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Title: Energy%20concept%20for%20future%20oil%20refineries%20with%20an%20emphasis%20on%20separation%20processes


1
Energy concept for future oil refineries with an
emphasis on separation processes
  • Antonio Carlos Brandão de Araújo
  • Department of Chemical Engineering
  • Norwegian University of Science and Tecnology
    (NTNU)
  • Trondheim, Norway
  • January 2007

2
About this presentation
  • Motivation
  • Focus on environmental aspects in oil refining is
    not enough (Szklo 2007, DOE 2000).
  • Energy-efficient processes in oil refining are
    paramount.
  • Need for research in this field is a must.
  • Focus
  • Whats up on the future of energy consumption.
  • Opportunities Ill give directions.
  • Looking at the big picture Not restricted to
    separation processes.
  • Goal
  • Attempting to show what one can expect in terms
    of more energy-efficient refineries.

3
About this presentation
  • Lets tear things down

Energy concept Energy efficiency. Keep it
simple!
Directions will be given but problems wontt be
solved here!
Catalytic cracking separation unit
Energy concept for future refineries.
Future Next 20 years. Nothing futuristic! No
revolution!
  • Directions will be given Well, it cannot be
    different since there are lots of alternatives to
    consider and details cannot be given here!

4
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

5
A vision for the future
  • According to the APIs Technology Vision 2020 A
    Technology Vision for the U.S. Petroleum Refining
    Industry API 2000 report,
  • The petroleum industry of the future will be
    environmentally sound, energy-efficient, safe and
    simpler to operate. It will be completely
    automated, operate with minimal inventory, and
    use processes that are fundamentally
    well-understood. Over the long term, it will be
    sustainable, viable, and profitable, with
    complete synergy between refineries and product
    consumers.
  • To improve energy and process efficiency, the
    industry will strive to use cost-effective
    technology with lower energy-intensity.
    Refineries will integrate state-of-the-art
    technology (e.g., separations, catalysts, sensors
    and controls, biotechnology) to leapfrog current
    refinery practice and bring efficiency to new
    levels.

6
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

7
A simple guide to oil refining
  • According to the North American Industry
    Classification System (NAICS) DOE 2006,
    petroleum refineries are defined as
  • Establishments primarily engaged in refining
    crude petroleum into refined petroleum.

Picture of the oil refinery of the future, if the
oil consumption maintains its crazy
growth Actually, this is a 1876 oil refinery in
California.
8
A simple guide to oil refining Exxon 2005
9
A simple guide to oil refining
  • In short
  • Everything is upgraded to valuable products More
    fuel!
  • Over 43 of production is gasoline.
  • Almost 80 is converted to fuel.
  • It is a huge process facility!!!
  • Lots of reactions and separations to add value to
    the product.
  • Many opportunities for energy savings.

10
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

11
Energetic issues in an oil refinery (DOE 2000,
Pellegrino 2005)
  • Refinery gas petroleum coke other oil-based
    by-products accounts for 65 of the energy
    sources in an oil refinery.
  • 38 of the energy sources in an oil refinery are
    used to produce non-fuel products like lubricant
    oils, wax, asphalt, and petrochemical feedstocks.
  • Oil refineries generate large amounts of
    electricity on-site. In the U.S., over 40 (1994)
    of electricity in refineries are on-site
    generated.
  • The cost of energy for heat and power accounts
    for 40 of the operating costs in the refinery!!!

12
Energetic issues in an oil refinery DOE 1998
  • According to the NAICS, the petroleum refineries
    consumed 3.1 quadrillion Btu in 2002, almost 20
    of the fuel energy consumed by the U.S..
  • From the Table 35 is consumed in two
    distillation processes.
  • As expected, hydrotreating is also very high, 19
    alone.
  • Units in circles are prone to be optimized
    energetically as they represent approx. 80 of
    the energy consumed by the refining process.
  • We will focus on these units.

13
Energetic issues in an oil refinery Worrell 2005
  • Hydrogen generation is yet another high energy
    consumption process.
  • Large amounts of energy are consumed as fuel,
    while the rest is basically steam.

