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A rigorous simulation-based procedure for retrofitting an existing Egyptian refinery distillation unit

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  • Gadalla, Mamdouh A.
  • Abdelaziz, Omar Y.
  • Kamel, Dina A.
  • Ashour, Fatma H.

Abstract

The simulation of existing crude oil distillation processes is distinctive and difficult owing to its complex nature and interactions, including variable feedstocks, highly integrated processes, tight cuts specifications, and environmental limitations. This study introduces a systematic simulation-based algorithm for retrofitting an existing crude distillation column. The algorithm accounts for all details of the associated heat recovery system. Both distillation unit and HEN (heat exchanger network) are addressed simultaneously in the simulation. The proposed procedure is applied to simulate an existing CDU (crude distillation unit) processing 100,000 bbl/d crude oil of an Arabian origin. The rigorous simulation model achieved can fully describe the existing plant performance, and for this it is thus validated with the actual data for column operation parameters, cuts flow and specification, and for all details of heat exchanger network. The results are found in a good agreement with the actual data. The model is then applied for optimisation and revamping projects to minimise the energy consumption and the amount of CO2 emissions from the refinery. The advantage of the simulation model is its relevance to refining industries in performing any future revamping studies, modification tests, product changes, and capacity enhancement.

Suggested Citation

  • Gadalla, Mamdouh A. & Abdelaziz, Omar Y. & Kamel, Dina A. & Ashour, Fatma H., 2015. "A rigorous simulation-based procedure for retrofitting an existing Egyptian refinery distillation unit," Energy, Elsevier, vol. 83(C), pages 756-765.
    • Handle: RePEc:eee:energy:v:83:y:2015:i:c:p:756-765
    DOI: 10.1016/j.energy.2015.02.085
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    References listed on IDEAS

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    1. Gu, Wugen & Huang, Yuqing & Wang, Kan & Zhang, Bingjian & Chen, Qinglin & Hui, Chi-Wai, 2014. "Comparative analysis and evaluation of three crude oil vacuum distillation processes for process selection," Energy, Elsevier, vol. 76(C), pages 559-571.
    2. Ochoa-Estopier, Lluvia M. & Jobson, Megan & Smith, Robin, 2014. "The use of reduced models for design and optimisation of heat-integrated crude oil distillation systems," Energy, Elsevier, vol. 75(C), pages 5-13.
    3. Zhang, Nan & Smith, Robin & Bulatov, Igor & Klemeš, Jiří Jaromír, 2013. "Sustaining high energy efficiency in existing processes with advanced process integration technology," Applied Energy, Elsevier, vol. 101(C), pages 26-32.
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    1. Osuolale, Funmilayo N. & Zhang, Jie, 2016. "Energy efficiency optimisation for distillation column using artificial neural network models," Energy, Elsevier, vol. 106(C), pages 562-578.
    2. Kamel, Dina A. & Gadalla, Mamdouh A. & Abdelaziz, Omar Y. & Labib, Mennat A. & Ashour, Fatma H., 2017. "Temperature driving force (TDF) curves for heat exchanger network retrofit – A case study and implications," Energy, Elsevier, vol. 123(C), pages 283-295.

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