03-06-2025

Refinery performance: How to control hydrocarbon loss

Reducing Hydrocarbon Loss in Refineries: A Data-Driven Approach. Hydrocarbon loss costs refineries millions of dollars every year. It happens when systems, processes, and behaviors in the refinery aren’t optimized. Industry best practices aim for losses below 0.25%, and under 0.5% is an achievable goal for most. But if your refinery isn’t hitting these numbers, or you’re unsure where you stand, there’s good news: Hydrocarbon Loss Control Programs can help.

What is a Hydrocarbon Loss Control Program?

A Hydrocarbon Loss Control Program is a set of measures designed to reduce losses systematically. At the heart of these programs is mass balance. Unlike volume, mass doesn’t change due to temperature, pressure, or chemical reactions. Mass balance helps identify where gains and losses happen in the system.

The Role of Mass Balance
A solid mass balance program tracks every refinery input and output, flagging known losses and exposing hidden ones. At Trindent, we’ve shared the main causes of hydrocarbon loss before. Our team uses a structured, proven approach to control these losses and restore balance.
 
Reducing Losses with Accurate Data
Accurate data is the foundation for reducing mass balance losses. At refineries, measurement errors can come from many sources. Here’s how we help:
 
- Meter Troubleshooting: First and foremost, we ensure the meter you’re using is appropriate for the specific measurement, considering the process and environmental factors. Next, we verify that the meters are proven at the correct frequency and under suitable conditions, so the readings are accurate and reliable. Our team relies on meter proving checklists and control charts to confirm that your meters deliver trustworthy data.

- Tank Gauging: Different storage methods - tanks, railcars, marine vessels have their own measurement challenges. Tanks, for example, can have shifted bottoms or stratification. Marine vessels face dynamic ocean conditions. We use our expertise and standard checklists to identify and fix these issues.

- Measuring Sediment and Water (S&W): It’s crucial to account for sediment and water properly. Many refineries miss best practices here. For instance, grab samples should be taken from the top down to avoid contamination. Or, using expired demulsifiers can hinder separation of water and crude. We help refineries avoid these mistakes using standard checklists and measurement analysis tools.
 
A Sustainable, Data-Driven Approach
At Trindent, our approach is always data-driven. We tie our results directly to financial and operational KPIs, making improvements tangible and trackable. Plus, we focus on sustainability, training your teams to maintain these improvements long after we’re gone.
 
Without capital investment, we create actionable ways to sustainably increase refinery margins by 2-3%. Contact us for a complimentary assessment, to help solve your complex business issues. We are here to Make It Happen™.