Comparative techno-economic evaluation of potential processing schemes for petroleum crude oil distillation

The two most commonly used schemes for crude oil distillation in operating refineries have been compared with two new schemes using two different crude oils for the energy consumption and energy cost parameters. Seven cases for each crude were conceptualized to carry out a realistic techno-economic evaluation of these schemes. Study results reveal the scope to reduce the ADC bottom stripping steam in 32.7-75% for the proposed scheme-I and 100% for scheme II. The furnace duty is reduced -4.3-4.7% for the scheme-I and -4.6-6.15% for the scheme-II. Overall, the energy cost for crude oil distillation can be reduced in the range of 7.3-9.4% with scheme-I and 10.7-16.3% with scheme-II by implementing proposed schemes for revamping the existing and designing the new CDUs. The lower vapour rate in the rectification section and higher vapour rate in the stripping section of ADC in the proposed schemes compared to the conventional schemes suggests an opportunity to either increase the throughput without revamping the ADC or implement the proposed schemes to revamp existing AVUs without ADC modification and assistance in addressing the challenges associated with poor vapour liquid contact, lower tray efficiency, and fouling on tray decks. The structural topology of new schemes is similar to existing schemes, which ensure their easy and practically possible implementation for revamping the existing and designing the grass-root units CDUs to reduce energy costs and emissions significantly.