This case study explores how the MicroDist analyzer helps refineries reduce product giveaway and maximize profitability

The Refinery Challenge — Controlling Product Giveaway

Refineries maximize profits by adjusting crude mixes and optimizing operational procedures to enhance the market value of final products. Product giveaway occurs when a refinery produces a product with a higher value than specifications require. This giveaway translates to the erosion of profitability and is something refineries are driven to improve using technologies and methods approved by current regulations.

Refineries in the U.S. are required to blend various petroleum products to meet stringent quality standards while optimizing costs. Distillation of crude oil to separate hydrocarbon components so they can be processed into higher value products is one of the first steps of the refining process. This process, which takes place in atmospheric crude towers, has not changed significantly in nearly 70 years.

From Traditional Methods to Real-Time Precision

What has changed is the instrumentation technologies and software capabilities that optimize the distillation process. Crude oil is highly complex, with 1000 identifiable components with boiling temperatures that range from 20°C for butane and propane to over 550°C for heavy residuals, like lubricating oil or asphalt. Refineries process sweet and sour crude oils into a wide range of products, including gasoline, distillates, propane, coke, and aromatics, distributed through multiple channels.

To simplify the process, refineries typically use a combination of technologies to efficiently optimize the final blend, with the PAC MicroDist being one of the analyzers of choice for blending managers. MicroDist uses the same technology as the OptiPMD which complies with ASTM D7345, Standard Test Method for Distillation of Petroleum Products and Liquid Fuels at Atmospheric Pressure (Micro Distillation Method), which is an approved and proven alternative to D86 for gasoline distillation.

The MicroDist analyzer just runs with very few problems, very little maintenance requirements – and it is a true representation of what is happening.

Proven Reliability, Lower Maintenance, and Measurable Savings

Unlike conventional methods that rely on calculated guesses, MicroDist provides rapid, accurate distillation data, enabling proactive decision-making and minimizing giveaway opportunities.

The diver behind most U.S. refiners adoption of MicroDist is compelling cost-saving projections. MicroDist reliability translates into extended equipment life, reduced maintenance demands and enhanced overall operational efficiency. Some refiners have found that when the MicroDist is taken offline for service, the backup near infrared (NIR) analyzer is much less efficient – and increases product giveaway by thousands of dollars per day.

MicroDist operates seamlessly with minimal maintenance requirements. Its ability to deliver true representations of distillation data eliminates the guesswork associated with traditional methods, ensuring consistent and reliable results.

A blending manager at a refinery remarked, “What’s nice about the MicroDist is its quick response. The results from other instruments are delayed, so they’re not a true representation of distillation—just a calculated guess. When we calculate distillation through the lab, that guess takes much longer. With the MicroDist, it’s a true, real-time calculation.”

The true cost-benefit MicroDist is far reaching. In addition to minimizing giveaway there are big benefits from running process equipment inside the preferred operating envelope, which extends the life of catalysts, extending the life of the refinery’s fixed assets.

Smarter Distillation Decisions for Long-Term Profitability

In addition to the technical benefits, MicroDist is serviced and supported by a world-class service organization. Refiners value instrument uptime as much as, or in some cases more than, the technical features of the analytical method.

Key Takeaways:

• The MicroDist online analyzer to be a reliable, efficient solution for distillation.
• Compliance with ASTM D7345.
• Rapid 10-minute cycle time and the ability to automatically pull samples from the process.
• Correlates with ASTM D86, ISO 3405, IP 123.
• MicroDist maximizes upgrading with tighter control of low-value v. high-value products.

The MicroDist analyzer empowers refineries to make faster, smarter blending decisions, improve profitability, and maintain long-term operational excellence, offering a true representation of refinery performance in real time.