Refinery Research Articles

California tightens refinery regulations

California tightens refinery regulations

Higher prevalence of metabolic syndrome among male employees of a gas refinery than in their counterparts in nonindustrial environments

Background: Occupation and working conditions may affect the risk of developing metabolic syndrome (MetS), an important risk factor for diabetes and cardiovascular disease (CVD). Objective: To investigate the prevalence of MetS and its risk factors in employees in an industrial workplace and compare them with those in employees from a nonindustrial setting. Methods: Male employees (n = 757) from a gas-refinery and 2700 adult men from the general population of whom 750 were nonindustrial employees (Khorasan province, Iran), were evaluated for CVD risk factors, including those used to define MetS. Individuals were matched for age and educational attainment, and 670 industrial and681 nonindustrial employees were included in the final analysis. International Diabetes Federation (IDF) and Adult Treatment Panel (ATP) III criteria were used for diagnosis of MetS. We compared MetS and its risk factors between the two groups. Results: There were more gas refinery employees with a body mass index > 30 kg/m2, abdominal obesity, and a high fasting blood glucose level than nonindustrial employees (P Conclusions: The prevalence of MetS among male gas refinery employees was higher than for male nonindustrial employees. Keywords: Cardiovascular disease, industrial employees, metabolic syndrome, obesity

“Refinery Town” Points the Way Forward to Protect Communities and Defend Rights

“Refinery Town” Points the Way Forward to Protect Communities and Defend Rights

Teaching Multivariable Model Predictive Control in a Laboratory Scale Three-tank Process

This paper proposes to study the potential of use a three-tank system in laboratory scale to teach how to design a predictive controller (MPC) applied to a system with multiple inputs/multiple outputs (MIMO). An algorithm that predicts the future behavior of the plant characterizes the controllers (MPC). With a representative model of the process, the algorithm calculates the future optimal control actions that will minimize the error between the controlled variables and their respective reference values, then, only the first values calculated for the plant inputs is sent. These controllers have a high popularity in the academy and in the industry because they provide high performance control systems without requiring interventions of operators for many hours. These important controllers were emerged initially in the 70’s, in order to overcome occurring difficulties in oil refineries and in power plants. Today, MPCs are also in food processing, aerospace industry, and automotive industry among others. The system used in this study can provide students with practical knowledge of automation and process control that it is not possible to be acquired using only the process simulators or theory. For this purpose, a predictive controller based on a linear state-space model was developed and evaluated to check the influence of tuning parameters in the response of variables controlled and the control actions. The mainly parameters studied were the prediction horizon, control horizon and weight of future increases in the system actuators.

The Critical Success Factors for Marginal Oil Field Development in Nigeria

The purpose of this research was to assess the critical success factors of marginal oil field development in Niger Delta region. There are considerable potential of marginal oil field in Niger Delta region. However, it is sad to know that the development of marginal oil fields is lagging or have not been fully successful, despite policy initiative by the Federal Government of Nigeria. Many of the marginal field operators are battling with the issues of funding, social political, environmental and technical issues. Using data collected through document analysis and survey questionnaires from oil and gas experts and other government agencies, the research identified the success factors for marginal oil field development to include collaboration, infrastructure sharing, Joint ventures and partnerships and implementation of corporate social responsibility by the indigenous fields operating in the region. Technical issues associated with marginal field development and policies issues are addressed. The paper concludes that a policy shift and support to the marginal field operators are needed to enhance the development of marginal oil field in Niger Delta region. It also concludes that a favorable investment climate, the development of support infrastructure like refineries and power, financial institutions, as well as collaboration and integration by the stakeholders is essential for the sustainable development of marginal oil field in Nigeria.

Optimisation of Non-isothermal Utilities Using the Unified Total Site Heat Integration Method

Total Site Heat Integration is an effective method for design of large scale utility systems that serve large chemical processes, such as refineries, petrochemicals or even lower temperature chemical and process plants. Total Site Heat Integration of different chemical plants might confront batch, semi-continuous or continuous plants which are clustered into one large site. Excess heat produced from one plant could be transferred to other plants using an intermediate fluid. In this paper, Total Site optimisation of targeting utility generation and consumption for lower temperature processes, which mainly use non-isothermal utilities, is presented. The utility temperature selection optimisation applies to the recently developed Unified Total Site Heat Integration Targeting (UTST) method. The new method shows that, for low temperature processes where non-isothermal utilities are used, the supply and target temperatures of a utility is an important constraint, while for higher temperature processes, where isothermal utilities are applied, no significant change in targets from conventional Total Site are obtained. New heuristics based on UTST method with respect to non-isothermal utility temperature selection are proposed. A Kraft Pulp Mill case study has been investigated in this research, using optimised non-isothermal utilities, showing a 3.6 MW increase in heat recovery, 0.87 MW decrease in shaft work generation, and $ 330,000 /y utility cost saving in the system applying the new UTST method compared to the conventional Total Site method.

