Blending Giveaway Economic Performance Assessment Study for: Gasoline, Diesel, Bunker

Gasoline Blending Studies


Today many US refineries are leaving million dollars/year “on the table” because of: RVP, AKI giveaway, recipe giveaway (disconnection between planned and actual), VOC giveaway, not using properly MBO (multi blend optimizer), and Refinery LP, re-blending too many times, overusing the tanks and etc. We quantified all these issues and we put some numbers to give you an idea.

USA “ABC” Refinery – Summary of Blending Improvements Economics
(1)Basis of Estimates = Extrapolation from US Complex Refinery, 100 KBPD Gasoline Production



Area of ImprovementComments
Reduction of Blend AKI and RVP GiveawayIncludes conflicts betw RefLP and Blending
Reduction of TVL GiveawayTVL competes against RVP
Reduction of VOC GiveawaySwitch to “Per Gallon” VOC spec
Reduction of Planned Recipe GiveawayLower recipe variability
Exploit Ethanol Octane BoostAllows RBOB/CBOB neat spec “fat” reduction
Lowering Reformer Severity from 100 RON to 94RONZero risk at 100RON
Reduce RVP Seasonal Rollover GiveawayMulti-blend multi-time period schedule optimization
Short term logistics optimizationBest timing for producing a batch
Reducing tankage1 RBOB and 1 Cat Gas tanks
Improved segregation of blend components
Reduced RIN exposure by increasing exports10% of gasoline exported to Mexico
Total “ABC” Refineryr Potential Benefits (M$/yr)5 to 15+ millions/yr depending on production capacity
(2)Costs to Capture Benefits2 to 15 millions, depending on existing blending facilities

We do gasoline blending economic performance analysis and recommend ongoing monitoring to capture these potential improvements, potentially contribute another $5 to $15 million annually to the bottom line.

Typical Study Table of Content

Attachment 1

Sample Gasoline Blending Study Report Table of Contents

Ara Barsamian, Refinery Automation Institute, LLC,
Tel 1-973-644-2270/email:

1.0 Introduction and Summary4
2.0 Current and Future Gasoline Blending Operation5
 2.1 Current Gasoline Blending Configuration6
 2.2 Gasoline Grades Specifications7
 2.3 Export Gasoline Grades to mitigate RIN RVO’s7
 2.3 Blend Planning8
  2.3.1 Current and Future Improved Blend Planning10
  2.3.2 Ethanol Blending and RIN’s10
  2.3.3 Ethanol Blending Octane Boost and Reformer Severity10
  2.3.4 Minimizing RVP Seasonal Rollover with Improved Blend Planning10
 2.4 Gasoline Blending Performance and Improvement Benefits12
  2.4.1 Physical Blend Quality Giveaway12
  2.4.2 Planning Recipe Giveaway14
  2.4.3 Total Recoverable Giveaway17
 2.5 Benefits of In-Line Blend Release/EPA Waiver Petition18
3.0 Gasoline Tankage and Inventory Utilization19
 3.1 Current Tankage Utilization Efficiency19
 3.2 Potential Tankage Re-Allocation for Improved Utilization21
 3.3 Blending Use of Automatic Tank Gauging and Profitability23
4.0 Gasoline Blending Facilities25
 4.1 New or Refurbishing Existing In-Line Blender25
  4.1.1 In-Line Blender Capacity27
  4.1.2 In-Line Blender Modular Design for Easy Installation and Maintenance27
 4.2 The Existing/Future Blending Control System28
 4.3 The Existing/Future On-Line Analyzers29
5.0 Proposed In-Line Blend Release Architecture31
 5.1 In-Line Blender Configuration and Design32
 5.2 On-Line Analyzers for Blend Property Control33
  5.2.1 NIR Analyzer for Blender Header Measurement33
  5.2.2 RVP Analyzer for Blender Header Measurement34
  5.2.3 Sulfur Analyzer for Tier 3 Blender Header Measurement34
  5.2.3 On-Line Analyzers Performance Monitoring34
 5.3 Automatic Composite Samplers35
 5.4 Blending Software37
  5.4.1 Blend Control System Hierarchy37
  5.4.2 New Blend Control System Implementation39
  5.4.3 Blend Control Software Alternatives40
 5.4.4 Blend Control System Implementation Phases41
 5.5 Blending Key Performance Indicators (KPI) Reporting42
6.0 Blending Operator Location45
 6.1 Peculiarities of Blending/Offsites Operation vs. Onsites45
 6.2 Examples of Blending/Offsites Control Rooms46
7.0 Cost Estimates48
8.0 Blending Project Execution Plan51
 8.1 Typical Gasoline Blending Project Schedule51
 8.2 Typical Gasoline Blending Project Organization52
 8.3 Typical Post- Project Organization54
9.0 Recommendations58
10.0 Acknowledgements59
11.0 Appendix60

