Refinery Operations Optimization: Executive 5-Day Training Course

Course Overview

This advanced Refinery Operations Optimization training program delivers strategic and technical expertise for refining professionals across the Kingdom of Saudi Arabia (KSA), Oman, GCC countries (UAE, Qatar, Kuwait, Bahrain), and Africa. The course covers linear programming, refinery economics, energy optimization, advanced process control, digital transformation, and integrated planning strategies essential for maximizing profitability, efficiency, and sustainability in modern refinery operations.

With the Middle East hosting some of the world’s most sophisticated refineries and Africa’s downstream sector experiencing rapid modernization, this training addresses critical competencies for professionals at Saudi Aramco (Ras Tanura, SATORP, YASREF, Jazan), ADNOC Refining, Sohar Refinery, Duqm Refinery, KNPC, Dangote Refinery, SASOL, EGPC, and other operators implementing Industry 4.0 technologies, pursuing operational excellence, and aligning with Saudi Vision 2030 and Oman Vision 2040 sustainability and efficiency goals.

Target Audience

• Refinery Managers and Operations Directors across Saudi Arabia, Oman, UAE, Africa

• Process Engineers responsible for unit optimization and efficiency improvement

• Planning Engineers developing refinery operating plans and crude slates

• Economics Analysts evaluating refinery margins and investment decisions

• Energy Managers optimizing utility systems and reducing carbon footprint

• Advanced Control Engineers implementing APC and digital solutions

• Technical Managers leading operational excellence initiatives

• Project Engineers evaluating debottlenecking and expansion opportunities

• Supply Chain Managers optimizing crude procurement and product distribution

Day 1: Refinery Economics & Planning Fundamentals

Morning Session: Refinery Economics Principles

• Refinery business environment: crude oil markets, product pricing, crack spreads

• Regional market dynamics: Brent-Dubai spread, product demand in GCC and African markets

• Refinery margin calculation: gross refinery margin (GRM), operating costs, fixed costs

• Crude oil economics: API gravity premium/discount, sulfur differential pricing

• Product value optimization: gasoline, diesel, jet fuel, petrochemical feedstocks

• Refinery complexity: Nelson Complexity Index and its impact on margins

• Configuration analysis: topping, hydroskimming, conversion, deep conversion refineries

• Regional benchmarks: SATORP, YASREF, Jazan (Saudi Arabia), Sohar, Duqm (Oman), Dangote (Nigeria)

• Investment economics: ROI, NPV, IRR for refinery projects and upgrades

• Case studies: Saudi Aramco integrated refining-petrochemical complexes, ADNOC downstream strategy

Afternoon Session: Refinery Planning & Linear Programming

• Refinery planning hierarchy: long-term strategic, medium-term tactical, short-term operational

• Crude slate optimization: matching crude properties to refinery configuration

• Linear programming (LP) models: mathematical optimization for refinery planning

• LP model structure: objective function, constraints, decision variables

• Planning software: Aspen PIMS, Spiral Suite, AVEVA Unified Planning widely used in GCC refineries

• Model building: unit representations, blending models, utility systems

• Crude selection optimization: balancing quality, availability, cost across Arabian Gulf suppliers

• Product slate optimization: meeting market demand and specifications profitably

• Scenario analysis: sensitivity studies for crude price, product demand changes

• Planning vs. actual performance: variance analysis and continuous improvement

• Hands-on workshop: Introduction to LP optimization concepts and calculations

Day 2: Process Unit Optimization Strategies

Morning Session: Crude Unit & FCC Optimization

• Crude distillation unit (CDU) optimization: maximizing throughput, energy efficiency, product yields

• Cut point management: balancing product quality and quantity

• Desalter optimization: minimizing salt content, reducing crude unit corrosion

• Heat integration: preheat train efficiency, furnace optimization

• Fluid Catalytic Cracking (FCC) optimization: maximizing gasoline/propylene production

• Feed quality management: pretreatment, metals reduction, Conradson carbon control

• Catalyst optimization: E-cat activity, additives selection, circulation rates

• Reactor temperature and catalyst-to-oil ratio optimization

• Conversion targets: balancing gasoline yield vs. light cycle oil (LCO) production

• Energy recovery: power generation from flue gas, CO boiler optimization

• Operational case studies: SATORP FCC performance, ADNOC Ruwais conversion optimization

Afternoon Session: Hydrotreating & Hydrogen Management

• Hydrotreating unit optimization: desulfurization efficiency, catalyst cycle length

