Crude Oil Processing & Distillation: Comprehensive 5-Day Training Course

Course Overview

This intensive Crude Oil Processing and Distillation training program provides in-depth technical knowledge for refinery professionals across the Kingdom of Saudi Arabia (KSA), Oman, GCC countries (UAE, Qatar, Kuwait, Bahrain), and Africa. The course covers crude oil characteristics, atmospheric and vacuum distillation, fractionation technologies, process optimization, and operational best practices essential for maximizing refinery efficiency and product yields.

With the Middle East refining capacity exceeding 10 million barrels per day and Africa’s expanding refinery sector, this training addresses critical skill requirements for engineers and operators at Saudi Aramco refineries (Ras Tanura, Riyadh, Yanbu, Jazan), Sohar Refinery (Oman), ADNOC Refining, Qatar Petroleum refineries, Dangote Refinery (Nigeria), EGPC facilities (Egypt), and other major downstream operations undergoing modernization and capacity expansion across the region.

Target Audience

• Process Engineers in crude distillation units across Saudi Arabia, Oman, UAE, Africa

• Operations Personnel managing atmospheric and vacuum distillation towers

• Technical Supervisors in refinery crude processing units

• Production Engineers optimizing distillation performance and yields

• Process Optimization Specialists improving refinery economics

• Maintenance Engineers supporting crude unit reliability

• Project Engineers designing new distillation facilities or revamps

• Technical Managers overseeing refinery crude processing operations

• Quality Control Engineers ensuring product specifications compliance

Day 1: Crude Oil Fundamentals & Characterization

Morning Session: Crude Oil Properties & Classification

• Crude oil composition: hydrocarbons, sulfur compounds, nitrogen, metals, salts

• Crude oil classification: light/heavy, sweet/sour, paraffinic/naphthenic/aromatic

• Regional crude characteristics: Arab Light, Arab Heavy, Arab Extra Light (Saudi Arabia), Oman Export Blend, Murban (UAE), Bonny Light (Nigeria), Saharan Blend (Algeria)

• API gravity, sulfur content, TAN (Total Acid Number), and their impact on processing

• True boiling point (TBP) curves and distillation analysis (ASTM D2892, D5236)

• Crude assay data interpretation and significance for refinery planning

• Crude slate selection strategies for GCC and African refineries

Afternoon Session: Pre-Treatment & Desalting

• Crude oil storage and blending operations at coastal refineries (Ras Tanura, Shuaiba, Sohar)

• Desalting process fundamentals: electrostatic desalters, chemical additives

• Salt content effects: corrosion, fouling, catalyst poisoning in downstream units

• Desalter design: single-stage vs. two-stage systems

• Water washing and chemical treatment programs for high-salt crudes

• Desalter operation and troubleshooting: emulsion problems, interface control

• Overhead system corrosion management: neutralizers, filming amines

• Case studies: Saudi Aramco refineries processing high-TAN crudes, Sohar Refinery operations

Day 2: Atmospheric Distillation Technology

Morning Session: Atmospheric Distillation Unit (ADU) Design

• CDU (Crude Distillation Unit) process flow diagrams and equipment configuration

• Crude preheat train design: heat exchanger networks, furnace systems

• Atmospheric column design: number of trays, feed location, reflux systems

• Side strippers and product draw-off optimization

• Product streams: light ends, naphtha, kerosene, diesel, atmospheric gas oil (AGO), atmospheric residue

• Column internals: trays vs. packing, efficiency considerations

• Energy integration and heat recovery optimization in hot GCC climates

• Pump-around systems for heat removal and reflux control

Afternoon Session: ADU Operations & Control

• Start-up and shutdown procedures for atmospheric distillation columns

• Normal operating parameters: temperature profiles, pressure, reflux ratios

• Product quality control: flash point, distillation ranges, pour point, cloud point

• Cut point optimization between products for maximum profitability

• Column pressure control and overhead system management

• Reflux ratio adjustments and their impact on separation efficiency

• Troubleshooting operational issues: flooding, weeping, entrainment, foaming

• Crude switchover procedures when changing crude slates

• Operational case studies: SATORP (Saudi Aramco Total Refinery), ADNOC Ruwais, Sohar Refinery

Day 3: Vacuum Distillation & Heavy Oil Processing

Morning Session: Vacuum Distillation Unit (VDU) Technology

• Vacuum distillation fundamentals: principles, pressure-temperature relationships

• VDU process configuration: vacuum column design, ejector systems, surface condensers

• Vacuum-creating systems: steam ejectors, liquid ring pumps, hybrid systems

• Feed heater (reduced crude heater) design and operation in high-temperature service

• Vacuum column products: light vacuum gas oil (LVGO), heavy vacuum gas oil (HVGO), vacuum residue

• Wash oil systems for column cleanliness and tar removal

• Operating under vacuum: typical pressures (25-50 mmHg absolute), temperature control

• Vacuum system troubleshooting: air leaks, poor vacuum, column fouling

Afternoon Session: Heavy Residue Processing Options

• Vacuum residue characteristics and utilization options in GCC refineries

• Delayed coking, fluid catalytic cracking (FCC) feedstock preparation

• Solvent deasphalting (SDA) for lube base oil production

• Visbreaking and thermal cracking for fuel oil viscosity reduction

• Residue hydrocracking technologies in Saudi Aramco and ADNOC facilities

• Integration with Gasification and IGCC projects (Jazan Refinery)

