Enhancing Distillation Efficiency at Petroleum Refinery Through Hydraulic Performance Analysis of Atmospheric Distillation Tower

Efficient operation of petroleum refineries is crucial for optimizing energy production and economic viability. This study innovatively applies aspen HYSYS Version.14 to conduct a comprehensive hydraulic performance analysis of atmospheric distillation tower trays at Refinery. By integrating real plant operational data, the research addresses pivotal inefficiencies in the distillation process, particularly focusing on mechanical challenges such as tray weeping and flooding. The simulation efforts validate the model against empirical data, showcasing high correlation coefficients for key petroleum fractions, with values exceeding 0.93 for light naphtha, heavy naphtha, and gasoil, and slightly lower at 0.86 for kerosene. The findings highlight specific hydraulic deficiencies in the lower trays of the stripping section and propose precise improvements in tray design and alignment. Implementation of these recommendations is projected to substantially enhance separation efficiency, reduce maintenance frequency, and decrease operational disruptions. This paper contributes a novel, validated methodology for employing simulation tools in troubleshooting and optimizing refinery operations, offering a significant advancement in applying simulation technology to improve the petroleum industry’s sustainability and reliability. The actionable insights derived from this study, demonstrated through the enhanced correlation coefficients, have the potential to revolutionize refinery practices by providing a robust basis for future enhancements.