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Refinery to airport

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Supplying aviation products - from refinery to aircraft

Jet fuels are made from the kerosine fractions of crude oils and have a typical distillation range of 150 to 280_C. These fractions generally need further treatment - hydrotreating or a chemical sweetening process - to remove or reduce potentially harmful trace constituents such as sulphur, oxygen, nitrogen compounds and certain trace metals.

 

The quality and yield of a jet fuel depend on:

 

    • the source of the crude oil
    • the type of conversion and treatment processes available at the refinery
    • demand for other distillate products such as gas oils and gasolines.

 

The choice of crude oil can be an important factor in jet fuel production. A crude from the North Sea Forties field, for example, can yield almost 25% jet fuel whereas a heavy Middle Eastern crude may yield only 10%. Jet fuel composition can vary depending on crude oil composition and the different process treatments used to manufacture the finished products. (Hence the importance of fuel specifications since even small variations in fuel composition can have a dramatic effect on the safe and prolonged operation of jet engines.)

 

Large complex refineries may produce more than one kerosine grade, whereas smaller or less sophisticated refineries may find it economic to produce just one grade. Such dual purpose kerosines (DPK) - produced for sale as jet fuel and for heating or lighting - must, of course, conform to all jet fuel specification requirements.

 

The physical properties of the kerosine fraction for jet fuel are affected by the demands for competing fractions - naphthas for gasoline components and gas oils for diesel and heating oils. Refineries - especially those supplying temperate climate zones where demands for gasolines, jet fuel and heating oils change between summer and winter - often have to make adjustments to meet competing market requirements. In the summer months in Europe, for instance, the kerosine market is dominated by the demand for jet fuel for charter flights whereas in winter, the demand is more for heating oils.

 

The supply chain - emphasis on quality controls

The aviation industry is extremely safety conscious in all its operations and the supply of aviation fuel is no exception. Great care is taken to ensure that clean, dry and on-specification fuel is supplied to aircraft safely and efficiently at all locations around the world.

 

The quality control system is based on the principle that aviation fuel is clean, dry and on-specification following manufacture at the refinery. The distribution system from refinery to airport is designed to minimise the chance of contamination with dirt, water or other fuels so that the aviation fuel remains on-specification.

 

Where contamination with other products could occur (for example in multi-product pipelines or on multi-product tankers), contamination-sensitive properties are always laboratory tested to confirm that no contamination has occurred. If product traceability is lost and contamination cannot be checked in this way, a complete specification analysis must be performed.

 

At airports there are dedicated facilities for each grade of aviation fuel to avoid any contamination with other fuels. The presence of dirt and water in the fuel is minimised by the combined use of product setting, microfilters, and filter water separators throughout the distribution system. At the final stage of delivery into plane, fail-safe filter monitors may be used to prevent the passage of dirt and free water. Shell companies were among the first to introduce this equipment on all their refuelling vehicles.

 

In addition to this emphasis on quality, it is essential to ensure that fuel is always delivered into the aircraft safely and efficiently. With the need to minimise aircraft turn-round times, high fuelling rates are required: a typical Boeing 747 uplift of 150 tonnes, for instance, needs to be delivered at flow rates of up to 6.5 tonnes/minute. Any system failure could thus have disastrous results, and comprehensive procedures are enforced at each airport to ensure that hoses, pressure controllers and other components are regularly tested.

 

Detailed records are kept of all fuel and equipment test results. The system is designed so that the history of any batch of fuel delivered into any aircraft anywhere in the world can be traced back to the original refinery, (including all equipment used to handle the fuel, when the equipment was tested, laboratory results, etc). To ensure compliance with all these international requirements, all airports are inspected at frequent intervals.

 

Outside North America, oil companies generally own the airport storage and hydrant systems and contract with an airline to supply into plane, following the strict operational guidelines described earlier. In the USA and Canada the situation is very different. There, airlines - often in a consortium - generally own the fuel facilities which are operated on a contract basis by a specialist company. This fuelling contractor undertakes a number of additional tasks associated with into-plane fuelling - eg. operating switches and valves on the aircraft's fuelling panel. Outside North America, these tasks have hitherto been carried out by airline staff, but some airlines are now requiring them to be conducted by the fuel suppliers. These services incur greater costs and liabilities, factors which need to be taken into consideration in the fuel supply contracts.

 

This is an extract from `Fuelling aviation', copies of which can be obtained from Group Public Affairs, Shell international Petroleum Company Limited.

 

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