Assumption of the hottest future refinery

2022-07-26
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Future refinery ideas

as a senior director of the global oil refining industry, Marcelo carugo, together with expert teams from Emerson departments, leads the implementation of oil refining projects. Carugo has accumulated 30 years of rich industry experience in the oil refining and petrochemical industry. Its areas of expertise include leveraging technologies to improve refinery profitability, optimize operations, and improve compliance and reliability. Mr. carugo holds a master's degree in electronic engineering from Nuffic in the Netherlands and a degree in electronic engineering from the University of Buenos Aires

it is unrealistic to try to predict the global refining Market in 2026. The only thing we can be sure of is the uncertainty of the market. The development of electric vehicles, alternative energy and artificial intelligence, the intensification of market fluctuations, political uncertainty and the continuous improvement of people's living standards in developing countries are only some of the factors that will affect the development of the oil refining industry in the next few years. We can only speculate that this unprecedented rate of change will have a significant impact on the next 10 years

since we cannot predict the future, refiners need to plan ahead to meet the challenges posed by the unknown. In other words, future refineries should always be ready for the future

around the following three basic operational and business objectives, we can achieve this goal:

flexibility. Future refineries can quickly switch between fuel oil and petrochemical products in order to fully respond to market demand and seize market opportunities

reliability. By 2026, benchmark refineries with the best operating performance will basically realize non shutdown operation

sharing intelligence. In the future, successful refineries will simplify business processes and realize automation, and enterprises will be able to share professional knowledge and make joint decisions across facilities

if the above three points can be successfully achieved, the refinery in 2026 will be able to easily cope with various challenges and opportunities brought about by technological development, market changes and global events

flexibility. In the next 10 years, the pursuit of business flexibility is likely to become the yardstick to distinguish successful enterprises from failed enterprises

in the future, benchmark refineries with the best operating performance will be able to seize fleeting opportunities, rather than missing opportunities due to failure to respond in time. If the business director has mastered the integrated data analysis of all processes from the source of crude oil to the gas pump, he can determine the types of raw materials and products in real time according to the market demand. If managers can access supply chain data, timely inventory will become the new normal

to achieve these goals, a large number of new challenges need to be met. One of the challenges is how to design relevant production facilities to handle different crude oils from various sources, including the heaviest and most corrosive crude oils. In order to ensure timely response to market changes and quickly switch production, Jinan gold assay experimental machine also attaches great importance to its hardware types. It may be necessary to keep some process units in hot standby state to avoid time waste caused by its startup and shutdown process. This operation can also reduce the risk, because transient operation is the most common cause of safety accidents

however, greater flexibility in the front end of the plant is not enough to ensure profitability in all markets. Refineries should become facilities that can be freely converted between multiple purposes to help meet the global demand for fiber and plastics, not just limited to the production of fuel oil. The functions of operators in the industry will be more diversified through the small batch manufacturing of intermediate products with rich categories and the rapid conversion from fuel oil to petrochemical products. In order to process all these output streams, an independent refinery may need up to 50000 additional data points, and each data point needs to be easily reconfigured to adapt to different process conditions

reliability. If the refining industry can finally solve the problem of poor reliability, downtime and the attendant high costs will become a thing of the past. For example, thermal overhaul can avoid process unit shutdown due to maintenance or replacement of components. By redesigning the valves and other equipment, it is easier to view the easily worn parts, and the staff can complete the maintenance in situ on site, avoiding the interruption of production

dedicated asset reliability network is another promising field. These networks will provide operators with a virtual perception dome on the whole facility, so as to provide them with the type and amount of information needed to implement the remote maintenance strategy based on actual conditions. With the help of self diagnosis equipment and early alarm management, maintenance and management personnel can also know the abnormalities in a far place in advance to prevent production stoppage or chaos that will affect production capacity

today, the average refinery has less than 20% of its total assets equipped with a continuous asset health monitoring program. However, due to the continuous development of cost-effective wireless technology, this range will rapidly expand to 60% within 10 years. Microsensors can even float inside the product, transmitting instant quality readings between process units

sharing intelligence. The organizational structure of the refinery will also change fundamentally. Field staff can be reduced by 50% in the next 10 years. Soon, staff will only arrive at the site when performing specific human tasks. Decision makers (management, business operation, reliability, engineering and integration departments) can remotely link to one or more plants and command the entire refining system through a single, centralized operation center

in addition, automation will continue to change many conventional operations that are traditionally operated manually. With the help of the augmented reality helmet with head up display function, the maintenance personnel can effectively bring the control room personnel to the site. The UAV will be used to locate short-term discharges/leaks, search for fault locations, and identify pipeline and vessel integrity issues in hard to reach areas

these innovations have a great impact on the safety of the oil refining industry by identifying potential problems that are about to occur and reducing the time workers spend in hazardous areas. Other developments may also include:

breakthroughs in chemical engineering may lead to the continuous regeneration of the existing catalyst of the professional laboratory machine manufacturer in Jinan, so as to maintain the continuous operation of the production process

the learning function of the machine may enable the factory to absorb the knowledge of operators and make immediate adjustments to changing conditions

with the progress of science and technology, one day the refiner may realize the automatic startup and shutdown of process units, eliminating manual intervention and further increasing safety

refineries may soon be able to recycle almost all the waste they produce, and new carbon recovery and sequestration methods may permanently change the way producers deal with compliance. By 2026, the waste gas flare and waste water dump tank may be abandoned by the times

these advances may seem unimaginable, but they are very irregular in shape. The fact is that most of the knowledge and technology needed to achieve these future visions have now emerged. For example, the development of information technology in recent years has allowed enterprises to remotely access a large amount of data and make full use of professional technology and experience, without geographical restrictions. Therefore, oil refiners are beginning to make full use of big data analysis results and new collaboration technologies to integrate their business operations

in addition, the latest progress in humanized design has made the operation easier and the demand for on-site experts better; The overall energy density of wireless instruments has been improved and more widely used in the industry, and some oil refiners are starting to hire remote control UAVs to collect the required measurement data

to occupy a place in the market in 2026, refiners should immediately start to adopt and integrate these innovative technologies. Waiting and waiting will only lose the county level. In order to better develop in the face of unknown and uncertainty, it usually means that operators should dare to challenge the status quo. In the world situation of reshaping oil refining, overcoming resistance and striving for change will become more critical

after all, as someone said, the future belongs to those who are willing to make preparations today

originally published on: July, 2016, hydrocarbon processing, and the use has been licensed

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