14
Energetic issues in an oil refinery
15
Energetic issues in an oil refinery DOE 2000
  • Future characteristics of oil refineries in terms
    of energy use
  • Energy use is optimized throughout the refinery
    complex.
  • Energy efficiency and process controls are
    integrated.
  • Fouling of heat exchangers is essentially
    eliminated.
  • Innovative heat exchangers are in place (all
    helical, vertical, no baffles)
  • Use of cogeneration in refineries is optimized,
    and refineries are power producers.
  • Use of very energy-intensive processes (e.g.,
    distillation, furnaces) is minimized.
  • Source of heat loss (e.g., in pipes) are easily
    identified through monitoring.
  • How?
  • Identify entirely new technology.
  • Upgrade existing inefficient technology.

16
Energetic issues in an oil refinery DOE 2000
  • Replacing the conventional energy-intensive
    separation processes has a tremendous impact on
    energy consumption.
  • Waste recovery in the short term.
  • Fouling mitigation and new refining processes in
    the mid and long terms.
  • Membrane is the first step.
  • Catalytic distillation is in the mid run.
  • Long run distillation beyond membrane.
  • Pelegrino 1999 say the target is 15-20 energy
    reduction for U.S. refineries.

17
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

18
Thermodynamic analysis DOE 2006
  • Remember the 5 processes with the largest energy
    consumption?
  • A thermodynamic analysis of these 5 processes is
    performed.
  • Three measures are defined
  • TW Theoretical Work The least amount of energy
    that a process would require under ideal
    conditions.
  • CW Current Work Energy consumed under actual
    plant conditions.
  • PW Practical Work Minimum energy required to
    run the process in real-world, non-standard
    conditions by applying cutting edge technologies
    still on the drawing board.
  • By applying these state-of-the-art technologies
    the maximum potential for energy savings can be
    quantified by

PI (Potential Improvement) CW (Current Work)
PW (Practical Work)
19
Crude oil distillation (atmospheric and vacuum)
  • Atmospheric distillation
  • It is the heart of the refinery.
  • It produces a range of products, from LPG to
    heavy crude residue.
  • High temperature (bottom 600oC), low pressure
    (near atmospheric) process.
  • Vacuum distillation
  • It has heavy crude (high boiling point) as
    feedstock.
  • It must then be conducted at vacuum conditions.
  • It produces light and heavy gas oil and asphalt
    (or resid).
  • These products are upgraded.

20
Crude oil distillation (atmospheric and vacuum)
21
Crude oil distillation (atmospheric and vacuum)
  • Atmospheric distillation energetic assessment
    DOE 2006
  • Theoretical work 22 x 103 Btu/bbl feed
  • Current work 109 x 103 Btu/bbl feed
  • Practical work 50 x 103 Btu/bbl feed
  • Potential improvement 59 x 103 Btu/bbl feed
  • The potential improvement can be achieved by
    (Gadalla 2003a, Gadalla 2003b, ANL 1999,
    TDGI 2001, Liporace 2005, Seo 2000, Rivero
    2004, Yeap 2005, Hovd 1997, Sharma 1999)
  • Control of fouling in the crude preheat train and
    fired heater.
  • Improved heat integration between the atmospheric
    and vacuum towers.
  • Improved tray design and heat integration between
    trays, and optimization of the number of trays
    and operating conditions for improved
    vapor-liquid contact and higher throughput.
  • Enhanced cooling to lower overhead condenser
    cooling water from 75F to 50F.
  • Implementation of advanced control.

22
Crude oil distillation (atmospheric and vacuum)
  • Vacuum distillation energetic assessment DOE
    2006
  • Theoretical work 46 x 103 Btu/bbl feed
  • Current work 89 x 103 Btu/bbl feed
  • Practical work 54 x 103 Btu/bbl feed
  • Potential improvement 35 x 103 Btu/bbl feed
  • The potential improvement can be achieved by
    (Gadalla 2003a, Gadalla 2003b, ANL 1999,
    TDGI 2001, Sharma 1999, Liporace 2005, Seo
    2000, Rivero 2004, Yeap 2005)
  • Control of fouling in the fired heater.
  • Improved heat integration between the atmospheric
    and vacuum towers.
  • Improved tray design and heat integration between
    trays, and optimization of the number of trays
    and operating conditions for improved
    vapor-liquid contact and higher throughput.
  • Enhanced cooling to lower overhead condenser
    cooling water from 75F to 50F.
  • Implementation of advanced control.