Seasonal variations in seawater quality of two tourism affected shores off South Saurashtra Coastline, India

The nature and distribution of the flora and fauna in the aquatic system are mainly controlled by the fluctuations in the physical and chemical characteristics of the water body (Sundaramanickamet al., 2008). The Arabian Sea is considered as one of the most productive zones in the world oceans (Qasim, 1977; De Sousa et al., 1996). Coastal regions between Okha and Bhavnagar is now a hot-spot for mega industries like Refineries, Cement, Chemicals, Soda Ash, Rayon, Power plant, Fertilizer and other supportive industries. This coastline is known for its rich marine life especially intertidal biota in its extended intertidal and sub tidal areas (Shukla and Misra, 1977). Going through the literature it was revealed that water quality studies of this area were patchy and meager (Bhadja and Kundu, 2012). Present studies therefore, have been aimed to set up a seasonal database of standard water quality parameters of five shores along the South Saurashtra coastline which are favorite for setting up mega industries or SEZ's. The investigation was carried out from November-2011 to April-2012 at two different stations Veradale (200 53' N, 700 26' E) and Diu (200 42' N, 710 01' E) along the South Saurashtra coastline of Arabian Sea (Figure 1). Veradale coast being, a part of the biggest commercial fishing centers in Asia, receives a huge amount of wastes, oil and effluents from the port. It also receives wastewater from domestic sewage system as well as from heavy industries and small scale fish processing plants of the city. On the other hand Diu, a small tourist town, is devoid of sorts of major industrial pollution and anthropogenic pressure. Each sampling stations were visited monthly and at least six samples of surface seawater were collected from different locations of the same coast. However, the locations for the collection of samples in a particular coast were fixed. Seawater samples were collected once in a month at uniform space from all the sampling sites for various water quality parameters. All the Parameters were determined following methods given in American Public Health Association (1995) and Trivedi and Goel (1986). Some of the parameters such aspH, Temperature, Conductivity measurement were carried out at site immediately after the collection of the water samples, while for other parameters, sample.

Mathematical Modeling of Catalytic Cracking Fluidized Bed Process for the Production of Hydrocarbons

The purpose of the catalytic cracking process fluid bed is conversion of heavy oil to light hydrocarbon at a lower cost and more reliable method. Some of the products include with the distillates, gasoline and light olefins. Efficient performance of catalytic cracking fluidized bed for the refinery economy is essential and important process in oil refineries. The efficiency of the FCC unit depends to a large number of parameters such as feed composition, residence time, temperature, the ratio of catalyst to feedstock oil, catalytic properties, the partial pressure of hydrocarbons and hydrodynamic riser. In this study fluidized bed catalytic cracking process modeling was performed and operating conditions as input to the program and the results obtained. The modeling of kinetic model was used four lumps, first order and changes in radius is ignored. The balance of energy, mass and momentum are written that yield can be calculated via the mass balance, velocity can be achieved through the momentum equation and temperature profiles during reactor can be obtained via energy balance. Products yield, profiles of temperature and velocity of the gas phase were obtained by using the proposed model. The results showed that feed efficiency is increased and products yields are reduced during reactor length. It was observed that during the process catalyst performance is decreased and also compare the results with experimental results indicate good agreement between the proposed model and industrial results that these results can be used to achieve high-precision products. The mean error is 3.3% for gasoline yield, 5.5% for coke yields and 2% for reactor temperature.

Estimates of safety distances for hydrogen sulfide leak emission from gas refinery

SAŽETAK: Rafinerijski procesi moraju biti organizirani i održavani tako da jamče sigurnost radnika, susjeda i okoliša. Rafinerije su izvor mnogih nesreća i incidenata budući da su opasne tvari, proizvodi i proizvodni procesi smješteni vrlo blizu. Cilj studije je proučiti posljedice raznih scenarija istjecanja vodikova sulfida u plinskim rafinerijama i utvrditi granice zone opasnosti i rizike svakog scenarija. Priroda studije bila je opisno-analitična, a istraživanje je provedeno u plinskim rafinerijama. Za utvrđivanje načina širenja plina i utjecaja njegova istjecanja primijenjen je PHAST software. Razrađeno je više scenarija, a također su utvrđivani i utjecaji različitih vremenskih uvjeta na te scenarije i to na dvije razine, LC (lethal concentration = smrtonosna koncentracija) i IDLH (immediately dangerous to life or health = neposredna opasnost za život ili zdravlje). Rezultati ukazuju da je zona smrtne opasnosti LC50 pri širenju vodikova sulfida i zona opasnosti širenja otrova 224 odnosno 386 m. Također je utvrđeno da je ENI-jevo boravište za radnike smješteno u zoni utjecaja dominantne struje i to na udaljenosti od samo 200 m od rafinerije. U slučaju istjecanja mogu se očekivati znatni gubici života i štete za zdravlje. Stoga je nužno preseliti boravište radnika na drugu lokaciju i poduzeti mjere tehničke kontrole.

