Billions Saved Through Operational Optimization at Dung Quat Refinery

Technological Breakthrough

After over 16 years of commercial operation, the engineering team at Binh Son Refining and Petrochemical Joint Stock Company (BSR) has fully mastered modern refining and petrochemical technology, from operation and maintenance to process optimization. Among them, Master Le Quoc Viet stands out as a key figure. He proposed the implementation of the solution “Changing the LCO-HDT Unit Operation Mode and Diesel Blending to Save Energy,” which has brought billions of VND in economic benefits to the plant, showcasing BSR’s expertise and intelligence.

Joining BSR during the plant’s trial run phase, Master Le Quoc Viet has held various positions, from operation to research and development, gaining a deep understanding of each unit’s technology. Currently, as Deputy Head of the Processing Technology Department, he is responsible for evaluating and proposing technical optimization solutions to ensure stable, efficient, and safe plant operations.

In the process chain, the LCO-HDT unit acts as the plant’s “purification filter,” playing a critical role in ensuring product quality. This unit uses hydrogen to remove sulfur, nitrogen, and unsaturated hydrocarbons from the LCO fraction (from the RFCC unit) to meet diesel blending standards. This process consumes significant energy, hydrogen, steam, and fuel gas—major components of production costs.

Drawing from his operational experience and observations, Master Le Quoc Viet noticed that during periods of low sulfur content in crude oil, diesel products could still meet standards without LCO-HDT treatment. This led him to ask: “Under which operating conditions and crude oil characteristics can the LCO feedstock be directly blended to produce standard diesel without LCO-HDT unit processing?”

The research team analyzed years of operational data and developed a correlation model between sulfur in crude oil, LCO fraction, diesel products, and the capacity of the sulfur recovery unit (SRU2). They identified an “optimal operating range” where the LCO-HDT reaction section could be bypassed, allowing direct LCO blending into diesel while maintaining product quality. Viet’s keen data analysis and innovative approach to process management transformed a minor technical insight into a solution saving billions for BSR.

Energy Savings and Environmental Protection

While determining the possibility of bypassing sulfur treatment, Master Le Quoc Viet’s solution faced the challenge of defining the optimal sulfur content range in crude oil. Additionally, the impact on diesel properties such as Cetane number, viscosity, and water content required careful consideration.

To address this, Viet and his team conducted extensive research. They analyzed years of operational data, established sulfur distribution balances from crude oil input to each process stream and final product, and determined the relationship between sulfur in crude oil and diesel products, as well as SRU2 capacity. This led to the identification of the ideal technical threshold. The team also performed numerous blending experiments, laboratory analyses, and organized dozens of workshops to assess risks and propose solutions, ensuring successful implementation.

Finding the “optimal operating range” was one of the most challenging aspects of Master Le Quoc Viet’s solution, requiring prolonged research.

Through multiple real-world trials, daily diesel sampling, and quality analysis, the team confirmed that products met standards when crude oil sulfur levels ranged from 500-700 ppm. This range became the “optimal operating window,” enabling the plant to flexibly adjust operations, save energy, and maintain product quality and safety.

Master Le Quoc Viet’s initiative to modify LCO-HDT unit operations and directly blend LCO/HVN into diesel has delivered impressive economic and energy savings, contributing to environmental protection. After two short implementation periods (September 11-25, 2021, and October 3-19, 2022), the plant saved nearly 7 billion VND in operating costs. This was achieved by halting the reaction section, significantly reducing hydrogen, steam, electricity, fuel gas, and demineralized water consumption—factors accounting for 60-70% of production costs. Moreover, each hour of unit downtime saved nearly 90% of auxiliary energy, reducing CO₂ and greenhouse gas emissions, thus supporting environmental protection. This seemingly minor adjustment highlights BSR engineers’ technological mastery, innovation, and commitment to sustainable development.

“I am incredibly happy that this solution not only saves costs and energy but also lays the groundwork for deeper operational optimization research, aligning with BSR’s goals of efficiency, safety, and green development,” shared Viet.

Through solutions optimizing operations and enhancing productivity, BSR’s “refining artisans” continue to demonstrate their technological mastery and readiness for sustainable growth.

Master Le Quoc Viet’s innovation in LCO-HDT unit operations exemplifies the agility, innovative thinking, and technological mastery of BSR’s workforce. His efforts were recognized when the solution “Changing the LCO-HDT Unit Operation Mode and Diesel Blending to Save Energy” won third prize at the 14th Quang Ngai Provincial Technical Innovation Competition and was nominated for the 18th National Technical Innovation Competition.

Master Le Quoc Viet and his solution have showcased BSR’s technological expertise and innovative mindset. The initiative not only delivers economic benefits but also contributes to reducing emissions and promoting sustainable development at Dung Quat Refinery, affirming Vietnamese engineers’ capabilities in modern refining and petrochemicals.