23
Fluid catalytic cracking
  • Objective Convert heavy oils into more valuable
    gasoline and lighter products.
  • Feedstocks are light and heavy gas oil from
    atmospheric or vacuum distillation, coking, and
    deasphalting operations.

High temperature, catalytic cracking reactions
24
Fluid catalytic cracking
25
Fluid catalytic cracking
  • Energetic assessment DOE 2006
  • Theoretical work 40 x 103 Btu/bbl feed
  • Current work 183 x 103 Btu/bbl feed
  • Practical work 132 x 103 Btu/bbl feed
  • Potential improvement 51 x 103 Btu/bbl feed
  • The potential improvement can be achieved by
    (Linhoff 2002, ANL 1999)
  • Addition of a power recovery turbine.
  • Conversion of condensing turbine drive to
    electric motor drive (wet gas compressor).
  • Improved heat integration, pinch analysis.
  • Minimization of other miscellaneous losses.

26
Catalytic hydrotreating
  • Objective Remove sulfur, nitrogen, and metals
    and upgrade heavy olefinic feed by saturation
    with hydrogen to produce paraffins.
  • It commonly appears in multiple locations in a
    refinery (5 or more of these units).
  • They are usually placed upstream of units where
    catalyst deactivation may occur.
  • Typically we can distinguish Naphtha
    hydrotreater, kerosene hydrotreater, and gas oil
    hydrotreater.
  • Main reactions

27
Catalytic hydrotreating
28
Catalytic hydrotreating
  • Energetic assessment DOE 2006
  • Theoretical work 30 x 103 Btu/bbl feed
  • Current work 81 x 103 Btu/bbl feed
  • Practical work 55 x 103 Btu/bbl feed
  • Potential improvement 26 x 103 Btu/bbl feed
  • The potential improvement can be achieved by
    (ANL 1999, Gary 2001, Linhoff 2002,
    Liebmann 1998)
  • Improved pre-heater performance.
  • Improved catalyst.
  • Improved heat integration, pinch analysis.
  • Minimization of other miscellaneous losses.

29
Catalytic reforming
  • Objective Convert naphthas and heavy
    straight-run gasoline into high-octane gasoline
    blending components and hydrogen production.
  • It essentially restructures hydrocarbon molecules
    to increase the octane of motor gasoline.
  • Main reactions
  • Dehydrogenation of naphthenes to aromatics
  • Methylcyclohexane ? Toluene 3H2
  • Methylcyclopentane ? Cyclohexane ? Benzene 3H2
  • Dehydrocyclization of paraffins to aromatics
  • n-Heptane ? Toluene 4H2
  • Isomerization
  • n-Hexane ? Isohexane
  • Methylcyclopentane ? Cyclohexane
  • Hydrocracking
  • n-Decane ? Isohexane nButane

30
Catalytic reforming
31
Catalytic reforming
  • Energetic assessment DOE 2006
  • Theoretical work 79 x 103 Btu/bbl feed
  • Current work 264 x 103 Btu/bbl feed
  • Practical work 203 x 103 Btu/bbl feed
  • Potential improvement 61 x 103 Btu/bbl feed
  • The potential improvement can be achieved by
    (ANL 1999, Gary 2001, Packinox 2003)
  • Improved feed and interstage process heater
    performance (e.g., improved convection section
    heat recovery).
  • Replace horizontal feed/effluent heat exchangers
    with vertical plate and frame exchanger.
  • Improved equipment efficiency (e.g., recycle and
    net gas compressor, reactor product air cooler).
  • Additional process cooling to improve light ends
    recovery (vapor compression vs. ammonia
    absorption).
  • Minimization of other miscellaneous losses.

