Resilience-based Integrated Process System

Hazard Analysis (RIPSHA) approach:

Application to a chemical storage area in an
edible oil refinery
R. Pramoth, S. Sudha, S. Kalaiselva
Received 10 December 2019, Revised 19 February 2020, Accepted 13 May 2020,
Available online 22 May 2020, Version of Record 10 June 2020.

Abstract

The hazard that prevails in the chemical storage area of a process industry is
exceptionally high in contrast to other different areas. In the present scenario, upcoming
process industries handle different hazardous chemicals for processing, due to which
the chemical storage area draws more attention with regard to safety. It is very hard to
repair the damages brought about unintentionally in a chemical warehouse. Resilience-
based Integrated Process System Hazard Analysis (RIPSHA) approach is a recently
developed methodology to examine the varied nature of an accident. In this study,
storage areas of chemicals, namely sulfuric acid, phosphoric acid, hydrochloric acid,
caustic (sodium hydroxide), ammonia in an edible oil refinery in South India were
considered for resilient analysis. The results of the study were made in RIPSHA
worksheet and represented graphically. The existing risk has been adequately
investigated in both plant system layers and managerial system layers, and it has been
found that the safety precautions and structural design of the chemical storage area
needed development.
Decarbonizing the oil refining industry: A
systematic review of sociotechnical systems,
technological innovations, and policy
options
Steve Griffiths a, Benjamin K. Sovacool b, Jinsoo Kim e, Morgan Bazilian d, Joao
M. Uratani
Received 1 December 2021, Revised 11 January 2022, Accepted 4 February 2022, Available
online 17 February 2022, Version of Record 17 February 2022.

Abstract

The oil refining industry, which was established in the mid-19th century, has become a
foundation of modern society. While the refining of crude oil to produce transportation
fuels, petrochemical feedstocks and a variety of other products has brought manifold
benefits, it has also led to the global proliferation of greenhouse gas emissions as well as
local air pollution from the combustion of fossil fuels. The industry is therefore
confronted with a growing need to decarbonize its operations, as well as to support
decarbonization of the end use sectors that it directly enables. This paper provides a
systematic and critical literature review to uncover the means by which the oil refining
industry can decarbonize and evolve as part of an increasingly carbon constrained
future. A sociotechnical perspective is used to understand the full range of industrial
and economic activities where a decarbonized oil refining industry is expected to remain
important and to provide the framework to assess key technical, economic, social and
political factors that will likely impact the evolution of the oil refining industry. We
highlight key opportunities for this industry to decarbonize while also exposing gaps in
the existing literature concerning its decarbonization. The insights provided are
expected to support policy makers, researchers and practitioners with the tools needed
advance a low-carbon transition of the oil refining industry.
Palm oil refining
Véronique Gibon, Wim De Greyt, Marc Kellens
First published: 12 April 2007

Abstract

Crude palm oil is rich in minor components that impart unique nutritional properties.
The most relevant are tocopherols and tocotrienols (vitamin E) and carotenoids (α- and
β-carotene). Palm oil is generally refined by the physical process, which is preferred over
the chemical process since high acidity (up to 5%) can lead to excessive loss of neutral
oil in the soapstock after alkali neutralization. The quality of the crude oil is to be
considered as it can greatly affect the efficiency of the refining process and the quality of
the end-products. The deterioration of bleachability index (DOBI) is a good indicator of
the capability of palm oil to be successfully refined. Beside commodities, especially
refined oils open a market for new high-quality products like golden palm oil, red palm
oil, white soaps, fractionated products (CBE), etc. Optimization of the deodorization
technology and of the process conditions for a maximal retention of natural
characteristics without affecting the quality of the palm oil is an important challenge.
LUBRES: An expert system
development and implementation for
real-time fault diagnosis of a
lubricating oil refining process
Yu Qian , Liang Xu , Xiuxi Li , Li Lin , Andrzej Kraslawski
a a b a a

Available online 15 September 2007.

Abstract

An expert system LUBRES (LUBricating oil Refining Expert System) is introduced in

this paper. It helps plant operators in monitoring and diagnosing of abnormal situations
in refining process of lubricating oil. The LUBRES structure, the knowledge base, and
the inference machine are presented in detail. A new strategy is proposed for conflicts
resolution – the sorting strategy of antecedents, and a selection strategy of knowledge
rules in the memory knowledge base. Knowledge acquisition mechanism is based on an
empirical knowledge table, while knowledge verification is carried out based on
the directed graph approach. C++Builder and SQL Server 2000 have been used in
developing the proposed system. LUBRES has been successfully implemented in
Microsoft Windows Server environment. For 1 year, LUBRES has been used for
monitoring and diagnosing of refining process of the lubricating oil. The industrial
application of LUBRES proved its high reliability and accuracy.
Smart Manufacturing for the Oil
Refining and Petrochemical Industry
Zhihong Yuan a, Weizhong Qin b, Jinsong Zhao
Received 20 December 2016, Revised 9 March 2017, Accepted 10 March 2017, Available online
12 May 2017, Version of Record 12 May 2017.
Available online 22 March 2017

