Process Optimization & Slop Oil Reduction( Fahad Khan)

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The document discusses process optimization and reducing slop oil at a refinery. It identifies the main sources of slop oil as process unit sample points, desalter/jet filters drain, process unit startups and shutdowns, and upsets. Specific sources include blending 550 bbls/month from sample points, 75 bbls/month from jet filter drain, 1525 bbls/month from vacuum systems in HCU units, and 4210 bbls/month from Lummus vacuum separators. Through recovery efforts, 6360 bbls of slop oil per month was recovered, reducing reprocessing costs. Recovered oil was blended with HSD to meet quality standards.

A R L
Process Optimization & Slop Oil
Reduction
2nd Plant Maintenance & Operations
Conference 2014
Muhammad Fahad Khan
Engineer 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
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
A 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

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
RESULTS
Sp.
Gravity
Color
(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

HOT WELL
STORAGE TANK
LUMMUS SLOP REDUCTION
4210 bbls / month
A 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
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

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
TOTAL
9110 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.)

NO QUESTIONS ???
A R L
THANKS FOR ASKING

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