32
Alkylation
  • Objective Produce branched paraffins that are
    used as blending components in fuels to boost
    octane levels without increasing the fuel
    volatility.
  • There are two alkylation processes sulfuric
    acid-based and hydrofluoric acid-based.
  • Both are low-temperature, low-pressure,
    liquid-phase catalyst reactions.
  • Main reaction

33
Alkylation (H2SO4 process)
34
Alkylation (H2SO4 process)
  • Energetic assessment DOE 2006
  • Theoretical work -58 x 103 Btu/bbl feed
  • Current work 250 x 103 Btu/bbl feed
  • Practical work 156 x 103 Btu/bbl feed
  • Potential improvement 94 x 103 Btu/bbl feed
  • The potential improvement can be achieved by
    (Gadalla 2003a, TDGI 2001, DOE 2006,
    Schultz 2002)
  • Improved compressor efficiency, from 25 to 50.
  • Improved heat integration, pinch analysis.
  • Use of a dividing wall column design or other
    advanced separation technology.
  • Upgraded control system.

35
Summary
Process TW PW CW PI PI ()
103 Btu/bbl feed 103 Btu/bbl feed 103 Btu/bbl feed 103 Btu/bbl feed 103 Btu/bbl feed
1. Atmospheric distillation 22 50 109 59 54
2. Vacuum distillation 46 54 89 35 39
3. Alkylation H2SO4 -58 156 250 94 38
3. Alkylation HF -58 152 245 93 38
4. Catalytic hydrotreating 30 55 81 26 32
5. Fluid catalytic cracking 40 132 183 51 28
6. Catalytic reforming 79 203 264 61 23
  • As expected, crude distillation (atmospheric and
    vacuum) has the largest potential for savings.
  • Followed by alkylation and catalytic treatments.
  • Note that separation sections are also included
    in the conversion processes.
  • As a general potential improvement, I
    particularly would also include assessment of the
    control structure design of the refinery.

36
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

37
Separation processes
  • The majority of the available literature is
    related to the issue concerning distillation and
    they are heavily concentrated in the atmospheric
    and vacuum columns. I bet you know the reason!
  • Future solutions for improving energy efficiency
    in separation processes in oil refineries are
    basically related to
  • Membrane technology.
  • Fouling mitigation.
  • Advanced process control and optimization.
  • Heat integration.
  • Design of efficient separation systems.
  • What follows are mostly on the drawing board,
    i.e., no real-world implementation.

38
Separation processes
  • Membrane technology
  • Wauquier 2000 discusses that membrane
    technology is still an infant in the world of
    grown-up inefficient processes in the oil
    industry. Its main application is in
    hydrodesulfurization processes in catalyst
    hydrotreating units, replacing existing
    separation processes with energy savings up to
    20.
  • Nevertheless, Goulda 2001 and White 2000
    claimed a fuel reduction of 36,000 bbl/year (or
    20 w.r.t. the conventional process) by adding a
    membrane unit in the dewaxing unit to recover
    part of the solvent stream. The membrane is
    selective to the solvent from the solvent/oil/wax
    mix.
  • According to Szklo 2007, further research is
    needed to develop appropriate membrane materials
    that can withstand the harsh conditions in
    petroleum refining processes.

39
Separation processes
  • Fouling mitigation
  • Panchal 2000 presented a performance monitoring
    via an Excel spreadsheet of the preheat train
    for a crude distillation unit. The authors claim
    that by using their technique the energy loss in
    a period of 2 years can be reduced by almost 60.
  • Nasr 2006 proposed a model of crude oil fouling
    in preheat exchangers with the aim of better
    controlling fouling formation. In contrast with
    other models, the one proposed by the authors
    consider the mechanisms of formation and natural
    removal.
  • Yeap 2005 presented the application of existing
    fouling models to maximize heat recovery in the
    preheat train of the crude oil distillation. The
    authors conclusion was that designing for
    maximum heat recovery results in a less efficient
    system over time due to fouling effects.
  • However, Szklo 2007 states that the very
    complex mechanisms which lead to fouling are
    still not properly understood to the extent they
    can be safely used for fouling mitigation
    techniques (anti-fouling agents and coatings).