Abstract
Smart manufacturing will transform the oil refining and petrochemical sector into a
connected, information-driven environment. Using real-time and high-value support
systems, smart manufacturing enables a coordinated and performance-oriented
manufacturing enterprise that responds quickly to customer demands and minimizes
energy and material usage, while radically improving sustainability, productivity,
innovation, and economic competitiveness. In this paper, several examples of the
application of so-called “smart manufacturing” for the petrochemical sector are
demonstrated, such as the fault detection of a catalytic cracking unit driven by big data,
advanced optimization for the planning and scheduling of oil refinery sites, and more.
Key scientific factors and challenges for the further smart manufacturing of chemical
and petrochemical processes are identified.
Analysis and simulation of an
industrial vegetable oil refining
process
Gabriele Landucci , Gabriele Pannocchia , Luigi Pelagagge , Cristiano
a a b

Nicolella a

Received 10 August 2012, Revised 1 November 2012, Accepted 27 January 2013,

Available online 4 February 2013.

Abstract

This work focuses on the performance analysis of an industrial vegetable oil refinery.
Using a commercial process simulator, a process model was developed and validated
against actual vegetable oil refinery field data. The simulator allowed investigating both
energy and safety aspects related to the presence of residual extraction solvent
(extraction grade hexane) in the processed crude vegetable oil. The critical nodes for
hexane accumulation in the process were evaluated, both considering ordinary operative
conditions and undesired process deviations due to increase of the hexane content. In
this latter case, the control actions able to restore the normal operation were simulated,
in terms of increased utility consumption (e.g., motive steam for ejectors and cooling
water) or by modifying and optimizing equipment operating conditions. Finally, the
possibility of flammable mixtures formation inside process vent pipes, caused by the
entrainment of air due strong vacuum conditions, was also investigated.

Highlights
► We modeled the refining process of crude seeds oils extracted with hexane.
► We implemented a detailed simulation model on UniSim® Design.
► The effect of residual hexane on the refinery energetic performance was investigated.
► The operating conditions were optimized according to the hexane content.
► The possibility of flammable mixtures formation in vent pipelines was evaluated.
Renewable Diesel Fuel from
Processing of Vegetable Oil in
Hydrotreatment Units: Theoretical
Compliance with European Directive
2009/28/EC and Ongoing Projects in
Spain
Daniel Garraín, Israel Herrera, Carmen Lago, Yolanda Lechón, Rosa Sáez
Received August 2nd 2010; revised August 5th 2010; accepted August 10th 2010.

ABSTRACT
Oil hydrotreating units in refineries are aimed at reducing the sulfur content of fuels to
accomplish standard particular specifications. However, this process is currently one of
the best available technologies to produce biofuels from vegetable oil in a refinery.
Vegetable oils can be processed or co-processed in these units if several adaptations are
performed, so some properties could be improved in comparison with conventional fuel
such as density and cetane number. This study highlights the theoretical greenhouse
gases (GHG) emissions (using a life cycle assessment–LCA-approach) of a hydrotreated
vegetable oil (HVO) from bibliographical data. Results were compared with other
biofuel production processes, such as those obtained by transesterification of vegetable
oil (FAME, fatty acid methyl ester). It has also been included the comparison with
conventional fossil diesel as a benchmark in order to assess the theoretical compliance
with GHG savings proposed in European Directive 2009/28/EC. Finally, ongoing
projects and future perspectives in Spain are mentioned.
Controlling the Oil Rectification
Process in a Primary Oil Refining
Unit Using a Dynamic Model
A. V. Zatonskiy, L. G. Tugashova, N. N. Alaeva & K. L. Gorshkova
Published: 07 February 2018
Abstract
The composition of Devonian oil has been simulated using an experimental true-
boiling-point (TBP) curve, and the physicochemical properties (density, molecular
weight, enthalpy, etc.) of the feedstock arriving at the plant have been calculated. The
optimization criterion proposed is the calculation of the yield of light fractions. The
optimization problem with constraints on variables (initial and final boiling points of
light fractions) and constraints in the form of inequalities (overlapping neighboring
fractions) using the function fmincon has been solved and implemented in the
programming environment Matlab. A nonlinear dynamic model of the oil rectification
process has been developed and implemented. The Matlab ode 15s solver and the
explicit second-order Euler method have been used to develop the model. The model in
the form of a system of algebraic–differential equations has been applied to the
distillation column control system of an atmospheric pipe still at a small oil refinery. In
the case of controlling according to the model, the column profile temperatures are
maintained at optimal (preset) values and the quality of the petroleum products is also
maintained. A comparison has been made between two operating modes of the
distillation column in the processing unit. The results of the study suggest the following.
The method of controlling in accordance with the model provides an increase in the
recovery of light products through the use of optimization and the dynamic model,
shortening of the overlap intervals of the temperatures of the gasoline and diesel
fractions, and a decrease in deviations of the boiling points of petroleum products.
IMPROVING THE QUALITY OF
PROCESS MODELS IN OIL
REFINERY INFORMATION SYSTEMS
Viacheslav I. Kuvykin Mikhail Yu. Petukhov
Received 29.08.2018 Accepted 23.02.2019