• Diesel hydrotreating: meeting Euro 5 ULSD specifications (10 ppm sulfur) efficiently

• Gasoline hydrotreating: sulfur removal while preserving octane

• Catalyst management: activity monitoring, temperature progression, regeneration planning

• Hydrogen network optimization: production, consumption, purification, distribution

• Hydrogen sources: catalytic reformers, steam methane reformers, hydrogen plants

• Hydrogen purity management: PSA units, membrane systems

• Hydrogen header pressure optimization across refinery consumers

• Pinch analysis: minimizing hydrogen losses and maximizing utilization

• Hydrogen balance: importing vs. producing hydrogen economics for GCC refineries

• Alternative hydrogen: blue hydrogen, electrolysis integration in Saudi Vision 2030 context

• Workshop: Hydrogen network optimization calculations

Day 3: Energy Optimization & Sustainability

Morning Session: Energy Management Systems

• Energy consumption patterns: fired heaters, steam systems, cooling water, electricity

• Energy intensity benchmarks: GJ/barrel of crude processed in Middle East refineries

• Process integration: pinch technology, heat exchanger networks optimization

• Utility system optimization: steam balance, power generation, heat recovery

• Furnace efficiency improvement: air preheating, oxygen enrichment, burner optimization

• Flare minimization: reducing hydrocarbon losses and emissions

• Combined heat and power (CHP): cogeneration opportunities in refineries

• Energy monitoring systems: meters, data acquisition, performance tracking

• ISO 50001 energy management: implementation in Saudi Aramco and ADNOC facilities

• Energy audits: identifying improvement opportunities and payback calculations

• Regional challenges: high ambient temperatures (45-50°C) impact on cooling systems in GCC

Afternoon Session: Carbon Management & Environmental Optimization

• Carbon footprint assessment: Scope 1, 2, 3 emissions calculation for refineries

• CO2 emissions sources: fired heaters, FCC regenerator, hydrogen plants, flares

• Carbon capture utilization and storage (CCUS): technologies and implementation in GCC

• Carbon circular economy: Aramco’s initiatives, ADNOC carbon capture projects

• Energy efficiency as decarbonization: reducing fuel consumption, waste heat recovery

• Renewable energy integration: solar for refinery power needs in sunny GCC region

• Emissions monitoring: continuous emissions monitoring systems (CEMS), reporting requirements

• NOx, SOx reduction: SCR, low-NOx burners, flue gas desulfurization

• Water management: minimizing freshwater consumption, wastewater treatment optimization

• Circular economy: waste-to-value, plastic pyrolysis oil co-processing

• ESG reporting: environmental, social, governance metrics for refineries

• Alignment with Saudi Green Initiative, UAE Net Zero 2050, Oman sustainability goals

Day 4: Advanced Process Control & Digital Technologies

Morning Session: Advanced Process Control (APC)

• APC overview: multivariable control, model predictive control (MPC) fundamentals

• Benefits of APC: throughput increase, yield improvement, energy savings, constraint management

• APC implementation: model identification, controller design, commissioning

• Common applications: crude unit, FCC, reformer, hydrotreater optimization

• Performance monitoring: KPIs, benefit tracking, controller health assessment

• Sustaining APC performance: model maintenance, retuning, operator training

• Regional implementations: APC at Saudi Aramco refineries, ADNOC downstream facilities

• Real-time optimization (RTO): economic optimization layered above APC

• Integration with planning: closing loop between planning models and operations

• ROI analysis: typical 3-6 month payback periods for APC projects

• Vendor technologies: AspenTech DMC, Honeywell Profit Suite, Yokogawa PACE widely deployed

Afternoon Session: Industry 4.0 & Digital Transformation

• Digital refinery vision: connectivity, analytics, automation, intelligence

• Industrial Internet of Things (IIoT): sensors, edge computing, cloud platforms

• Big data analytics: processing vast operational data for insights

• Artificial intelligence and machine learning: predictive maintenance, quality prediction, optimization

• Digital twins: virtual refinery models for simulation, training, optimization

• Augmented reality (AR): maintenance support, operator training applications

• Drone inspections: tank inspections, flare stack monitoring, facility surveillance

• Robotics: hazardous area inspections, automated sampling, cleaning operations

• Cybersecurity: protecting operational technology (OT) systems from threats

• Blockchain: crude tracking, product certification, supply chain transparency

• Saudi Aramco digital initiatives: 4IR center, AI applications, smart refining

• ADNOC digital transformation: Panorama Digital Command Center

• Change management: preparing workforce for digital transformation

• Case studies: Digital implementations at Jazan Refinery, SATORP smart operations

