Refinery Process Yield Optimisation

About the Course

Refinery operations require continuous optimisation to maximise product yield, improve energy efficiency, and maintain operational reliability under changing market and feedstock conditions. Increasing pressure on refining margins, product quality requirements, feedstock variability, and energy performance requires organisations to apply structured process optimisation strategies across refinery systems. Refinery personnel must evaluate process conditions, operating constraints, unit interactions, and equipment performance to improve conversion efficiency and product recovery. The integration of process analytics, operational monitoring, advanced process control, and real-time optimisation is essential to support stable and profitable refinery operations. In many facilities, process variability, inefficient operating conditions, energy losses, and weak optimisation practices contribute to reduced yield performance, operational instability, and increased production costs.

This 5-day Refinery Process Yield Optimisation training course provides a structured approach to improving refinery process performance and product yield across refining operations. It integrates practical methods in process optimisation, operational analysis, energy management, advanced process control, and yield improvement aligned with refinery operational requirements. Emphasis is placed on process efficiency, unit performance, product quality optimisation, and operational stability using performance-based optimisation approaches. Delegates will strengthen their ability to analyse refinery performance, identify operational inefficiencies, and implement optimisation strategies across refinery process units. It equips delegates with structured frameworks and practical tools to improve refinery profitability, increase operational efficiency, and support sustainable refining performance.

Core Objectives

By the end of the training course, delegates will be able to:

• Interpret refinery process performance indicators and operational constraints
• Assess yield performance across refinery process units
• Analyse process variability and operational inefficiencies
• Apply advanced process control and optimisation strategies
• Evaluate energy utilisation and process integration opportunities
• Develop yield improvement and operational enhancement plans
• Monitor refinery performance using operational indicators and KPIs
• Strengthen process reliability and operational stability practices

Training Approach

This training course adopts a structured and application-focused approach, integrating refinery process analysis, optimisation exercises, APC-based operational scenarios, and refinery performance evaluation activities. Delegates will apply practical frameworks to improve refinery efficiency, optimise yields, and enhance operational decision-making.

The Attendees

This training course is designed for professionals involved in refinery operations, process optimisation, production performance, and operational reliability.

A broad range of professionals will benefit, including but not limited to:

• Refinery Process Engineers
• Operations and Production Engineers
• Process Optimisation Specialists
• Refinery Supervisors and Controllers
• Energy and Utilities Engineers
• Operations and Reliability Professionals
• Health, Safety, and Environment (HSE) Professionals
• Technical Personnel involved in refinery operations

Daily Discussion

DAY ONE: REFINERY OPERATIONS AND YIELD PERFORMANCE

• Refinery Configuration and Process Flow Overview
• Crude Characteristics and Yield Impacts
• Process Unit Functions and Operational Constraints
• Refinery Mass Balance and Yield Tracking
• Process Performance Indicators and KPIs
• Crude Slate Flexibility and Feedstock Optimisation

DAY TWO: PROCESS OPTIMISATION AND ADVANCED CONTROL

• Process Optimisation Principles and Strategies
• Advanced Process Control (APC) Applications
• Real-Time Optimisation and Process Adjustment
• Process Variability and Stability Management
• Heat Integration and Energy Efficiency Techniques
• Operational Intelligence for Process Decision Support

DAY THREE: YIELD IMPROVEMENT ACROSS REFINERY UNITS

• Distillation Unit Yield Optimisation
• Catalytic Cracking and Conversion Efficiency
• Hydroprocessing and Product Quality Control
• Reforming and Octane Enhancement Strategies
• Residue Upgrading and Bottom-of-the-Barrel Optimisation
• Product Blending and Yield Balancing Techniques

DAY FOUR: EQUIPMENT PERFORMANCE AND ENERGY OPTIMISATION

• Heat Exchanger and Furnace Performance Optimisation
• Pump, Compressor, and Utility System Efficiency
• Fouling, Corrosion, and Process Constraints
• Steam and Energy Consumption Optimisation
• Shutdown Reduction and Operational Continuity
• Maintenance Coordination and Reliability Support

DAY FIVE: DIGITAL REFINERY OPTIMISATION AND RELIABILITY

• Digital Refinery Monitoring and System Integration
• Real-Time Process Performance Monitoring
• Predictive Analytics and Yield Optimisation
• Root Cause Analysis of Yield Losses
• Operational Risk and Reliability Assessment
• Yield Recovery and Refinery Profitability Optimisation

Certificate Awarded

Upon successful completion of this training course, participants will be awarded a Certificate of Completion from XCalibre Training Centre, acknowledging their accomplishment. This certificate serves as a testament to their dedication to developing their skills and advancing their expertise in their respective fields.