40
Separation processes
  • Advanced process control and optimization
  • Domijan 2005 optimized a crude distillation
    unit by using a model that, according to the
    authors, has some advantages over commercial ones
    since it is adapted to real plant conditions, it
    is open source as well as flexible and fast.
    Moreover, it can also identify fouling level and
    be applied for planning shutdowns and maintenance
    stops. They claimed they found an optimal
    solution that saves up to 3.2 of energy
    consumption vis-à-vis actual operating
    conditions.
  • Seo 2000 considered the optimal design of the
    crude distillation unit (atmospheric, vacuum, and
    naphtha stabilizer) by optimizing feed locations,
    heat duties of pumparounds and operating
    conditions of the preheat train. They use a MINLP
    framework. They claim the energy recovery in
    pumparounds and preheat train could save up to 20
    million kcal/h.
  • Hovd 1997 proposed the implementation of MPC in
    a crude oil distillation. They used the MPC
    package (D-MPC) of Fantoft Prosess and a linear
    model of the process obtained using
    first-principle model equations and laboratory
    data. They implemented the MPC strategy in a
    refinery in Sweden and reported a reduction in
    energy consumption equivalent to USD20,000/year
    for a project investment of USD250,000.
  • Gadalla 2003b performed a very simple
    optimization of existing heat-integrated
    distillation systems for crude oil units where
    the column (with fixed configuration) and the
    associated heat exchanger network are considered
    simultaneously. Only one design (retrofit)
    variable is assumed area of the HEN. They
    claimed savings up to 25 over the base case.

41
Separation processes
  • Heat integration
  • Gadalla 2006 optimized an existing crude
    distillation column where a gas turbine/generator
    is integrated with the preheat furnace. They
    claim energy reductions of up to 21. The idea
    was then to maximize the energy generated in the
    gas turbine by adjusting the temperature of the
    feed, reflux ratio, steam flow rates, temperature
    difference of each pumparound, and the flow rate
    of the liquid through each pumparound.
  • Gadalla 2005 studied the design of an
    internally heat-integrated distillation column
    for separating an equimolar propylene-propane
    mixture where the 57 stages of the stripping
    column are heated by the first 57 stages of the
    rectification column. They claim that by
    increasing the heat transfer rate per stage,
    energy savings can reach up to 100 of reboiler
    duties. For this, the compressor power would
    increase only 15 w.r.t. the base HIDiC case.
  • By applying pinch analysis, Plesu 2003 propose
    to thermally couple crude distillation units and
    delayed coking units through the utility system.
    They basically proposed to send the vacuum
    bottoms to the delayed coking unit at a higher
    thermal load and use this artifice to generate
    part of the steam needed in the crude
    distillation unit. They do not report energy
    saving figures.

42
Separation processes
  • Heat integration
  • Liebmann 1998 proposed a systematic algorithm
    based on pinch analysis that lends to automation
    of the design procedure of crude oil distillation
    units where the column, the heat exchanger
    network, and their simultaneous interactions are
    considered together. Modifications that further
    increase the efficiency of the process are
    installation of reboilers rather than stripping
    stream and the thermal coupling of column
    sections. They claimed that units conceived by
    this method can save up to 20 energy w.r.t. the
    base case.
  • Szklo 2007 states that heat integration and
    waste heat recovery appears as one of the main
    options for saving fuel in the short to mid terms.

43
Separation processes
  • Design of efficient separation systems
  • Szklo 2007 discussed the use of catalytic
    distillation (CD) as an alternative to
    hydrotreating units, namely to FCC gasoline. The
    idea is to fractionate the gasoline by
    distillation, which yields several gasoline
    fractions, and then treat these fractions for
    sulfur according to their prevailing sulfur
    compound reactivities, all in the same unit.
    Lighter fraction are treated more severely while
    the heavier ones undergo desulfurization at
    higher temperatures at the bottom of the CD
    column. The authors claimed that up to 62 of
    energy can be saved w.r.t. conventional HDS
    processes.
  • Szklo 2007 also discussed the application of
    biodesulfurization in replacement of conventional
    HDS with energy savings of up to 80. This is at
    the very beginning of development and the main
    barriers are the understanding of biological
    mechanisms of biocatalysts and the development of
    efficient two-phase biodesulfurization systems.
  • Schultz 2002 defended the thesis that
    dividing-wall columns (DWC) can save up to 30 in
    energy costs. In this technology, remixing of
    components towards the bottom or top of a direct
    sequenced train which causes thermal inefficiency
    is mitigated by cutting the product at their
    maximum compositions. However, Szklo 2007
    emphasized the need for further development of
    DWC for major distillation processes in the oil
    refining industry.

