Rompetrol Rafinare: APC digital control boosts Petromidia production and cuts costs
- Advanced Process Control generated estimated cost reductions of over USD 2.5 million in 2025.
- White‑product yield reached a record 87.1% wt, supported by high crude volumes from KazMunayGas.
- Refinery utilization rose to 98.1% with average throughput above 16,000 tons/day and technological losses of 0.78%.
- APC has been used across all installations since 2020, adjusting process parameters every minute to optimise quality, capacity and energy use.
System and operation
Petromidia implemented an Advanced Process Control (APC) digital process control system that replaces manual tuning of temperatures, pressures and flows. Operators set desired product quality and the APC software recalculates optimal unit settings every minute, effectively running each unit on a digital autopilot.
Operational impact
The refinery reports APC-driven increases in high‑value product yields and the ability to run installations at maximum capacity under stable conditions. In 2025 this contributed to estimated cost reductions of over USD 2.5 million, a record white‑product yield of 87.1% wt, and maximum production levels for gasoline, diesel and jet fuel.
Efficiency and energy
Petromidia recorded a utilization rate of 98.1%, average feedstock throughput above 16,000 tons/day, technological losses of 0.78% and a historic low Energy Intensity Index of 92.5 points. Fuel‑gas production reached 205,000 tons/year, reducing natural gas consumption and processing costs.
Skills and rollout
The APC has been deployed across all installations since 2020 and is used for predictive control to reduce production risks. Rompetrol Rafinare also deployed the first stage of an Operator Training Simulator (OTS) to improve operator skills, safety and reaction times in critical situations.
Source: KMG
