Inputs
Example Data Table
Sample scenarios below show how inputs translate into net throughput.
| Flow | Density (kg/m³) | Hours/day | Util (%) | Net (%) | Net bbl/day | Net t/day | Net bbl/year |
|---|---|---|---|---|---|---|---|
| 250 m³/h | 850 | 24 | 92 | 98 | 34,025 | 4,598.2 | 12,419,257 |
| 160,000 bbl/day | 870 | 24 | 95 | 100 | 150,480 | 20,814.2 | 54,925,200 |
| 1,800 L/min | 820 | 20 | 88 | 97 | 11,713 | 1,527.0 | 3,865,281 |
Formula Used
API-to-density conversion is an approximation using specific gravity at reference conditions. For custody transfer work, use site-approved density and correction factors.
How to Use This Calculator
- Enter the feed flow rate and choose the correct unit.
- Provide density for best accuracy, or enter API gravity.
- Set operating hours/day and utilization to reflect downtime.
- Use the yield/net factor to represent net processed output.
- Adjust VCF when working with corrected versus observed volumes.
- Set days/year for budgeting or turnaround planning.
- Optionally add nameplate capacity to see utilization percent.
- Press Calculate; then download CSV or PDF if needed.
Throughput as a Core Refinery KPI
Throughput links field operations to commercial performance. A 200,000 bbl/day refinery running at 92% utilization delivers about 184,000 bbl/day net capacity before yield effects. Small percentage changes compound: improving utilization from 92% to 94% adds roughly 1.6 million barrels per year at a 200,000 bbl/day nameplate, assuming 365 days. Gross versus net separates uptime limits from processing losses.
Unit Conversions and Standard Volumes
Sites record flow in m³/h, bbl/day, or L/min depending on meters. This calculator converts everything to m³/h, then reports barrels using 1 m³ = 6.28981077 bbl. The volume correction factor (VCF) adjusts observed volume to reference conditions, reducing bias from temperature swings and density drift. A consistent basis helps reconcile tank receipts, pipeline tickets, and CDU charge logs when totals differ by 0.2–0.5%. It supports consistent KPI reporting across shifts and units.
Utilization, Onstream Time, and Reliability
Utilization captures unplanned outages, catalyst changeovers, and scheduled turnarounds. Onstream hours/day = hours/day × utilization; 24 h/day at 90% equals 21.6 onstream hours. Normalize by days and utilization to separate demand cutbacks from reliability constraints. Reliability teams map utilization to MTBF and repair time; each hour recovered increases crude processing and blending flexibility.
Mass Throughput and Crude Quality
Mass throughput (tonnes/day) depends on density, which varies with crude slate and blending. Typical crude densities range roughly 820–900 kg/m³; a 50 kg/m³ shift can move daily tonnage by about 6% at constant volume. If density is unavailable, API gravity provides an estimate via specific gravity; use lab or custody-transfer density for emissions, energy intensity, and crude accounting. Mass rates also support heater duty and sulfur load screening.
Capacity Benchmarking and Planning
Nameplate capacity is a reference, not a guarantee. The tool computes net bbl/day and optional capacity utilization = net bbl/day ÷ nameplate, useful for dashboards. Combine annualized throughput with days/year to test turnaround cases, for example 330 operating days versus 365. Pair results with unit constraints (CDU, VDU, FCC, hydrotreaters) to find the bottleneck, then evaluate projects by incremental net bbl/day gained.
FAQs
1) What does net throughput represent here?
Net throughput equals gross processed volume after applying the yield/net factor. Use 100% when you want pure charge rate, or reduce it to reflect net delivered output after losses and internal recycle effects.
2) Should I enter density or API gravity?
Enter density whenever you have a lab value or custody-transfer density. API gravity is only a backup estimate and can introduce error, especially for blended crudes or when temperature and composition vary.
3) How do I choose utilization?
Use a period-average value that reflects downtime, maintenance, and operational slowdowns. For monthly reporting, calculate utilization from onstream hours divided by available hours, then apply the same basis across units.
4) When is the volume correction factor needed?
Apply VCF when your measured flow is at observed conditions but you need reference-condition volumes for planning or reconciliation. If your instruments already report corrected volume, keep VCF at 1.00.
5) Why are annual results based on days per year?
Days per year lets you model turnarounds and feed constraints. Planning cases often use 330–350 days, while continuous operation uses 365. The calculator multiplies daily results by your chosen days.
6) How are the CSV and PDF exports generated?
CSV is produced by the server from the last saved calculation in your session. PDF is generated in the browser from the displayed results table, which makes it fast to share without extra server libraries.