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Advanced CPD

Refinery Process Yield Optimisation

This advanced 5 days programme provides professionals with a rigorous, practice-oriented grounding in Refinery Process Yield Optimisation. Designed for those working across the Downstream Refining & Petrochemicals sector, the course combines established theoretical frameworks with current industry practice through expert-led instruction, structured case studies, and hands-on workshops.

5 daysDuration
AdvancedLevel
5 Days · 15 ModulesProgramme
YX-REF-002Code
Classroom Online In-House Blended
Starting From
$4,950
per delegate · live online
Classroom
Face-to-face at a global venue
$5,950
Online
Live interactive virtual sessions
$4,950
In-House
Delivered at your premises
Quote
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Internationally Accredited
50+ Global Locations
Expert Advisory Team
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Course Overview

About this programme

This advanced 5 days programme provides professionals with a rigorous, practice-oriented grounding in Refinery Process Yield Optimisation. Designed for those working across the Downstream Refining & Petrochemicals sector, the course combines established theoretical frameworks with current industry practice through expert-led instruction, structured case studies, and hands-on workshops.

Participants will engage with the most relevant tools, standards, and methodologies used in Petroleum Refining today. By the final day, delegates will leave with a clear personal action plan and the confidence to apply their learning immediately, contributing to improved performance, compliance, and competitive advantage within their organisations.

Programme Objective

Equip professionals with the knowledge, skills, and frameworks required to excel in Refinery Process Yield Optimisation, driving measurable improvement in Downstream Refining & Petrochemicals performance and delivering tangible value to their organisations.

5 daysTotal Duration
5 DaysTraining Days
15 ModulesModules Covered
Max 20Class Size
EnglishLanguage
CPDAccreditations

What You Will Learn

10 key learning outcomes

01

Understand crude oil refining process units and their role in producing petroleum products to specification

02

Apply refinery yield optimisation techniques to improve product slate and margin performance

03

Evaluate petrochemical feedstock options and process routes for key commodity chemicals

04

Apply process safety management to refinery and petrochemical operations and major hazard control

05

Understand refinery and petrochemical utilities: steam, hydrogen, fuel gas, power, and cooling water systems

06

Evaluate crude oil assay data and select crude slates for optimal refinery economics

07

Apply environmental regulations relevant to downstream operations including emissions, effluent, and waste

08

Understand product quality specifications and blending strategies for fuel and petrochemical products

09

Evaluate refinery and petrochemical plant performance KPIs including yield, energy, and reliability

10

Apply energy efficiency and decarbonisation strategies to reduce the environmental footprint of downstream assets

Course Outline

5 training days · 15 modules · hands-on workshops

1
Crude
Oil
2
Refinery
Conversion
3
Petrochemical
Processes
4
Refinery
Operations,
5
Yield
Optimisation,
Day 1

Crude Oil & Refinery Fundamentals

Understand crude oil composition, refinery configurations, and core process units.

8 hours 3 modules
Module 1

Crude Oil Composition & Assay

  • Crude oil characterisation: API gravity, sulphur, and TAN
  • Crude assay data: TBP distillation, yield, and property profiles
  • Crude classification: light sweet, heavy sour, and opportunity crudes
  • Crude selection economics: premium, discount, and total cost of crude
Module 2

Refinery Configurations

  • Simple refinery: topping and hydro-skimming configurations
  • Complex refinery: cracking and coking upgrade units
  • Integrated refinery-petrochemicals: steam cracker and aromatic complex
  • Refinery margin: crack spread, Nelson complexity index, and asset value
Module 3

Atmospheric & Vacuum Distillation

  • Crude distillation unit (CDU): preheat train, desalter, and fractionation
  • Distillate fractions: naphtha, kerosene, gas oil, and atmospheric residue
  • Vacuum distillation unit (VDU): vacuum column and side streams
  • Desalter operation: wash water, mixing valve, and brine disposal
Practical Workshop

Crude assay analysis: teams evaluate three crude assays, calculate the theoretical yield of key products, and rank the crudes for a provided refinery configuration.

Day 2

Refinery Conversion & Upgrading

Understand catalytic and thermal conversion units that improve refinery yield and product quality.

8 hours 3 modules
Module 1

Fluid Catalytic Cracking (FCC)

  • FCC process: riser, reactor, regenerator, and fractionation
  • FCC feedstocks and catalyst: zeolite types and activity
  • FCC products: LPG, gasoline, light cycle oil, and coke
  • FCC operating variables: riser temperature, CTO, and cat-to-oil ratio
Module 2

Hydroprocessing

  • Hydrocracking: feed, catalyst, and product yield profiles
  • Hydrotreating: desulphurisation, denitrogenation, and HDS kinetics
  • Hydrogen balance: consumption, production, and PSA units
  • Catalyst management: deactivation, regeneration, and replacement
Module 3

Coking & Thermal Processes

  • Delayed coking: drum cycle, coke cutting, and product yields
  • Visbreaking: soaker drum and thermal cracking severity
  • Solvent deasphalting (SDA): DAO and asphalt quality
  • Coker naphtha and gas oil: treating requirements before downstream processing
Practical Workshop

Refinery yield optimisation: teams adjust the operating variables for a simplified refinery linear programme to maximise diesel yield and refinery margin for a given crude slate.

Day 3

Petrochemical Processes & Products

Understand the key petrochemical process routes and their integration with refinery operations.

