Our client is a Fortune 500 agricultural cooperative with a strong presence in North American agronomical and energy markets. They requested a non-capital margin improvement project to optimize blending practices and tools to sustainably reduce product quality giveaway. Over 26 weeks Trindent implemented 11 changes reducing octane giveaway by 45% and volatility giveaway by 52%, improving margins over $10,500,000.
How we Made it Happen™
Planning and Optimization
- Reduced neat octane blend targets by implementing post ethanol blend reviews to better understand finished product give-away and added risk mitigation procedure to remedy potential low octane product by utilizing stored alkylate to re-blend.
- Developed a standardized Blend Optimization Tool to generate run down recipes and recipes for touch-ups along with a detailed instructional guide to ensure system and process sustainability.
- Developed a customized CHS Blending Deskbook for achieving blend optimization for abnormal operating conditions.
- Implemented a pricing update process for blend tools and the Giveaway Dashboard to maximize real time blend value.
Execution Excellence
- Implemented Mid Blend and Touch-up Tool with Pumphouse Operators, automating and standardizing recipe generation, enabling optimization of giveaway prior to blend completion (including nights and weekends) and minimizing need for Touch-ups.
- Improved Platformate octane predictability through increased Platformate sampling and automation of sample result upload into RMPC. Improved Platformate octane predictability, enabled better RON control and reduced Platformate RON targets.
- Installed weekly Blend Review Meeting (BRM) to review blend plans and operational constraints, to address performance issues, to celebrate giveaway performance improvements, and to understand root causes for giveaway.
Measurement Accuracy
- Installed a standard operating procedure and align knock engine operating procedures with ASTM (D2699 & 2700) to include rebracketing with new PRFs if the sample fuel falls outside of the bracketing range, use of amber bottles, and proper rounding of results, and conduct regular engine maintenance (i.e., carbon blasting, etc.) to maintain engine accuracy.
- Installed knock engine standardized operating procedures to align knock engine procedures with ASTM best practices.
- Enhanced the ethanol hand blend process to achieve required accuracy with ethanol solution.
- Enhanced sample procedures to maintain sample integrity during Lab tests.
- Developed and implemented RAMAN models for finished gasoline and Platformate streams to improve visibility into changing A23 properties, reduce octane result times for Touch-ups opportunities, and better control Platformate RON.
“Working with Trindent has been a truly collaborative experience, bringing our team closer together and fostering cross-functional communication and cooperation. Their commitment to sustainability has made it easy to adopt new processes and tools, ensuring we can carry forward the improvements achieved during the project and continue building on them.”