A large U.S. Gulf Coast refinery sought a more rigorous and accurate tool than its existing linear programming (LP) model to evaluate process optimization and margin improvement opportunities.
Over years of expansion, the refinery had evolved into a complex configuration with multiple crude units, hydroprocessing units, cokers, and other processing units. The refiner needed a high-fidelity, refinery-wide model that could assess “what-if” scenarios—such as stream rerouting, operating condition changes, and new capital projects—while delivering deeper operational insights and stronger economic justification.
KBC partnered with the client to develop a refinery-wide Petro-SIM® flowsheet, integrating every process unit—from crude supply through product blending—into a single, intgerated model.
To achieve this, KBC:
Even with limited lab data, KBC’s refining expertise filled information gaps, creating a robust and validated model that mirrored real-world refinery performance.
The refinery now uses its refinery-wide Petro-SIM flowsheet as a strategic tool for planning, optimization, and investment evaluation.
The model enhances decision-making confidence and margin capture potential by:
With a validated, physics-based model, engineers and planners can now evaluate scenarios, quantify economic impact, and prioritise the most profitability opportunities.