.05 13.5 25.9 1.6 0.1 0.00
Reformate (High Octane) 100.0 88.2 94.1 3.2 4.3 94.2 0.6 1.85
Reformate (Low Benzene) 93.7 84.0 88.85 2.8 3.6 61.1 1.0 0.12
FCC Naphtha 92.1 77.1 84.6 1.4 1.5 35.2 32.6 1.06
Alkylate 97.3 95.9 96.6 4.6 6.7 0.5 0.2 0.00

Cost & Availability Usage

Cost Minimum Maximum Minimum Maximum
($/gal) Required Available Regular Premium Total Slack Slack
Butane 0.85 0 30,000 17,925 12,075 30,000 30,000 0
Straight Run Naphtha 2.05 0 35,000 35,000 0 35,000 35,000 0
Isomerate 2.20 0 0 0 0 0 0 0
Reformate (High Octane) 2.80 0 60,000 43,599 16,401 60,000 60,000 0
Reformate (Low Benzene) 2.75 0 0 0 0 0 0 0
FCC Naphtha 2.60 0 70,000 24,226 45,774 70,000 70,000 0
Alkylate 2.75 0 40,000 0 40,000 40,000 40,000 0

Products Lower & Upper Limits on Properties Price & Production Requirements
Price Minimum Maximum
Lower Upper ($/gal) Required Allowed
Regular Octane 87 110 Regular 2.75 1 1,000,000
RVP 0.0 15.0 Premium 2.85 1 1,000,000
RVP1.25 0.0 29.5
Benzene 0.0 1.1
Premium Octane 91 110 Cost & Revenue
RVP 0.0 15.0 Revenue ($) $332,063 $325,613 $657,675
RVP1.25 0.0 29.5 Cost($) $272,051 $285,199 $557,250
Benzene 0.0 1.1 Profit ($) $60,011 $40,414 $100,425

Product Calculations Linear-Form Product Constraints

Volumes & Properties Lower Slack Upper Slack
Regular Premium Total Regular Volume 120,749 879,250
Produced 120,750 114,250 235,000 Vol*Octane 0 2,777,250
RON 91.00 95.15 Vol*RVP1.25 3,564,521 0
MON 83.00 86.85 Vol*Benzene 131,888 937
(R+M)/2 87.0 91.0 Premium Volume 114,249 885,750
RVP 15.0 10.6 Vol*Octane 0 2,170,750
RVP1.25 29.52 19.05 Vol*RVP1.25 2,176,967 1,195,675
Benzene 1.09 0.69 Vol*Benzene 78,862 46,813

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Gasoline Blending Example – Lower RVP &
Benzene
Raw Materials Properties for Blending Calculations
RON MON (R+M)/2 RVP RVP1.25 Aromatics Olefins Benzene
Butane 93.0 92.0 92.5 54 146.4 0.0 0.0 0.00
Straight Run Naphtha 78.0 76.0 77 11.2 20.5 2.2 0.9 0.73
Isomerate 83.0 81.1 82.05 13.5 25.9 1.6 0.1 0.00
Reformate (High Octane) 100.0 88.2 94.1 3.2 4.3 94.2 0.6 1.85
Reformate (Low Benzene) 93.7 84.0 88.85 2.8 3.6 61.1 1.0 0.12
FCC Naphtha 92.1 77.1 84.6 1.4 1.5 35.2 32.6 1.06
Alkylate 97.3 95.9 96.6 4.6 6.7 0.5 0.2 0.00

Cost & Availability Usage

Cost Minimum Maximum Minimum Maximum
($/gal) Required Available Regular Premium Total Slack Slack
Butane 0.85 0 30,000 8,187 0 8,188 8,188 21,812
Straight Run Naphtha 2.05 0 35,000 28,305 0 28,305 28,305 6,695
Isomerate 2.20 0 0 0 0 0 0 0
Reformate (High Octane) 2.80 0 60,000 0 0 0 0 60,000
Reformate (Low Benzene) 2.75 0 0 0 0 0 0 0
FCC Naphtha 2.60 0 70,000 60,824 0 60,824 60,824 9,176
Alkylate 2.75 0 40,000 40,000 0 40,000 40,000 0

Products Lower & Upper Limits on Properties Price & Production Requirements
Price Minimum Maximum
Lower Upper ($/gal) Required Allowed
Regular Octane 87 110 Regular 2.75 1 1,000,000
RVP 0.0 9.0 Premium 2.85 1 1,000,000
RVP1.25 0.0 15.6
Benzene 0.0 0.62
Premium Octane 91 110 Cost & Revenue
RVP 0.0 9.0 Revenue ($) $377,618 $3 $377,621
RVP1.25 0.0 15.6 Cost($) $333,125 $3 $333,127
Benzene 0.0 0.62 Profit ($) $44,493 $0 $44,493

Product Calculations Linear-Form Product Constraints

Volumes & Properties Lower Slack Upper Slack
Regular Premium Total Regular Volume 137,315 862,684
Produced 137,316 1 137,317 Vol*Octane 0 3,158,261
RON 90.76 95.03 Vol*RVP1.25 2,140,540 0
MON 83.24 86.97 Vol*Benzene 85,136 0
(R+M)/2 87.0 91.0 Premium Volume 0 999,999
RVP 9.0 9.0 Vol*Octane 0 19
RVP1.25 15.59 15.59 Vol*RVP1.25 16 0
Benzene 0.62 0.62 Vol*Benzene 1 0