Abstract
The paper considers the ways to improve the quality of oil refinery process models in
information systems at various management levels (ERP, APS, MES). The authors
demonstrate the necessity to introduce a universal (basic) for all management systems
in order to ensure their effective interaction and integration. It has also been shown that
a universal basic model is a subset of models of interacting systems based on balance
principles. The results of the practical implementation of the present approach at oil
refineries are presented in the article along with the proposed ways to optimize the basic
model. It should be noted that the development of a universal model can improve
knowledge transfer and increase labor efficiency of personnel.
A simulation modeling approach
used in the crude oil refining
process
Larisa Tugashova1, Ruslan Bazhenov2, Umut Abdyldaeva3, Irina Korosteleva4 and Elena
Muromtseva
Published: 2022

Abstract
Mathematical and simulation modeling methods are applied when defining parameters
of effective operation of oil fractionation. There is a review of software packages of
process modeling used for refining ventures in the study. Multisphere model of oil
fractionation with a low capacity applied is offered in the paper. The designed model
allows taking into account constructive peculiarities of the equipment of small capacity
units. The flow diagram of the model calculation algorithm with the additional evaluator
of petroleum products quality indices is given by the authors. A design matrix for a
three-factor experiment involving a multisphere model is obtained. An orthogonal
central composite design has been applied to improve the accuracy of the model and to
consider a non-linear parameter link. The MatLab software was chosen as an enabler.
The criterion was the energy cost of separation. Factors affecting the criterion are flow
rate of superheated water steam, reflux rate, potential light fractions in the crude/feed.
The adequate obtained regression quadratic dependency towards the initial values by
Fisher's criterion has been assessed. The average relative error was 0.21 percent. The
obtained statistical model can be applied for solving an optimization problem by the
criterion of power consumption within a variable fractional composition of the raw
material. Quality indices of oil products (gasoline fraction and diesel oil) serve as
constraints. The offered statistical model applied at oil fractionation low-power facilities
promotes the efficiency of plant operation improvement and the efficiency of obtaining
information about the quality of oil products.
Paraffin-based crude oil refining
process unit-level energy
consumption and CO2 emissions in
China
Feng-Rui Jia , Wan-Ting Jing , Guang-Xin Liu , Qiang Yue , He-Ming Wang , Le
a a b c c

i Shi
Received 26 September 2019, Revised 11 January 2020, Accepted 31 January 2020, Available
online 1 February 2020, Version of Record 5 February 2020.

Abstract

Petroleum refining is a technology complex, energy- and CO2 emission-intensive

industrial process, which is affected by the type and property of the crude oil. China has
been the exploitation of crude oil to paraffinic most. This paper targets to quantify and
evaluate the material or energy metabolism and environment loads of paraffin-based
petroleum at refining process unit-level through the established petroleum flow and
energy flow on the CO2 emissions accounting framework and explores energy
conservation and CO2 emission reduction pathways and policy implications, using a
typical paraffin-based petroleum refining enterprise in China as a case. The results
indicated that the crude oil from the inputs were fractionated in the atmospheric and
vacuum distillation (AVD) unit, and its energy consumption and CO 2 emissions
accounted for 14.38% and 13.2% of the total energy consumption and CO 2 emissions in
the case study, respectively. With the transformation of petroleum refinery plant
structure, fluid catalytic cracking (FCC), ketone benzol dewaxing (KBD), and delayed
coking units dominated more energy consumption and CO 2 emissions. FCC unit was
both the largest energy consumer and supplier, flue gas waste heat recovery efficiency of
which was an important factor affecting energy conservation and CO 2 emission
reduction for FCC unit and even enterprise. KBD unit records the largest energy and
CO2 emission intensities, which are 67.95 kgce/t product and 256.82 kgCO 2e/t product
respectively, due to the high wax content of paraffin-based crude oil and the coal-
dominated power generation structure. Based on these research findings, three
mitigation policy recommendations were proposed, including the improvement of
energy efficiency, optimization of energy consumption structure and product output
structure. Carbon capture and storage can reduce CO2 emission by about a third in the
concentrated units of primary energy consumption (i.e. AVD, FCC, and DC). The results
of this paper are key components of the life cycle assessment of the CO2 emissions
of petroleum fuels produced by domestic paraffin-based crude oil.
Thermodynamic analysis and techno-
economic assessment of fluid
catalytic cracking unit in the oil
refining process
Masoud Nahvi , Ahmad Dadvand Koohi , Mehdi Sedighi
a a

