An Intensive 5-day Training Course

Oil Refinery Cost Management

Effective Energy Management

INTRODUCTION TO THE COURSE

Cost efficiency has become a critical performance metric in the modern oil refining sector. As global competition intensifies and margins tighten, the ability to strategically manage and control refining costs determines long-term viability and profitability. A systematic and informed approach to cost management supports smarter production decisions, greater energy efficiency, and improved financial outcomes.

This Oil Refinery Cost Management training course is tailored to professionals seeking to enhance their expertise in refinery economics, cost structure allocation, and utility optimization. Participants will gain a comprehensive understanding of how to model, analyze, and reduce production costs at each stage of the refining process—from crude oil intake to final product distribution.

Through a combination of instructor-led sessions, real-world case studies, and practical Excel-based costing tools, delegates will learn how to establish effective cost control mechanisms and support their organization’s drive toward operational excellence and sustainable growth.

Key Learning Highlights

  • Techniques to evaluate and allocate costs across refining units and output streams
  • Integration of cost control with production planning and plant performance monitoring
  • Utility system optimization for energy savings and cost reduction
  • Strategic use of cost indicators to assess scheduling and refinery throughput
  • Practical modeling using Excel-based tools for cost forecasting and decision support
  • Insights into crude selection, blending strategies, and margin improvement

COURSE DETAILS

Objectives Icon

OBJECTIVES

By the end of this Oil Refinery Cost Management training course, participants will be able to:

  • Calculate individual unit and stream costs to identify profitability drivers
  • Develop and apply cost management models to support operational decisions
  • Streamline utility consumption and reduce excess energy expenditure
  • Identify cost-saving opportunities through process integration and optimization
  • Strengthening production planning through cost visibility and analysis
  • Align cost management practices with refinery performance improvement initiatives
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TRAINING METHODOLOGY

Oil Refinery Cost Management training course is a hands-on, stimulating learning experience. This training course will be highly interactive, with opportunities to advance one’s opinions and ideas. Participation is encouraged in a supportive environment.

To ensure the concepts introduced during this training course are understood, they will be reinforced through a mix of learning methods, including lecture style presentations, open discussions, case studies, and short videos. Hands-on computer software and simulations will be provided to illustrate the application of costing and cost management. The case studies provided for group work will be re-enforced with practical exercises in excel and there will be ample opportunities for discussion and sharing of experiences.

Organizational Impact Icon

ORGANISATIONAL IMPACT

Organizations that enroll staff in this training course will benefit through:

  • Enhanced cost transparency across refinery operations
  • Improved coordination between financial planning and production execution
  • Reduced operational waste and energy consumption
  • Higher levels of performance forecasting accuracy
  • Increased agility in adapting to changing market conditions
  • A more skilled workforce equipped to manage plant cost efficiency
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PERSONAL IMPACT

Professionals attending this training course will:

  • Strengthen their skills in cost modeling and financial assessment
  • Gain hands-on experience with real-world refinery scenarios and costing techniques
  • Improve their ability to link technical decisions with financial outcomes
  • Develop greater confidence in strategic planning and budget control
  • Become more valuable contributors to cross-functional refinery teams
  • Acquire tools that can be applied immediately in their workplace
Target Audience Icon

WHO SHOULD ATTEND?

This training course is designed to provide technical and practical approaches to executing a petroleum refinery related cost management.

This KC Academy Oil Refinery Cost Management training course is suitable to a wide range of professionals but will greatly benefit:

  • Refining Oil & Gas Field Engineers
  • Process Plant Energy Managers / Coordinators
  • All Professionals involved in Production, Planning and Scheduling
  • Blending Professionals
  • Financial Analysts

DAILY AGENDA

Day 1: Overview of Cost Management
  • Introduction to Cost Management
    • Resource Planning
    • Cost Estimating
    • Cost Budgeting
    • Cost Control
  • Energy and its Effect on Refinery Profitability
  • Refinery Material & Energy Balance
  • Energy Benchmarking
  • Fuel, Power and Steam Costing Methodology
Day 2: Crude Oil Refining
  • Types of Refinery
  • Key Process Units
  • Refinery & Process Utilization
  • Global Refining Situation
  • Refining Costs
  • Refining Investment
  • Size and Complexity
  • Location and Logistics
  • Maintenance Costs
Day 3: Refinery Process Unit Operational Costs
  • Physical Separation: Crude & Vacuum Unit Distillation
  • Product Enhancement
    • Hydrotreating
    • Catalytic Reforming
    • Fluid Catalytic Cracking
    • Hydrocracking
    • Bottom of the Barrel Upgrading
  • Process Simulations
  • Advanced Process Control and its Benefits
  • Blending for Product Specifications
  • Blending to Reduce Product Costs
Day 4: Economic Evaluation and Cost Management
  • Cost Estimation
  • Refinery Complexity and Netback
  • The Gross Refining Margin
  • The Net Refining Margin
  • Factors that Influence Margins
  • Margins According to Region
  • Refinery Utility System
  • Steam and Power System Optimization
  • Energy Efficiency: The Effect of Energy on Refinery Profitability
  • Quantification of Fuel Loss, Oil Accounting
Day 5: Process Heat Integration & Equipment Efficiency: Effective Energy Management
  • Process Heat Integration
  • How heat integration works?
  • Introduction to Pinch Technology
  • Heat Availability Curves and Energy Targeting
  • Equipment Efficiency: Effective Energy Management
    • Fired Heaters
    • Rotating Equipment
    • Heat Exchangers
  • Energy Focused Organisation
  • Course Review and Close
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Certificate

On successful completion of this training course, KC ACademy Certificate will be awarded to the delegates.

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