Process Optimization & Troubleshooting

Process Optimization Examples

Platformer Unit Capacity Optimization

Successfully increased Platformer unit's throughput to 118% of its nameplate capacity through:

  • Identification and addressing of key bottlenecks in heaters, net gas compressors, and coolers
  • Submission of detailed performance report to UOP for further optimization
  • Implementation of comprehensive monitoring and control strategies

Energy Management Program

Led the implementation of an energy management program using Solomon's Energy Intensity Index (EII):

  • Development of daily monitoring spreadsheets for each refinery unit
  • Implementation of effective benchmarking strategies
  • Identification of 12 major energy consumers (50% of total consumption)
  • Integration of real-time voltage and current readings with DCS for continuous monitoring

Troubleshooting Successes

Penex Unit Catalyst Deactivation

Resolved rapid de-activation issues in 2018 where temperature difference across the active bed was decreasing by 0.25°C per day:

  • Identified NHT catalyst deactivation as the root cause
  • Detected oxygenate slippage into penex liquid feed
  • Implemented corrective measures to restore unit efficiency

CCR Section Corrosion Resolution

Addressed persistent corrosion issues in the vent gas wash tower system:

  • Identified improper mixing of vent gas and caustic as primary issue
  • Discovered inadequate pipeline insulation problems
  • Implemented comprehensive solution to prevent future corrosion

Cost Optimization Initiatives

Nitrogen Usage Optimization

Reduced nitrogen consumption during turnarounds by 50% through:

  • Implementation of vacuum purging strategy (125 mm Hg absolute)
  • Optimization of pressure breaking procedures
  • Update of refinery procedures to reflect new best practices

Process Facility Change Proposal

Introduced cost-saving process change in 2014:

  • Rerouted penex driers knockout bleeder to closed drain
  • Prevented 0.7 M³ weekly waste (0.5 ton)
  • Achieved $350 weekly cost savings

Advanced Process Control Initiatives

APC Implementation

Led the evaluation and implementation of Advanced Process Control solutions:

  • Presented compelling use cases to executive leadership
  • Evaluated solutions from AspenTech, ABB, and AVEVA
  • Positioned refinery for adoption of cutting-edge automation