From Margins to Millions: How Aspen Hysys Optimizes Crude Distillation for Maximum Gasoline Yield (Case Study Included)

In the ever-competitive world of refining, maximizing profit hinges on efficient operations. Aspen Hysys emerges as a game-changer, empowering chemical engineers to optimize refinery units and processes for peak performance. This blog delves into the technical aspects of how Aspen Hysys unlocks profitability and energy savings, showcasing a detailed case study and the exciting advancements shaping the future.

Beyond Unit Operations: Aspen Hysys for Refinery-Wide Optimization

While Aspen Hysys excels at modeling individual units like distillation columns and catalytic crackers, its true strength lies in its ability to represent entire refinery configurations. This allows for a holistic approach to process optimization, considering the intricate interplay between units.

Key Features for Chemical Engineers:

• Equation-of-State Selection: Selecting the most appropriate equation of state (EoS) for your specific hydrocarbon feedstock is crucial for accurate property prediction. Aspen Hysys offers a robust selection of EoS models, including Peng-Robinson and SRK, allowing for tailored simulations.
• Reflux Ratio and Tray Efficiency Optimization: Distillation column performance hinges on optimal reflux ratio and tray efficiency. Aspen Hysys facilitates rigorous modeling of these parameters, enabling engineers to identify the sweet spot for maximizing desired product yields while minimizing energy consumption.
• Reaction Kinetics in Hydrocracking and Reforming: Accurately representing complex reaction kinetics within hydrocracking and reforming units is essential for optimizing product slate. Aspen Hysys provides robust kinetic modeling capabilities, allowing engineers to fine-tune reaction pathways and maximize valuable product generation.

Unveiling the Power of Aspen Hysys

Aspen Hysys goes beyond traditional process simulation software. It offers a comprehensive toolkit specifically designed for the complexities of refining. Here’s how it empowers engineers:

• Unit Modeling: Build detailed digital twins of crucial units like distillation columns, hydrocrackers, and reformers. Accurately predict their behavior under various operating conditions.
• Process Optimization: Identify bottlenecks, optimize operating parameters (e.g., reflux ratio, reaction temperature), and maximize desired product yields while minimizing energy consumption.
• Scenario Planning: Test different feedstock compositions, product slate configurations, and equipment upgrades to evaluate their impact on profitability before implementation.
• Integration with Aspen Plus: Combine Aspen Hysys’ process simulation with Aspen Plus’ rigorous thermodynamics for in-depth property prediction of complex refinery mixtures.

Case Study: Optimizing Crude Distillation for Profitability

Challenge: A refinery struggles to meet the growing demand for gasoline while maintaining profitability. Their existing crude distillation unit might not be operating at peak efficiency.

Solution:

1. Model Building: Chemical engineers construct a detailed model of the crude distillation unit in Aspen Hysys. The model incorporates key parameters like feedstock properties, tray efficiencies, and heat exchanger effectiveness.
2. Data Integration: Real plant data on feedstock composition, product yields, and utility consumption is integrated into the model for calibration and validation.
3. Scenario Testing: Different operating scenarios are simulated, varying reflux ratio, product cut points, and crude preheat temperature. The impact on gasoline yield, energy consumption, and product quality is evaluated.
4. Optimization: Utilizing Aspen Hysys’ optimization tools, the engineers identify the optimal operating conditions that maximize gasoline yield while adhering to product quality specifications and minimizing energy consumption.

Results: Through Aspen Hysys simulation, the team discovers a 2% increase in gasoline yield achievable by adjusting the reflux ratio and preheat temperature. This translates to significant revenue gains for the refinery without compromising product quality or incurring additional equipment costs.

The Ever-Evolving Aspen Hysys Landscape:

Aspen Hysys is constantly evolving, incorporating cutting-edge advancements:

• Machine Learning Integration: Leverage machine learning algorithms within Aspen Hysys to predict equipment performance degradation and optimize maintenance schedules.
• Cloud-Based Deployment: Utilize cloud computing for faster simulations and remote collaboration, enhancing accessibility and scalability.
• Advanced Property Prediction: Access a wider library of property prediction models for complex refinery feedstocks and products, ensuring higher simulation accuracy.

Discussion Points for Chemical Engineering Experts:

• Beyond conventional EoS models, have you explored the use of custom activity coefficient models in Aspen Hysys for complex refinery feedstocks? If so, how did it impact simulation accuracy?
• Aspen Hysys offers various options for modeling distillation column internals. In your experience, which methods provide the most reliable results for high-efficiency refinery columns?
• For reactor optimization, how do you approach the challenge of incorporating detailed reaction mechanisms within the Aspen Hysys framework while maintaining computational efficiency?

We invite chemical engineers and refinery process design experts to share their insights and experiences in the comments below!

Call to Action: Experts, Let’s Collaborate!

The power of Aspen Hysys lies not just in the software itself, but in the expertise of the engineers who wield it. We invite chemical engineers and refinery process design specialists to share their experiences and insights:

• How have you utilized Aspen Hysys to overcome specific challenges in your refinery operations?
• What advancements in Aspen Hysys are you most excited about, and how will they impact the future of refinery optimization?

Get the Full Picture: Detailed Case Study with Simulation Files

For a deeper dive into the crude distillation optimization case study, including the Aspen Hysys simulation files, please contact the author at [email protected]

By fostering collaboration and leveraging the collective knowledge of the chemical engineering community, we can unlock the full potential of Aspen Hysys for a more efficient and profitable refining future.