• Asphalt production from vacuum residue for regional construction markets

• Economic evaluation of residue upgrading alternatives for African refineries

Day 4: Distillation Optimization & Advanced Control

Morning Session: Process Optimization Strategies

• Yield optimization: maximizing valuable middle distillates (diesel, kerosene) production

• Cut point management for product quality and quantity balance

• Energy efficiency improvements: furnace optimization, heat integration, waste heat recovery

• Feed rate optimization based on crude quality and market demands

• Gap analysis and overlap between adjacent products

• Crude blending strategies to optimize refinery margin in volatile markets

• Linear programming (LP) models for refinery planning used by Saudi Aramco and ADNOC

• Real-time optimization (RTO) implementation in modern GCC refineries

Afternoon Session: Advanced Process Control & Instrumentation

• Distillation column control strategies: temperature, pressure, level, flow control loops

• Advanced control systems: model predictive control (MPC), multivariable control

• Inferential property control: estimating product qualities from process measurements

• Analyzer systems: gas chromatographs, distillation analyzers, sulfur analyzers

• DCS configuration for crude units: Honeywell, Emerson, Yokogawa systems

• Alarm management and rationalization for distillation operations

• Performance monitoring dashboards and KPIs for crude units

• Digitalization and Industry 4.0 applications: predictive maintenance, digital twins

• Hands-on exercises: Control strategy development and optimization calculations

Day 5: Reliability, Safety & Emerging Technologies

Morning Session: Equipment Reliability & Maintenance

• Fouling mechanisms in crude preheat trains: causes, monitoring, mitigation

• Chemical cleaning and mechanical cleaning strategies for heat exchangers

• Furnace tube monitoring: skin temperature, tube thickness, thermal efficiency

• Column tray inspection and maintenance during turnarounds

• Corrosion management: naphthenic acid corrosion, sulfidic corrosion, overhead corrosion

• Material selection for high-temperature and corrosive service

• Predictive maintenance technologies: vibration monitoring, thermography, ultrasonic testing

• Turnaround planning and execution best practices for Saudi and GCC refineries

Afternoon Session: Process Safety & Future Trends

• HAZOP studies for crude distillation units and common safety scenarios

• Overpressure protection: relief valves, flare systems, blowdown systems

• Fire and gas detection systems specific to crude processing areas

• Emergency shutdown (ESD) systems and safety instrumented systems (SIS) design

• HSE regulations: Saudi Aramco SAEP standards, PDO requirements, GCC safety codes

• Lessons learned from refinery incidents globally and in the Middle East

• Environmental compliance: emissions control, water treatment, waste management

• Future technologies: Modular refineries for remote locations in Africa

• Crude-to-chemicals (CTC) integration: maximizing petrochemical production (COTC project in Jubail)

• Digital transformation: AI for optimization, blockchain for crude tracking

• Sustainability initiatives: energy efficiency, carbon capture, green refining in Vision 2030 context

Learning Outcomes

Upon completion, participants will be able to:

• Interpret crude assay data and understand implications for refinery processing

• Operate and optimize atmospheric and vacuum distillation units efficiently

• Implement troubleshooting strategies for common operational problems

• Maximize product yields and refinery profitability through cut point optimization

• Apply energy efficiency measures to reduce operating costs

• Manage equipment reliability and prevent fouling, corrosion issues

• Design and implement advanced process control strategies

• Ensure safety and environmental compliance per GCC regulations

• Evaluate emerging technologies for refinery modernization and crude-to-chemicals integration

Course Delivery & Certification

• Format: Technical lectures, process simulations, case studies, calculation workshops, video demonstrations

• Simulation software: Hands-on training with refinery process simulation tools (Aspen HYSYS, Pro/II)

• Materials: Comprehensive technical manual, calculation templates, industry standards, crude assay databases

• Certification: Professional certificate recognized by major refiners across KSA, Oman, UAE, Qatar, Kuwait, and Africa

• Language: English (Arabic translation support available)

• CPD Points: Continuing professional development credits

• Locations: Riyadh, Jeddah, Jubail, Yanbu (KSA), Muscat, Sohar (Oman), Abu Dhabi, Dubai, Doha, Lagos, Cairo, Johannesburg

Why This Course is Critical for the Region

The GCC and African refining sector is experiencing unprecedented transformation with mega-projects like Jazan Refinery (400,000 bpd), Dangote Refinery (650,000 bpd - Africa’s largest), Duqm Refinery (230,000 bpd), and ADNOC Ruwais expansion. These facilities process diverse crude slates from extra-light to heavy, sweet to high-sulfur grades, requiring operators with deep distillation expertise.

This training delivers practical knowledge incorporating Saudi Aramco operational excellence practices, Oman refining standards, and international best practices, addressing specific challenges of processing Middle Eastern crudes, operating in extreme temperatures (50°C+ ambient), and meeting stringent Euro 5/6 product specifications for domestic and export markets.

Master distillation. Optimize yields. Drive refinery excellence.