Received 29 January 2023, Revised 4 April 2023, Accepted 8 May 2023, Available online 16
May 2023, Version of Record 24 May 2023

Abstract

Fluid catalytic cracking is an important, expensive, and energy-consuming unit that

produces light olefins, gases, and naphtha from heavy residues. This study aims to
increase light products and reduce heavy products at the FCC unit, simulated using
Aspen HYSYS software. Exergoeconomic analysis using the Sankey diagram was
performed for the first time for this unit, which provides the possibility of determining
the important quantities in the process from a thermodynamic and thermo-economic
perspective. Based on the results, the atmospheric tower consumes the most energy
(about 64%) and is the most destructive unit which is responsible for 61% of exergy
destruction. In terms of energy consumption, the FCC unit is ranked second with 16%.
However, the FCC unit with 11% share is the third destructive unit, but an exergy
efficiency of 98% was observed in this unit. A total of 267 MW of the tower's exergy was
destroyed, making it the second most destructive unit in the plant. Compared to other
process units, the FCC unit accounts for 9% of the total cost, while the fractionator tower
is the most expensive unit in the process at 48%. The Sankey chart shows crude oil has
the highest cost stream at $744,145 per hour. The FCC unit has the highest
exergoeocomic factor, while the cooler has the lowest exergoeconomic factor, with
2.4 M$/h cost of exergy destruction, as well as the lowest exergy efficiency.
Development of adaptive control
system for technological facility of
primary oil refining
Aygun Safarova, J. Damirova, Ismayil Huseynov
Published: 29 September 2023

Abstract
As it is known, primary oil processing facilities are designed for the production of light-colored
oil products and various oil fractions that meet modern requirements with their quality. The
main equipment of these technological facilities are rectification columns operating under
atmospheric and vacuum conditions, which perform the decomposition of crude oil and fuel oil
into various product fractions. Generally, the quality indicators of product fractions produced in
these columns are provided by stabilizing the temperature modes at certain points (plates) of
these or rectification columns by regulating the irrigation consumption supplied to those plates.
It should be noted that currently, in accordance with the requirements of the time, the design
and development of new control systems that can adequately respond to more dynamic and
variable external and internal stimulating influences for complex oil refining technological
facilities is one of the main problems facing the automatic control theory. The paper is dedicated
to the issue of developing a new automated control system that can provide the required
accuracy in terms of quality management. As an adaptive control system, the purpose of such
systems is to compensate in time for disturbance influences in the technological devices and to
ensure the production of oil products with stable quality indicators, regardless of these
influences. The purpose of study is to develop a control system that can meet the given
requirements and ensure the produced products with relatively stable quality indicators,
regardless of the controlled and uncontrolled exciting effects affecting the oil refinery
technological complex. The principle of operation of this system is based not only on the
compensation of disturbance influences but also on the calculation of new operation strategies
depending on these effects. The development of new automated control system that is able to
provide the necessary accuracy of quality control in the lack of information is relevant.
INTELLIGENT CONTROL SYSTEMS IN
OIL REFINING PROCESS
Nigar Abdullayeva, Momunat Shirinova Nigar Abdullayeva, Momunat Shirinova, Kamala Aliyeva Kamala Aliyeva
Published: 25 August 2023
Abstract
The oil refining industry is an industry with high requirements for process control.
Nowadays, an important problem is the creation of the concept of control systems for oil
companies and enterprises. Oil is one of the Earth's most important resources. Its
extraction and processing have become relevant for mankind. However, in the modern
environment, the tasks of extracting oil with the latest equipment, as well as the use of
cleaning and processing with minimal losses, have become important. This paper
discusses intelligent control systems and their use in the oil refining industry. The
purpose of the abstract is to create a structure that will be useful in the respective
enterprises. But in order to achieve the goal of the work, it will be necessary to take into
account such common problems as the instability of demand; restrictions imposed by
the state and many others. That is why the features of each enterprise, which may bring
various risks in the future, are considered at the design stage. Also, (it is necessary to
indicate that,) the implementation of intelligent control systems in various industries is
a time-consuming process. In these situations, the heads of enterprises need to take into
account the human factor and help their employees adapt to new systems in every
possible way. Among these methods, there are incentives with awards, the introduction
of a team to train how to work with intelligent systems, and others. To delve into this
topic, it is initially necessary to consider intelligent control systems separately from the
oil refining industry.