Geelong Refinery Plant Visit Report

By: Lanz Eidrich M. Manansala

School of Mechanical and Manufacturing Engineering, Mapua University Muralla St.,
Intramuros, Manila, 1002, Philippines

Overview of the Company

Viva Energy is a leading energy company that supplies about a quarter of Australia’s fuel
requirements. They make, import, blend and deliver fuels, lubricants, solvents, and bitumen
through their extensive national and international supply chains.

They are the exclusive Australian licensee of one of the world’s most recognizable brands, selling
high quality Shell fuels and lubricants to motorists across the country.

For industry, they provide the fuels, lubricants and support their customers in the transport,
mining, aviation, marine, manufacturing, defense and construction sectors need to keep their
businesses moving.
 Figure 1. Geelong Refinery

Viva Energy’s Geelong Refinery began operations in 1954. Today it’s one of two refineries
remaining in Australia, employing around 700 people and supplying over 50 percent of Victoria’s
and 10 percent of Australia’s fuel. The refinery can process up to 120,000 barrels of oil per day,
manufacturing petrol, diesel, LPG, jet fuel, avgas, bitumen, specialty solvents for a wide range of
industries, and Low Aromatic Fuel to support the Federal Government’s petrol-sniffing
prevention program.

Geelong Refinery manufactures and supplies more than half of Victoria’s fuel requirements.
Employing more than 700 people, their refinery is the only manufacturer of bitumen, solvents
and avgas in Australia, and a vital part of the country’s energy security.
Summary of the Manufacturing Process

Figure 2. Delivery of Crude Oil to the refinery

Figure 3. Distillation Tower

Delivering crude oil to the refinery is the first step in the process. While some crude oil comes via
pipeline or road tanker, the majority is unloaded from ships at their pier. After that, it is kept in
crude oil tanks that continuously supply our refinery units seven days a week. But when the crude
oil is heated and separated in crude distillation towers, where the many different hydrocarbon
molecules in crude oil are separated over the range of their boiling temperatures, the refining
process really starts.
 Figure 4. Variety of Products

As a result, a variety of gases and liquids are derived from crude oil that are used to make various
products. Other products had entered the tower at cooler temperatures and different heights,
formed by residue removed from the bottom in the form of bitumen. Products are gathered on
trays as they condense into different liquids, and the lightest gases are recovered for LPG as they
ascend to the top.
 Figure 4. Complicated Network of Pipes

The fuels are then moved about the refinery by a complicated network of pipes, which keeps
them separate and directs them to storage or additional processing. They need to produce as
much gasoline and diesel as possible because those are the items they need most.

Figure 5. Conversion Units

Figure 6. Cracking

Figure 7. Reforming
 Figure 8. Alkylation

Refineries use conversion units; in the case of Geelong, these include an alkylation unit, a
reformer, and a cracker or catalytic cracker. The heavy, long-chain hydrocarbons are cracked into
lighter, more usable molecules and gases. Reforming uses heat pressure and a catalyst to upgrade
the naphtha gas produced during distillation and cracking into new compounds for blending and
alkylation chemically reshapes key compounds generated through distillation to form the larger
branch to chain molecules crucial for high octane fuels like shell V-power. The result of these
various conversions are higher octane components for petrol blending and increase output of
diesel or LPG fuels.
 Figure 9. Petrol and Diesel Blending Units

One of the last steps in the refinery process for diesel and petrol is blending this is far more than
a simple mixing here fuel components are blended to achieve optimal performance and fuel
economy in the final product before being stored in tanks prior to transport. The flare works to
expel any extra gas created during refining safely throughout this time. To ensure the safety of
our community, people, and environment, everything is carried out in accordance with the
toughest processes and regulations. Even better, all of their fuels are routinely tested in an on-
site laboratory to guarantee that they consistently satisfy the highest quality standards and
regulatory requirements. Once finished, fuel is transferred to a new port terminal to serve
Victoria's urban and regional districts, and then it is available for delivery to gas stations and
commercial customers through trucks or pipelines. The cycle of the refining process is finished
by fuels being delivered out from the jetty.

Comments/Realizations/ Interest for working in that company

The processes of the refining of petroleum shown in the video were all interesting, especially the
reforming process where it uses heat pressure and a catalyst to upgrade the naphtha gas
produced during distillation and cracking into new compounds, then the new compounds are
used for blending and alkylation which are the key processes for having a high-octane fuel like
the shell V-power, which is famous fuel used on racecars. Also, I like the way that they ensure
the safety not only their people but the community surrounding their plant and also, they
guarantee that they produced high quality and regulatory specified products for their consumers.

I realized that in this kind of industry there are many processes involved not just the refinery
process also the exploration and transportation of the petroleum and it is fun to learn about
them in this age, this kind of information is helpful in deciding on what future industry should I
pick as a mechanical engineering student.

I am interested in working with this company because it can develop more of my growth as an
engineer in the future knowing that this company is established for a long time and still operating
at this time. I also like that they are committed in operating safely and protecting the
environment and the communities is one of their goals. I truly agree to on their other goals
towards sustainability, diversion and inclusion, climate change and human rights