Simulation of Vacuum Distillation Unit in Oil Refinery: Operational Strategies for Optimal Yield Efficiency

Muhammad Shahrukh Atta, Haris Khan, Muhammad Ali, Rasikh Tariq (), Ahmed Usman Yasir, Muhammad Mubashir Iqbal, Sullah Ud Din and Jaroslaw Krzywanski ()
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Muhammad Shahrukh Atta: Department of Mechanical Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
Haris Khan: Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Seri Iskandar 32610, Malaysia
Muhammad Ali: Department of Mechanical Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
Rasikh Tariq: Tecnologico de Monterrey, Institute for the Future of Education, Ave. Eugenio Garza Sada 2501, Monterrey 64849, Mexico
Ahmed Usman Yasir: Department of Mechanical Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
Muhammad Mubashir Iqbal: Department of Mechanical Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
Sullah Ud Din: Department of Mechanical Engineering, University of Engineering and Technology, Taxila 47080, Pakistan
Jaroslaw Krzywanski: Department of Advanced Computational Methods, Faculty of Science and Technology, Jan Dlugosz University in Czestochowa, 13/15 Armii Krajowej Av., 42-200 Czestochowa, Poland

Energies, 2024, vol. 17, issue 15, 1-15

Abstract: Oil refineries play a crucial role in meeting global energy demands, and optimizing the efficiency of critical processes is vital for economic feasibility and environmental sustainability. Simulation is an essential tool for the optimization of valuable products. This work presents the rigorous simulation of a vacuum distillation unit (VDU) based on actual data from the vacuum distillation processes using Aspen HYSYS V10. The Peng–Robinson fluid package is used in this simulation, and an input assay with a standard density of 29 API_60 (879.8 kg/m 3 ) is employed. True boiling point (TBP) assay data are the type that is being used. Methane, ethane, propane, i-Butane, n-Butane, i-Pentane, and n-Pentane are the components listed in the simulation. The research determines that achieving a yield capacity of 685 tons/h requires thirty stages in the atmospheric distillation unit and twelve stages in the vacuum distillation unit while operating at 420 °C temperature and 9 kPa pressure. Adjustments in the flash section temperature (FST) and steam flow rate (SFR) are proposed to enhance operational efficiency. Increasing the FST from 370 °C to 400 °C and adjusting SFR from 10 tons/h to 26 tons/h increases the Light Vacuum Gas Oil (LVGO) yield by 7.2% while elevating the FST from 400 °C to 430 °C and adjusting SFR from 10 tons/h to 26 tons/h enhances the High Vacuum Gas Oil (HVGO) yield by 7.4%. These optimization strategies offer a practical and effective approach for refineries to improve the economic benefits of vacuum distillation units. The implications of this research can act as a computational thinking exercise for higher education students considering the case study where only through changing the operational strategies can the yield be enhanced by 10.81% in the vacuum distillation unit of the oil refinery.

Keywords: oil refinery; vacuum distillation; Aspen HYSYS; optimization; educational innovation; computational thinking; higher education; thermodynamic simulation; net-zero emission; sustainability; energy efficiency (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2024
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