44
Separation processes
  • Design of efficient separation systems
  • According to Pellegrino 1999 a potentially
    attractive refining process modification is to
    input the crude directly into controlled thermal
    cracking units, thereby bypassing CDU. The idea
    is to crack large hydrocarbon molecules (e.g.,
    large asphaltene-type molecules) into smaller
    ones. They reported a reduction in energy
    consumption of 23 in addition to the fact that
    up to 80 of the energy generated in the unit can
    be recovered as reusable energy.
  • EIPCCB 2001 discussed the use of a radical
    revamp that encompasses atmospheric and vacuum
    distillation, gasoline fractionation, naphtha
    stabilizer and gas plant in one unit progressive
    distillation. It consists of a fairly complex set
    of separation steps and extensively uses pinch
    technology to minimize heat supplied by external
    means. This technology is called progressive
    distillation and the savings can reach up to 30
    on total energy consumption for these units.

45
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

46
Recap and future directions
  • It seems there is no radical revolution going on
    in oil refining industrial so to handle energy
    efficiency. Instead, the 2020 Vision report API
    2000 lists
  • Reduction of fouling in heat exchangers is a
    definite priority.
  • Improved convection in furnaces.
  • Cogeneration needs to be optimized.
  • Use of conventional distillation is minimized.
    Try membrane and catalytic distillation.
  • Lets not forget research in catalysis.
  • Comprehensive models in oil refinery are a must
    DOE 2000.
  • Process optimization is definitely in the oil
    refinery agenda Domijan 2005.
  • Investments in RD represent one way to help
    drive the industry toward a higher level o energy
    efficiency. However, implementation is still at
    its very infancy as there are still technological
    barriers.
  • Accordingly, separation processes need to be
    updated. However, one should loop at the big
    picture.
  • Needless to say, energy reduction ? CO2 emission
    reduction!

47
Recap and future directions
  • Wanna a hint to decide your PhD project? Energy
    efficiency program for future oil refineries.
    Ease, 5 PhD projects
  • Fouling modeling and elucidation of its
    mechanism in the crude distillation unit
    (atmospheric and vacuum columns and respective
    HEN) as well as development of anti-fouling
    chemicals that little affects the refining
    product quality.
  • Membrane theres still a technological barrier
    with the current membranes. More research is
    needed to extend the application to other
    separation units throughout the refinery.
  • Advanced process control and optimization
    investigation of plantwide control and
    optimization (I only found these issues applied
    to individual units).
  • Heat integration investigation of more plantwide
    heat integration opportunities by pinch or exergy
    analysis.
  • Distillation design more on reactive (catalytic)
    distillation and dividing-wall technology applied
    to energy-intensive units (FCC, alkylation,
    hydrotreating, reforming, and crude distillation
    units). Especially, biodesulfurization.

48
Outline
  • A vision for the future
  • A simple guide to oil refining
  • Energetic issues in an oil refinery
  • Thermodynamic analysis and measures to improve
    energy consumption.
  • Crude oil distillation (atmospheric and vacuum)
  • Fluid catalytic cracking
  • Catalytic hydrotreating
  • Catalytic reforming
  • Alkylation
  • Separation processes
  • Recap and future directions
  • References

49
References
  • Gadalla 2003a Gadalla, M., Jobson, M., and
    Smith, R., Increase Capacity and Decrease Energy
    for Existing Refinery Distillation Columns,
    Chemical Engineering Progress, April 2003, p. 44.
  • ANL 1999 - Petrick, M. and Pellegrino, J., The
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