- +12%Throughput potential
- 8%Furnace fuel saving
- 6Crude blends evaluated
- < 2 yrsPayback on key changes
The challenge
The refiner wanted to run heavier, lower-cost crudes without losing capacity. Operators suspected limits in the preheat train, furnace and column internals but had no calibrated model to confirm them.
Our scope
- Calibrated steady-state simulation
- Preheat train pinch analysis
- Column hydraulics and tray rating
- Relief and flare checks for new cases
- Modification cost estimates
Our approach
We built a simulation model calibrated against plant data, then tested each crude blend and throughput case to rank the real bottlenecks. Energy savings from preheat train changes were evaluated at the same time.
- Exchanger rating in HTRI
- Relief scenarios checked to API 520 / 521
- Payback analysis for each modification
The outcome
The study identified a short list of modifications with fast payback, including exchanger additions that reduce furnace duty, and set out a plan to implement them in the next turnaround.
Scope of work
- Process simulation
- Pinch analysis
- Column rating
- Relief checks
- Cost estimates