Day 5: Operational Excellence & Integrated Optimization

Morning Session: Operational Excellence Frameworks

• Operational excellence principles: safety, reliability, efficiency, sustainability

• Performance management: KPIs, dashboards, continuous improvement culture

• Reliability-centered maintenance (RCM): optimizing maintenance strategies

• Asset integrity management: inspection, corrosion monitoring, risk-based inspection

• Turnaround optimization: planning, scheduling, execution excellence

• Turnaround cycle extension: reliability improvements for longer run lengths

• Loss accounting: identifying and quantifying production losses, efficiency losses

• Benchmarking: comparing performance against industry standards and best practices

• Lean manufacturing: waste elimination, value stream mapping in refineries

• Six Sigma: DMAIC methodology for problem-solving and process improvement

• Best practices: Saudi Aramco Operational Excellence, ADNOC Performance Excellence programs

• Organizational culture: building continuous improvement mindset

Afternoon Session: Integrated Refinery Optimization

• Refinery-wide optimization: breaking silos, integrated planning and operations

• Supply chain integration: crude procurement, logistics, product distribution

• Refining-petrochemical integration: maximizing value through chemicals production

• Steam cracker integration: SATORP, PetroRabigh, SADARA examples

• Crude-to-chemicals (CTC) complexes: direct crude conversion to petrochemicals (COTC Jubail)

• Multi-refinery optimization: portfolio management for integrated companies

• Real-time economic optimization: adjusting operations to market changes

• Trading and scheduling integration: coordinating with commercial teams

• Risk management: managing price volatility, supply disruptions, demand fluctuations

• Scenario planning: preparing for energy transition, market shifts

• Future refining landscape: role of refineries in low-carbon economy

• Biofuels integration: renewable diesel, sustainable aviation fuel (SAF) production

• Circular carbon economy: Saudi Arabia’s framework for carbon management

• Vision alignment: supporting Saudi Vision 2030, Oman Vision 2040, UAE Centennial 2071

• Final workshop: Integrated optimization case study and action planning

Learning Outcomes

Upon completion, participants will be able to:

• Apply linear programming for refinery planning and crude slate optimization

• Calculate refinery margins and evaluate economic performance comprehensively

• Implement unit-level optimization strategies across crude, conversion, treating processes

• Design energy management programs reducing costs and carbon emissions significantly

• Deploy advanced process control and digital technologies for operational improvement

• Establish operational excellence frameworks driving continuous performance enhancement

• Integrate refinery operations with supply chain, petrochemicals, and commercial functions

• Develop sustainability strategies aligned with regional decarbonization goals

• Lead digital transformation initiatives preparing refineries for Industry 4.0

• Benchmark performance against international and regional best practices

Course Delivery & Certification

• Format: Executive lectures, optimization workshops, software demonstrations, interactive case studies, group exercises

• Software exposure: Aspen PIMS concepts, optimization tools, digital technologies overview

• Materials: Comprehensive manual, optimization templates, benchmarking data, industry reports

• Certification: Executive certificate recognized by major operators across KSA, Oman, UAE, Qatar, Kuwait, Bahrain, and Africa

• Language: English (Arabic translation support available for GCC participants)

• CPD Credits: Senior-level continuing professional development recognition

• Networking: Connect with optimization experts and peers from regional refineries

• Locations: Riyadh, Dhahran, Jubail (KSA), Muscat, Sohar (Oman), Abu Dhabi, Dubai, Doha, Kuwait City, Lagos, Cairo

Why This Course is Strategic for the Region

The GCC refining sector represents over $200 billion in assets requiring optimization to remain competitive globally. Saudi Aramco’s integrated refineries, ADNOC’s downstream expansion, Oman’s Duqm mega-refinery, and Dangote’s 650,000 bpd facility exemplify sophisticated operations demanding advanced optimization expertise. The energy transition requires refineries to maximize efficiency, minimize carbon intensity, and integrate with petrochemicals.

This training delivers executive-level knowledge incorporating world-class practices from Saudi Aramco’s operational excellence programs, ADNOC’s digital transformation, and international benchmarks, addressing specific challenges of complex configurations, extreme climates, integrated operations, and sustainability imperatives under Saudi Vision 2030 and regional development strategies.

Optimize operations. Maximize margins. Lead the future.