Past Companies Studies and Projects


  • Blending Components Selection Asia-USA (2017)
  • Blending Advice USA (2017)
  • In-line blender design Asia (2017-2018)
  • Alternative ON boosters Europe (2017)
  • Feasibility Study for a gasoline plant Asia (2017)
  • Feasibility Study and Design for ULSD 10 ppm Europe (2017)
  • Alternative Bunker Recipes for 2020 sulfur spec Asia (2017)
  • Colonial Pipeline Naphtha and Butane Blending Feasibility Project and Sourcing (2016)
  • Carrollton Oil-Manguinho Refinery Gasoline Blending Components Selection and Sourcing (2016)
  • FHR Corpus Christi, TX Refinery Gasoline Blending + Naphtha Optimization Project (2016)
  • ExxonMobil Research & Engineering Marine Bunker Blending Consulting (2015)
  • Trafigura TX Gasoline Blending Optimization Consulting (2015)
  • Blue Ocean Brokerage Gasoline, Diesel, and Biofuels Blending Consulting (2015)
  • MOL Hungary Gasoline, Diesel, and Marine Bunker Blending Consulting (2015)
  • Tesoro Anacortes refinery Gasoline & Diesel, Blending Consulting (2015)
  • WNR El Paso Refinery Gasoline Blending Improvement Project (2014-2015)
  • P66 Bayway Refinery Gasoline Blending Improvement Project (2014-2015)
  • SUNCOR Sarnia refinery Gasoline & Diesel, Blending Consulting (2014)
  • Socar Aurora Fujairah (UAE) Terminal Gasoline Blending Consulting (2014)
  • Sasol Gasoline Blending Consulting (2014)
  • Alcoa/Jamalco Power Plant: Fuel Oil Blending Project (2014)
  • ASTM Working Group on FT-NIR Gasoline In-line Blending Certification – (2012-2014)
  • JX Nippon Energy Bunker Blending Feasibility Study, Fujairah, UAE (2013-2014)
  • Eco-Energy Pipeline Gasoline Butanization Project (2012-2013)
  • Colonial Pipeline Gasoline Butanization Blending Project (2013)
  • Petrobras Pasadena Refinery Gasoline Blending Modernization Project (2012-2013)
  • Hess Port Reading Refinery Gasoline Blending Modernization Project Study (2012)
  • Celanese Gasoline and Synthetic Ethanol/Methanol Blending R&D (2011-2012)
  • ExxonMobil Torrance Marine Bunker In-Line Blender Design for Jacobs Engineering (2010)
  • Preem Gothenburg Refinery Gasoil/ULSD/Green Diesel Blending Study (2011)
  • Petro-Canada Edmonton Refinery Gasoline Blending Study/Benzene Reduction/Ethanol Blends
  • Buckeye Pipeline Gasoline and Diesel Transmix Recovery and Blending Consulting (2010)
  • NexGen Biofuels E10 Gasoline and B2 BioDiesel Blending: Blending Terminal Design, Optmized Blend Recipes (2010-2011)
  • Interchem BV Gasoline Blending Trading: Blending Facilities with New Tanks(LBC)
  • Chevron Pascagoula Refinery Gasoline Blending Improvement Study
  • Hovensa St. Croix Refinery Gasoline Blending Improvement Study
  • CITGO Lake Charles Refinery Gasoline Blending Improvement Study
  • Sunoco Marcus Hook Gasoline Blending Modernization/NIR Consulting
  • Sunoco Toledo Refinery Gasoline Blending Modernization Study
  • Sunoco Pt. Breeze Gasoline Blending Modernization Study (2006-2008)
  • Petrobras RLAM Refinery Diesel In-Line Blend Certification Feasibility Study
  • BP Cherry Point Refinery: 2 Diesel (ULSD and LSD) In-line Blend Certification Projects
  • Motor Oil Hellas Corinth Refinery Gasoline Blending Modernization Project Consulting
  • Petro-Canada Montreal Refinery Gasoline Blending Modernization Project
  • Suncor Sarnia Refinery Gasoline Blending Upgrading Study
  • Sasol Synfuels Secunda Refinery Diesel Blending On-line Certification Consulting
  • Sasol Synfuels Secunda Refinery Gasoline Blending On-line Certification Study
  • Motiva Port Arthur Refinery Gasoline + Diesel Blending On-line Certification Study
  • Golfo Brasil Petroleo Gasoline and Diesel Blending Automation Project
  • NIS Pancevo Refinery Gasoline and Diesel Computerized In-line Blending
  • Atofina Port Arthur Refinery Gasoline NMR and Diesel NIR Blending Consulting
  • Agip Raffineria di Milazzo Gasoline Computerized In-line Blending Study and FEED
  • PKN Orlen Plock Mogas in-line blender expansion project
  • Petrogal Blending and OM&S consulting
  • PDVSA Production Automation Project: Well Optimization and ASMS

Continuous blending is quite common in fuel oil blending but rarely any refinery uses it in the gasoline production this is all due to the complex requirements and component pools. Therefore it is quite important for refiners to understand how to minimize Blending Giveaway specifically in the aspect of the gasoline production. Here at Refinery Automation Institute, LLC, we offer blending advisory services, so that they can understand the minimal giveaway specification and save bucks on their table.

Besides, Blending Economic Performance Assessment studies are also an integral part of our services. We make sure that these economic assessments don’t hinder the functionality of organizations, for more performance guarantee is 100%. The achievable giveaway reduction helps in bringing improvement in the marketable gasoline production, profit generation and method of meeting strict quality standards of the responsible authorities. Therefore instead of wasting time in thinking, avail our commendable services. Further for any query contact us, we would be happy to assist you in this venture.

Schedule Consultation

Contact Info

Refinery Automation Institute, LLC

6 Leslie Court Morristown,
New Jersey 07960 USA
Phone: +1-973-644-2270
eFAX: +1-973-206-2256