Optimized Process Costing for Crude Oil, Diesel and Gas Refining Operations
Streamlining Crude Oil and Diesel Procurement and Refining Workflows
Integrated Production Planning for Oil, Diesel and Gas Refineries
Accurate Feedstock to Yield Forecasting for Diesel, Crude and Gas in Odoo
Enhancing Operational Efficiency in Petroleum, Diesel and Gas Processing Plants
The Crude Oil, Diesel, and Gas Processing Petroleum Refining solution in Odoo is designed to streamline and control every aspect of oil, diesel, and gas refining operations from crude feedstock planning to final cost tracking. Key features include a comprehensive Bill of Materials (BoM) that defines input crude grades, hydrogen requirements, catalysts, and major refining units such as atmospheric distillation, vacuum distillation, hydrodesulfurization, cracking, and blending. The system supports precise process costing, by product tracking (such as diesel, naphtha, fuel oil, gases, and lubricants), and automatic cost allocation across multiple refined products. Manufacturing Orders (MO) and Work Orders enable real time monitoring of crude throughput, hydrogen and catalyst consumption, machine and utility usage, and actual costs for each refined fuel, including diesel, or by product batch. Operators can record unit wise production data directly in the system, ensuring accurate tracking of yield, sulfur removal efficiency, and production economics. Job Cost Sheets provide a clear comparison of planned vs. actual input usage, enabling detailed cost reconciliation and insights into refinery margins and operational performance. Integrated Purchase Requisitions ensure timely procurement of crude oil, hydrogen, catalysts, and process chemicals, maintaining continuous refining operations and aligning procurement with dynamic production plans.
Main Features:
- Bill of Materials (BoM) Form View Overview
- The BoM defines all crude oil input grades and the refining process steps required to produce various refined fuels and by products to meet quality and regulatory standards. It includes:
- Crude feedstock: Different grades of crude oil and any blending requirements.
- Key refining units: Atmospheric distillation, vacuum distillation, hydrodesulfurization, catalytic cracking, and blending units.
- Process costing: Estimated costs for feedstock, energy (heat, steam, hydrogen), catalysts, and utilities.
- By products: Light gases, naphtha, residual fuel oil tracked for reuse, blending, or sale to maximize refinery margin.
- Manufacturing Orders (MO) Form View Overview
- Manufacturing Orders plan and track each batch or continuous run of refining operations. They show:
- Feedstock input quantities and blending instructions,
- Linked work orders for distillation, hydrotreating, cracking, blending, and storage,
- By products and waste streams with real time updates on yield and losses.
- Work Orders Form View for Unit Level Monitoring
- Work Orders break down refining into unit operations (e.g., distillation columns, reactors). Operators record:
- Actual throughput for each unit,
- Energy and hydrogen consumption,
- Catalyst usage and regeneration,
- Unit efficiency and performance tracking for compliance and optimization.
- Job Cost Sheets for Final Cost Reconciliation
- Job Cost Sheets compare planned vs. actual costs for:
- Crude feedstock and blending stock,
- Hydrogen and catalyst consumption,
- Energy usage (electricity, steam, fuel gas),
- Providing a full breakdown of cost per barrel and margin analysis for refinery profitability.
- Purchase Requisitions for Feedstock and Catalyst Planning
- Purchase Requisitions help secure crude oil, blending stocks, catalysts, and process chemicals in sync with production plans to ensure:
- On time delivery of feedstock,
- No refinery downtime,
- Efficient inventory turnover and cost control.
Workflow Overview:
- Bill of Materials (BoM) Configuration:
- Define the crude oil feedstock grades and blending requirements for producing refined fuels and by products.
- Set up refining units and operations such as atmospheric distillation, vacuum distillation, hydrotreating, catalytic cracking, and blending.
- Include by products (e.g., naphtha, fuel oil, light gases) and estimate Direct Material Cost, Hydrogen Cost, Catalyst Cost, and Utility Overhead Cost.
- Cost allocation for co products and by products is automatically handled for multi stream refinery output.
- Job Cost Sheet Preparation:
- Provides a detailed estimate of crude input, hydrogen consumption, catalyst usage, energy costs (steam, electricity), and operator time.
- Acts as a key tool for cost forecasting, yield planning, and refinery margin optimization.
- Manufacturing Order (MO) Creation Confirmation:
- The Production Planner generates the MO using the configured BoM for each refining run or batch.
- Odoo reserves crude oil feedstock and schedules operations for each refining unit.
- MO includes tabs for Work Orders, By products, and detailed cost tracking for the run.
- Work Order Execution:
- Operators access assigned Work Orders for each unit (e.g., distillation columns, hydrotreaters, crackers).
- They log actual throughput, hydrogen feed, catalyst condition, and machine/utility usage (heaters, compressors, pumps).
- Manufacturing Order Update with Actuals:
- The system records actual feedstock processed, hydrogen used, catalysts consumed, and utilities in real time.
- Real consumption values ensure accurate inventory updates and true cost accounting for each product yield.
- Production Finalization Job Cost Sheet Closure:
- Once the refining run is complete, the MO is marked as done in Odoo.
- Final figures for crude processed, hydrogen, catalysts, and plant hours are logged.
- Delivers a clear planned vs. actual cost comparison for each batch, supporting profitability and compliance tracking.
Key Benefits:
- Full control over crude oil processing and petroleum refining operations within Odoo.
- Accurate tracking of refining units, feedstock, and multiple refined products.
- Realtime visibility into cost efficiency, regulatory compliance, and product yield performance.
The Crude Oil, Diesel, and Gas Processing Petroleum Refining Management solution in Odoo is designed to support a wide range of industries and operations within the oil, diesel, and gas refining sector. This includes large scale crude oil refineries producing various refined fuels, including diesel, and by products to meet diverse market demands and regulatory requirements. It caters to integrated oil companies managing multiple refining units such as atmospheric and vacuum distillation, catalytic crackers, hydrocrackers, and hydrotreaters. Independent refinery operators specializing in fuel blending, sulfur removal, diesel production, and specialty product streams benefit from real time tracking of feedstock, hydrogen usage, catalyst performance, and unit efficiency. The solution is also suitable for petrochemical complexes producing fuels including diesel alongside other by products like naphtha, gasoline, fuel oil, and light gases. Companies involved in bulk diesel and fuel storage, distribution terminals, and downstream logistics can use this system to align production with supply chain and market needs. It is ideal for firms needing to demonstrate compliance with regional or international fuel quality standards, as well as engineering and EPC companies delivering refinery operations and services. Additionally, this solution supports refiners investing in cleaner fuel technologies and sustainability initiatives, helping optimize plant efficiency, cost control, and product quality across the entire operation.