Efficient gasoline blending is a fundamental strategy in refineries to survive in an environment of increasing competition and an ever-changing geopolitical and economic environment. Operating costs in online gasoline blending are considered to be fixed costs. This means that reducing costs/barrel of feedstock to be blended, and elimination of reprocessing are the keys to increasing the profit of gasoline blending.
Cost-Reducing Actions in Crude Blending
Cost-reducing actions in crude blending include:
- Preventing giveaways
- Errorless switching between blending recipes, different types of gasoline, and summer and winter gasoline
- Maximized incorporation of lower-cost feedstock, without losing required gasoline specification
- Minimizing “high cost” RON boosting feedstock
- Keeping physical parameters closest to those specification borders that can be composed of by utilization of cheapest blend components.
- Fast “adjusting” of the ratio between different process streams, in case physical properties drift away from their required values.
Importance of On-Line Process Analytics
Each component to be blended will differently influence one or more physical properties. This makes online process analytics of a variety of different gasoline properties essential in economic gasoline blending. Whereas conventionally, a complex of different on-line expensive process analyzers, such as knock engines, were required, nowadays the BEACON 3000 NIR process analyzer is a low-cost and simple to-install alternative to measure a broad scope of different physical properties which is performed by one analyzer and by one single measurement.
Benefits of the BEACON 3000 NIR Process Analyzer
The combination of continuous screening of a broad range of physical properties of each incoming feed stream and final blend are fundamentals in economizing gasoline blending. The BEACON 3000 has the benefit of measuring up to a distance of 3 km away from a central analyzer without losing the intensity of the spectroscopic signal. By installing up to eight different measuring probes, various incoming process streams and the blend can be measured by one single analyzer placed in the control room.
Accuracy and reliability are critical in on-line process analyzers. Single sporadic discrepancies between ASTM-measured laboratory results and correlative analyzer results can occur. However, a constant bias between analyzer results and laboratory results is unacceptable. Incorporation of propriety software FREETUNE ™ eliminates continuously occurring incompatibilities between the Beacon 3000 NIR process analyzer and laboratory analyses, by repeatedly validating NIR and lab results.
The correcting actions, which are performed by FREETUNE ™, ensure continuous compliance between predicted NIR values and laboratory measurements of physical properties. The following figures illustrate the correlation between representative BEACON 3000 and laboratory measurements in gasoline over a prolonged period of time.
Accuracy and reliability of online measured quantitative data of the BEACON 3000 NIR process analyzers are the basics to the successful implementation of many gasoline-blending stations worldwide.
Frequently Asked Questions about Gasoline Blending with the Beacon 3000
What is gasoline blending, and how is it relevant to Modcon Systems?
Gasoline blending combines various refined petroleum products and additives to produce gasoline that meets specific quality standards. At Modcon Systems, we provide advanced analytical tools and systems that monitor and optimize the blending process, ensuring optimal product quality.
What are the benefits of blended gasoline?
Blended gasoline has several benefits, including improved engine performance, reduced emissions, and enhanced fuel efficiency. By using advanced process technologies like those developed by Modcon Systems, the precision and effectiveness of gasoline blending can be significantly enhanced, resulting in superior-quality gasoline that meets stringent environmental and performance standards.
What is the typical fuel blending procedure in the petroleum industry?
The typical fuel blending procedure involves measuring and mixing different hydrocarbon streams, additives, and ethanol to achieve desired fuel properties such as octane level, vapor pressure, and emissions characteristics. Modcon Systems contributes to this process by providing real-time analytical data and process optimization solutions that ensure the blend meets the required specifications efficiently and consistently.
What are the key components used in gasoline blending?
The five key components typically used in gasoline blending include:
- Base hydrocarbons (e.g., naphtha, reformate)
- Oxygenates (e.g., ethanol)
- Antioxidants and stabilizers to prevent oxidation
- Detergents to clean engine parts
- Octane enhancers to improve fuel combustion
