Gasoline Blending System
Modern hydrodynamic (stream) blending plants have shown themselves in industrial operation as economic, accurate and steady means for high-quality motor fuel production with optimal prime cost. In comparison with existing technology of components blending at blending vessels, reached economy and increasing of production profitability can force investment return up to 60 % for a year and provide project payback for one year or less.
HYDRODYNAMIC BLENDER Blending process is used in hydraulic blender. This process allows supplying of all components simultaneously according to the set formula to batching collector. Through the collector finished product is delivered to storage vessel. The advantage of such technology is in the following: each component dosing accurate control, substantial reduction of batching process duration, no need in batching vessels for finished product homogenization. In the course of blending process at stream mixer the consumption of each component are permanently controlled for the purpose of providing finished product outlet with steady quality parameters, set with the formulas. Finished product, received from stream mixer, has homogenizing structure and component content in accurate compliance to set formulas.
Expected economic parameters growth According to our experience, using of one hydrodynamic blending plant for gasoline production can bring НПЗ 3-5 millions USD in a year due to economy, while annual gasoline production is about one million tonns. Inventory amount reduction Substantial reduction of blending cycle duration and steady outlet of finished product (no need in second batching) allow to speak about inventory amount balance reduction. Tank reserve operation rate decreasing Proposed technology provide tank reserve operation rate decreasing with the help of reduction of storage vessels due to technology process speeding up. With the help of traditional blending method in lots, production of one batch takes more than 40 hours in average. The same quantity of finished gasoline can be produced for less than 11 hours, using hydrodynamic blending plant. All these can provide economy of 1-2 million USD due to refusal of building new storage vessels. Production profitability risen, optimal component usage Production optimization system under condition «out of the real time» allows reaching optimal usage of components, availavle on НПЗ, having risen low-prime cost component portion in formulas of blending process, and also balance raw material inventory and their consumption for wide range of blending operations. According to our experience typical economy can come to 0,25–1,12 USD for one thousand litres of produced gasoline. (The economy is from 150 up to 480 USD per shift). labour outlay and operating personnel reduction Using of hydrodynamic blending plants and automation system help to reduce batching process duration and the quantity of the personnel, involved in batching process and laboratory analysis making.
Tank reserve automation maintenance allows refusing big quantity of operators, necessary for valve-frame and pumps manual maintenance. At the expense of this expected economy can come to 500 thousand USD. OTHER ADVANTAGES
Efficient and optimal usage of equipment;
Blending process automation;
Reduction to minimum the influence of changes in the process of raw material recycling at technological units НПЗ on the quality of finished product, received at blending plants;
Reduction to minimum transport dead time while finished product shipping;
Product level control at the vessels helps to use their vessels at most rate;
Blending process planning improvement;
Reduction of labor trade, professional development of the personnel and increasing professional interest.