Layers of protection analysis to achieve safety integrity level (SIL), Case study: Hydrogen unit of refinery

To identify and evaluate hazard in process industries as oil and gas, there are various methods in which hazard and operability study (HAZOP) and layers of protection analysis (LOPA) are the most common methods. The present study aims to analyze layers of protection to achieve safety integrity level in hydrogen unit of refinery. After performing library studies and data collection of events in refinery, hazards of hydrogen unit as operating nodes and deviations with causes and consequences are identified using HAZOP method. The next stage is presenting corrective solutions by LOPA method and target factor. Then, frequencies are determined for the initiating event by the experts. By completing the sheets of each event, independent layers of protection and integrity level are determined. The results of evaluation of identified risks showed that 11 cases had risk higher than 15 and it is not acceptable. The analysis of consequence of hazards showed that for 6 hazardous points, independent layers of protection can reduce risk as 100% to target factor (10-5) and safety integrity level is fulfilled. Regarding the eighths scenario “elimination of repulsive system of equipment and lines with the high temperature of very hot steam”, layers of protection cannot increase safety integrity level to more than 60% (10-3) and to provide safety to target factor, after eliminating the identified problems, other layers are positioned. In this study, to achieve safety integrity level in hydrogen unit of refiner. A three period plan (short-term, mid-term and long-term) is proposed.

Essar Oil to invest over Rup 1200 crore to upgrade Vadinar refinery

Essar Oil to invest over Rup 1200 crore to upgrade Vadinar refinery

Improving the safety and the operational efficiency of emergency operators via on field situational awareness

In rescue missions, the situational awareness represents an essential tool in supporting rescue team operating in unknown and complex indoor environments. In case of fire in highly congested industrial scenarios (e.g., refineries, oil depots, petrochemical plants, etc.), the smoke may reduce the awareness of the rescuer about potential local resources/hazards, affecting both operational efficiency and personal safety. The mitigation of potential consequences arising from major accidents can be limited providing the emergency staff with tools able to foster their role on field. In this paper, we present the RISING (indooR localizatIon and building maintenance using radio frequency Identification and inertial NaviGation) project that is devoted to support on field operators supplying them with a system for situational awareness and personal indoor positioning. The RISING solution is based on the integration of the RFID technology with the inertial navigation. A set of RFID tags, conveniently preinstalled in the working environment, can store information about their absolute position and the site of local items. This information can be easily retrieved on-the-fly using RFID readers and displayed on smart devices with which the user is equipped (e.g., tablet and/or smartphone) to allow on field situational awareness.

A Mixed-Integer Linear Programming Scheduling Optimization Model for Refinery Production

This paper addresses the problem of production planning and scheduling in an oil refinery process. In the process crude oil is transformed to bitumen and naphthenic special oils. The aim of the scheduling optimization is to decide which mode of operation to use in each processing unit at each point in time, in order to satisfy the demand while minimizing the production cost and taking inventory capacities into account. A mixed-integer optimization model is developed for the scheduling problem. The model can be regarded as a generalized lot-sizing problem, where inventory capacities are considered and more than one product is obtained for some modes of operation. It is shown how the optimization model can be used as a viable tool for supporting production planning and scheduling at the refinery, and that it is possible to analyze scheduling scenarios of realistic sizes.

Modelling and Optimisation of a Crude Oil Hydrotreating Process Using Neural Networks

This paper presents a study on the data-driven modelling and optimisation of a crude oil hydrotreating process using bootstrap aggregated neural networks. Hydrotreating (HDT) is a chemical process that can be widely used in crude oil refineries to remove undesirable impurities like sulphur, nitrogen, oxygen, metal and aromatic compounds. In order to enhance the operation efficiency of HDT process for crude oil refining, process optimisation should be carried out. To overcome the difficulties in building detailed mechanistic models, Bootstrap aggregated neural network models are developed from process operation data. In this paper, a crude oil HDT process simulated using Aspen HYSYS is used as a case study. It is shown that bootstrap aggregated neural network gives more accurate and reliable predictions than single neural networks. The neural network model based optimisation results are validated on HYSYS simulation and are shown to be effective.

