Our client is an integrated North American energy company seeking a non-capital improvement project to reduce their gasoline quality giveaway at one of their Mid-West refineries. Over 24 weeks, Trindent implemented 15 process changes and management operating systems that reduced quality giveaway by 53%, while increasing butane blending by 25% to increase refining margins by $21,500,000.
How we Made it Happen™
Scheduling and Optimization
- Implemented a process to update MBO and BPC with real-time component quality weightings to improve optimizer utilization by 67%.
- Implemented an RVP backcasting process based on regression analyses to improve prediction accuracy by 0.18 psi.
- Established a cross-departmental Review Meeting with a root cause analysis framework to holistically identify reasons for giveaway and develop actions to address underlying issues.
Execution Excellence
- Developed a Blend Optimization Tool to standardize blend adjustments for quality targets and component constraints when optimizer is not available.
- Implemented standardized blend start-up and execution procedures, supported by targeted coaching to reduce Operator driven variability and ensure consistency across shifts.
- Conducted training and developed Blend Guide Cards to standardize blend execution process across all shifts.
- Implemented real-time blend optimization and installed structured processes to APC utilization, resulting in a 31% increase in butane blended into gasoline.
- Aligned blend laws in MBO and BPC to minimize execution giveaway.
Measurement Accuracy
- Improved Raman prediction accuracy for blend and component stream by developing a site-specific modelling approach.
- Developed a butane property calculator to replace static butane quality assumptions in MBO, capturing 1.10 ON and 1.40 psi of variance.
- Implemented a statistically-driven ABB RVP analyzer bias management program to reduce variance between online and lab RVP readings by 0.13 psi.
- Installed a quality giveaway oversight tool and giveaway-specific KPIs to track and evaluate performance on a weekly basis and communicate
- Developed a methodology to determine V/L with chemometric or direct ASTM D4814 calculations to enable real-time blend control.
“Your team’s commitment to collaboration was a clear differentiator. By thoughtfully challenging established practices and working closely with our operations at every level, novel and meaningful opportunities were identified and brought to fruition. This approach fostered open dialogue and trust while reinforcing accountability and alignment across the organization, enabling greater ownership of performance and results.”