8 hours 3 modules
Module 1

Steam Cracking & Olefins

  • Steam cracker feedstocks: naphtha, ethane, propane, and LPG
  • Cracking severity: COT, steam ratio, and olefin yields
  • Ethylene, propylene, and butadiene: downstream derivatives
  • C4 hydrocarbon processing: butadiene extraction and alkylation
Module 2

Aromatics Complex

  • Catalytic reforming: naphtha reforming, H2 production, and BTX yield
  • Aromatics extraction: solvent extraction and extractive distillation
  • Xylene isomerisation and paraxylene production: adsorptive separation
  • Benzene, toluene, and xylene derivatives: key petrochemical products
Module 3

Polymer Production

  • Polyethylene: HDPE, LLDPE, and LDPE production processes
  • Polypropylene: Ziegler-Natta and metallocene catalyst systems
  • PET and polyester: PTA and ethylene glycol production chain
  • Polymer markets: commodity vs. engineering plastics and packaging
Practical Workshop

Petrochemical value chain mapping: teams trace the value chain from crude oil to a final polymer product, identifying all process steps, key intermediates, and margin contribution points.

Day 4

Refinery Operations, Safety & Energy

Apply process safety and energy management to downstream operations.

8 hours 3 modules
Module 1

Refinery Process Safety

  • Major accident hazards in refineries: fire, explosion, and toxic release
  • HAZOP in refinery context: complex interlock systems and batch operations
  • Fired heaters: safety interlocks, decoking, and tube failure scenarios
  • Sulphur recovery: Claus unit operation and tail gas treating
Module 2

Energy Management in Refineries

  • Refinery fuel and loss: fuel gas balance and energy accounting
  • Pinch analysis for heat integration: minimum utility and network design
  • Steam system optimisation: header pressures, condensate recovery, and letdown
  • Flare minimisation: recovery systems, torch-off reduction, and carbon reduction
Module 3

Environmental Compliance

  • Refinery air emissions: SOx, NOx, VOC, and particulate control
  • Wastewater management: API separator, DAF, and biological treatment
  • Solid waste: spent catalyst, filter cake, and RCRA compliance
  • EU ETS and refinery carbon intensity: benchmark, allocation, and compliance
Practical Workshop

Energy audit exercise: teams conduct an energy audit of a simplified refinery heat and mass balance, identify the three largest energy losses, and quantify the saving potential.

Day 5

Yield Optimisation, Digitalisation & Future of Downstream

Apply LP optimisation, digital tools, and decarbonisation strategies to future-proof downstream assets.

8 hours 3 modules
Module 1

Refinery Linear Programming

  • LP model structure: crude, process units, blending pools, and products
  • Objective function: margin maximisation vs. product yield targets
  • Sensitivity analysis: crude price, product value, and capacity constraints
  • LP model validation: benchmarking to actual plant performance
Module 2

Digital Refinery

  • Digital twin for process units: virtual sensors and soft analysers
  • Advanced process control (APC): MPC for CDU, FCC, and hydrocrackers
  • Predictive maintenance for refinery equipment: rotating equipment and heat exchangers
  • Real-time optimisation (RTO): closed-loop integration with DCS
Module 3

Downstream Decarbonisation

  • Refinery CO2 intensity: benchmark and reduction targets
  • Blue hydrogen from refinery hydrogen: CCS integration options
  • Biofuels co-processing: HVO, biomass pyrolysis, and SAF feedstocks
  • Net-zero refinery: electrification, CCS, and biomass integration pathways
Practical Workshop

Capstone refinery optimisation: teams use a simplified LP model to determine the optimal crude slate and operating conditions for a provided refinery configuration, maximising margin under product and environmental constraints.

The course outline is indicative. Content may be adapted to reflect current industry developments and delegate experience levels.

Who Should Attend

This programme is designed for professionals across these roles

Refinery Process Engineers

Engineers responsible for unit performance, yields, and process optimisation in refining operations

Petrochemical Engineers

Technical professionals working in olefins, aromatics, and polymer production facilities

Refinery Economists & Commercial Staff

Commercial teams responsible for crude selection, product pricing, and margin management

Process Safety Engineers

Safety professionals managing HAZOP, LOPA, and major accident hazard prevention in downstream

Maintenance & Reliability Engineers

Engineers responsible for rotating equipment reliability and planned turnaround management

Environmental & Sustainability Managers

Professionals managing emissions, energy efficiency, and decarbonisation in downstream operations

Schedule & Fees

Upcoming public dates — enrol anytime

Jun
02
02 Jun – 06 Jun 2026
Dubai, UAE
Classroom Only 3 seats left!
$5,950
per delegate
Jun
30
30 Jun – 04 Jul 2026
Live Online (Zoom)
Online 6 seats available
$4,950
per delegate
Jul
30
30 Jul – 03 Aug 2026
Singapore
In-House 4 seats available
Quote
custom pricing
Aug
22
22 Aug – 26 Aug 2026
Houston, USA
Blended 8 seats available
Quote
custom pricing
Sep
23
23 Sep – 27 Sep 2026
Abu Dhabi, UAE
Classroom Only 3 seats left!
$5,950
per delegate
Oct
24
24 Oct – 28 Oct 2026
Live Online (Zoom)
Online 5 seats available
$4,950
per delegate
Can't find a suitable date? Contact us for private cohort scheduling or in-house delivery options at your premises.

Accreditations & Recognition

This course carries internationally recognised professional credits

CPD Certified

Course Resources

Request documentation before you book

Ready to Enrol?

Speak with our training advisors to confirm availability, group rates, and customised in-house options.