Updated: July 1, 2019

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Copyright © 2016-2019 John Jechura ([email protected])
Gasoline Blending Example –Low Benzene
Reformate
Raw Materials Properties for Blending Calculations
RON MON (R+M)/2 RVP RVP1.25 Aromatics Olefins Benzene
Butane 93.0 92.0 92.5 54 146.4 0.0 0.0 0.00
Straight Run Naphtha 78.0 76.0 77 11.2 20.5 2.2 0.9 0.73
Isomerate 83.0 81.1 82.05 13.5 25.9 1.6 0.1 0.00
Reformate (High Octane) 100.0 88.2 94.1 3.2 4.3 94.2 0.6 1.85
Reformate (Low Benzene) 93.7 84.0 88.85 2.8 3.6 61.1 1.0 0.12
FCC Naphtha 92.1 77.1 84.6 1.4 1.5 35.2 32.6 1.06
Alkylate 97.3 95.9 96.6 4.6 6.7 0.5 0.2 0.00

Cost & Availability Usage

Cost Minimum Maximum Minimum Maximum
($/gal) Required Available Regular Premium Total Slack Slack
Butane 0.85 0 30,000 13,552 1,355 14,907 14,907 15,093
Straight Run Naphtha 2.05 0 35,000 35,000 0 35,000 35,000 0
Isomerate 2.20 0 0 0 0 0 0 0
Reformate (High Octane) 2.80 0 0 0 0 0 0 0
Reformate (Low Benzene) 2.75 0 65,400 53,656 11,744 65,400 65,400 0
FCC Naphtha 2.60 0 70,000 70,000 0 70,000 70,000 0
Alkylate 2.75 0 40,000 35,854 4,146 40,000 40,000 0

Products Lower & Upper Limits on Properties Price & Production Requirements
Price Minimum Maximum
Lower Upper ($/gal) Required Allowed
Regular Octane 87 110 Regular 2.75 1 1,000,000
RVP 0.0 9.0 Premium 2.85 1 1,000,000
RVP1.25 0.0 15.6
Benzene 0.0 0.62
Premium Octane 91 110 Cost & Revenue
RVP 0.0 9.0 Revenue ($) $572,172 $49,147 $621,318
RVP1.25 0.0 15.6 Cost($) $511,423 $44,848 $556,271
Benzene 0.0 0.62 Profit ($) $60,749 $4,299 $65,048

Product Calculations Linear-Form Product Constraints

Volumes & Properties Lower Slack Upper Slack
Regular Premium Total Regular Volume 208,061 791,938
Produced 208,062 17,244 225,307 Vol*Octane 0 4,785,436
RON 91.10 94.51 Vol*RVP1.25 3,243,372 0
MON 82.90 87.49 Vol*Benzene 106,189 22,810
(R+M)/2 87.0 91.0 Premium Volume 17,243 982,756
RVP 9.0 9.0 Vol*Octane 0 327,645
RVP1.25 15.59 15.59 Vol*RVP1.25 268,815 0
Benzene 0.51 0.08 Vol*Benzene 1,409 9,282

Updated: July 1, 2019

27
Copyright © 2016-2019 John Jechura ([email protected])
Adjusting operations to meet
targets

Updated: July 1, 2019

Copyright © 2016-2019 John Jechura ([email protected])
Cutpoint Economics
Adjust upstream cutpoints to meet needs in the downstream blending
▪ Heavy LSR…value as blending component
versus Reformer feed
▪ Heavy Naphtha…value as Reformer feed
versus kerosene blend stock
▪ Heavy Kerosene…value as kerosene blend
stock versus diesel blend stock
▪ Heavy Diesel…value as diesel blend stock
versus FCC feed
▪ Heavy Gas Oil…value as FCC feed versus
resid/asphalt production or coker feed
The refinery LP can determine the optimum
cut point for each of these given any set of constraints

Updated: July 1, 2019

29
Copyright © 2016-2019 John Jechura ([email protected])
Cutpoints To Meet Operating Economies
TBP Cut Points (°F) for Various Crude Oil Fractions

Cut IBP EP Processing Use

LSR 90 180 Min LSR cut
90 190 Normal LSR cut
80 220 Max LSR cut
Naphtha 180 380 Max reforming cut
190 330 Max jet fuel
220 330 Min reforming cut
Kerosene 330 520 Max kerosene cut
330 480 Max Jet A cut
380 520 Max gasoline
Diesel 420 650 Max diesel cut
480 610 Max jet fuel cut
520 610 Min diesel cut
Gas Oil 610 800 Cat cracker feed
VGO 800 1050 Cat cracker feed
Resid 1050+ Coker feed, asphalt

Updated: July 1, 2019

30
Copyright © 2016-2019 John Jechura ([email protected])
Optimize FCC Gasoline Distillation
Frame the analysis
▪ What is the value of the molecules in the
stream above?
▪ What is the value of the molecules in the
stream below?
▪ What upstream unit operations affect
the stream value?
▪ What downstream unit operations affect
the stream value?
▪ What unit specific operations affect the
stream value?
▪ What product blending constraints affect
the stream value?
Ref: http://www.refinerlink.com/blog/Truly_Optimize_FCC_Gasoline_Distillation

Updated: July 1, 2019

31
Copyright © 2016-2019 John Jechura ([email protected])
Gasoline Blending – Modify Upstream
Operations
How much gasoline can be produced by blending Reformate+LSR
with respect to the Reformer’s severity?

Updated: July 1, 2019

33
Copyright © 2016-2019 John Jechura ([email protected])
Summary

Updated: July 1, 2019

Copyright © 2016-2019 John Jechura ([email protected])
Summary
Equations for the blending of intermediate stocks to meet final
product specifications
Equation forms have been developed to be used with
optimization tools (such as linear programming)
Proper optimization of a facility will include adjusting upstream
operations to meet downstream targets

Updated: July 1, 2019

37
Copyright © 2016-2019 John Jechura ([email protected])