Within 2 years (2020 – 2021), the fluctuations in crude oil prices and the sharp decline in consumer demand due to the epidemic have caused many difficulties for the operation and efficiency of Dung Quat oil refinery.

Successfully overcome the “double crisis”

In the face of difficulties, Binh Son Petrochemical Refining Joint Stock Company (BSR) determined: Taking advantage of all opportunities, thoroughly applying technical solutions, optimizing operation, maintaining safe, stable and continuous operation of the Plant is the key factor for BSR to successfully overcome the double storm.

In 2020, in Vietnam, the social isolation lasted many months, causing a serious decline in the demand for gasoline. This leads to a high inventory of BSR products, it is imperative to send products to avoid the risk of tank-top causing stop Dung Quat NMLD. In addition, the price of crude oil dropped sharply, many products at low levels, there were months of ADO and Jet-A1 prices lower than the price of crude oil, along with margin crack profit to the detriment of oil refining activities, which put BSR at risk of suffering losses up to trillions of VND.

It can be said that BSR has suffered the “double crisis” from the Covid-19 epidemic and the price of crude oil and products has fluctuated sharply. Many times Dung Quat NMLD is in danger of stopping production because the price of raw materials decreases as soon as they are transported at sea, the output price also decreases proportionally. So BSR is at risk, the production will be ineffective. So how does BSR overcome this “double crisis”?

With the complex fluctuations in the price – supply-demand of crude oil and products, BSR has followed the evolution of the market, evaluating, selecting and optimizing capacity, operating mode and product structure to enhance the production of valuable products, bringing the highest efficiency, minimizing to the minimum the impact of the market.

BSR regularly optimally adjusts the capacity of technology workshops to produce maximum production of products, especially Mogas 95 gasoline, minimum production of JetA1 products, DO 0.05%S when crack margin and market demand are low. At the same time, increase the use of ZSM5 additive to increase Propylene production (to increase Polypropylene workshop capacity) and LPG.

By the end of 2020, BSR has operated Dung Quat NMLD safely and stably with an average capacity of 105%. Although Dung Quat refinery stopped the plant for nearly 2 months to carry out General Maintenance (BDTT) for the fourth time, the annual production volume still reached about 5.96 million tons, reaching 107% of the 2020 plan.

After total maintenance, BSR has gradually increased its capacity, especially to optimize the production of products that the market is well priced. The factory has tested and increased the capacity of NHT workshop from 127% to 135%, CCR from 103% to 110%, ISOMER from 130% to 150%, PP from 112% to 114% of the design capacity.

Optimization of processing capacity and operation mode of the Plant

In 2021, BSR continues to promote research, evaluation and testing to increase the capacity of technology workshops. Since then, the capacity used has been maximized, contributing to reducing costs, operating flexibility and improving the processing efficiency of the Plant, estimated at about 20 million USD/year.

At the same time, due to the impact of Covid-19 and the sharp decrease in demand for petroleum products, the Plant has studied and handled complex technical issues and successfully reduced RFCC workshop capacity to 70% in August 2021 to ensure continuous operation, avoid tank-top products and avoid the risk of having to stop the Plant.

In addition, the Plant has successfully implemented many optimal solutions to improve operation and efficiency of the Plant. The solution to increase the peak Naphtha flow rate of the CDU tower from 233m3/hr to 255m3/hr has helped increase the capacity of processing light crude oil containing a lot of Naphtha (WTI, Std…). Optimizing DCO flow reduction (RFCC) from 26m3/hr to 22m3/hr has also helped reduce FO and increase ADO, contributing to efficiency of about USD2-3 million/year. On the other hand, optimizing the reduction of the volume of catalyst used at the RFCC workshop from about 11 tons/day to 9 tons/day also resulted in savings of about USD 3 million/year.

In the optimum aspect, the operating mode has increased the maximum production of highly economical products such as LPG, Propylene/PP and gasoline. In particular, BSR’s Mogas 95 gasoline production has been increased from 210,000m3/month to 245,000m3/month (accounting for 77% of the gasoline product structure). Tackle technical issues to blend up to (over 80%) Jet-A1 products into ADO as demand and price deepen due to the impact of the Covid-19 outbreak in 2020-2021.

Earlier, the initiative “Maximizing the capacity of Naphtha workshop cluster to increase the production capacity of gasoline and increase the processing flexibility of imported crude oil at Dung Quat refinery” was put into application in the actual operation of production, with the efficiency of 15 million USD/year. This initiative helps to increase the production of gasoline products, meet the increased demand of the market, and increase the flexibility of processing imported crude oil rich in Naphtha in the conditions of decreasing domestic crude oil production (Bach Tiger oil and equivalent oil).

ByNhip song Kinh te