Reproducible Research in the Cloud with the Refinery Platform

Reproducible Research in the Cloud with the Refinery Platform

Short-term operational planning of refined products pipelines

Fil: Cafaro, Diego Carlos. Consejo Nacional de Investigaciones Cientificas y Tecnicas. Centro Cientifico Tecnologico Conicet - Santa Fe. Instituto de Desarrollo Tecnologico para la Industria Quimica. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnologico para la Industria Quimica; Argentina

Heavy Metal In Food Ingredients In Oil Refi nery Industrial Area, Dumai

Background: Industrial waste generally contains a lot of heavy metals such as Plumbum (Pb), Arsenic (As), Cadmium(Cd) and Mercury (Hg), which can contaminate the surrounding environment and cause health problems. Bioaccumulation ofheavy metals from the environment can occur in foodstuffs. The study aims to determine levels of heavy metals Pb, Cd, Asand Hg in foodstuffs in the oil refi nery industry. Methods: The analytical method used Atomic Absorption Spectrophotometer(AAS). Samples were taken from two locations, namely: the exposed area and non exposed area. The sample consisted ofcassava, papaya leaves, fern leaves, cassava leaves, guava, papaya and catfi sh. Results: The analysis showed levels ofmetals As in all samples at exposed locations is below the maximum limit of SNI, the location is not exposed only in catfi shlevels of As (2.042 mg/kg) exceeds the SNI. Cd levels of both locations are not detected. Pb levels in catfi sh in exposedlocations (1,109 mg/kg) exceeds the SNI. Hg levels in leaves of papaya, cassava leaves, fern leaves, cassava and fruitpapaya exceed SNI. Conclusion: There has been a heavy metal contamination in foodstuffs. Recommendation: Thelocal people are advised to be careful when consuming food stuffs from oil refi nery industrial area.

Lagrangian decomposition approach for solving continuous-time scheduling models of refinery production problems

Lagrangian decomposition approach for solving continuous-time scheduling models of refinery production problems

What Do Gas Blows, Iron Dust Accumulations and Sulfidation Corrosion Have in Common?

This paper presents an analysis of three process incidents recently investigated by the US Chemical Safety Board (CSB): (i) Kleen Energy natural gas explosion (Middletown, CT), (ii) Hoeganaes Corporation iron dust flash fires and hydrogen explosion (Gallatin, TN), and (iii) Chevron Richmond refinery pipe rupture and fire (Richmond, CA). The starting point for the analysis is identification of the main hazardous materials, activities or conditions underlying the specific incident losses. These are, respectively: (i) Kleen Energy - purging of process pipelines with natural gas, (ii) Hoeganaes Corporation - accumulations of combustible iron dust in work areas, and (iii) Chevron Richmond refinery - a pipeline damage mechanism known as sulfidation corrosion. While the three incidents have many aspects in common, chief among the similarities are the key process safety concepts of inherently safer design (ISD), recognition of warning signs (precursor events), and safety culture. Each incident is analyzed for evidence of these concepts. The analysis is drawn from the relevant CSB investigation reports with the primary objective of illustrating the strong experiential learning that case histories of actual incidents can provide. While the lessons learned from these incidents are useful in and of themselves, capturing these lessons by incorporation in a safety management framework extends their usefulness to the prevention and mitigation of other potential process incidents. A typical process safety management system is employed in the current work to accomplish this secondary objective. Overall conclusions are made concerning the effectiveness of ISD, precursor recognition, and safety culture with respect to risk reduction in the process industries. It is anticipated that this work will help in communication of lessons learned to both the research and practice communities.

CFD Based Reproduction of Amuay Refinery Accident 2012

Amuay refinery accident 2012 is the recent follower of similar nature accidents happened in Buncefield, UK (2005), Jaipur, India and Puerto-Rico, USA (both in 2009), respectively. The failure of a mechanical part i.e. valve or piping led to the escape of a flammable dense-than-air cloud. Approximation of size of such clouds depends on the density of the dispersed gas, atmospheric turbulence (wind, temperature and humidity), gravity and their mutual interactions. Since experimental reproduction of such accidents are not always possible numerical simulations help a lot to understand and replicate the scenarios on qualitative basis. In the present work Amuay refinery accident (2012) is reproduced with a CFD (Computational Fluid Dynamics) model which takes into account the heaviness of the gas (LPG here), wind and gravity driven spread. The extent to which the dispersed gas could travel is specified as LFL (Lower Flammability Limit) criterion. It is assumed that the running vehicles on the street across the plant were the major source of ignition. Scenarios for different atmospheric conditions are considered and compared. For validation purposes also a reproduction of the Thorney Island Trial 26 is conducted.