Abstract
Hydrocarbon processing from extraction to the final product is an important aspect that needs an optimised technology for consumption-led market growth. This study investigated real data from the oil processing facility and analysed the simulation model for the entire crude oil processing unit based on the process system engineering aspect using Aspen HYSYS. The study mainly emphasises the process optimisation in processing the hydrocarbon for the maximum yield of the product with less energy consumption. The investigation also includes a thorough economic analysis of the processing facility. The datasets for oil properties are obtained from a modern petroleum refinery. The investigation comprises of varying transient conditions, such as well shutdowns using three oil reservoirs (low, intermediate, and heavy oil). The impact of various conditions, including process heating, well shutdown, oil combinations, presence of water on the production, is analysed. The results indicate that the factors involving crude oil processing are significantly affected by the process conditions, such as pressure, volume, and temperature. The vapour recovery unit is integrated with the oil processing model to recover the separator's gas. The optimisation analysis is performed to maximise the liquid recovery with Reid vapour pressure of 7 and minimum water content in oil around 0.5%. Economic analysis provided an overall capital cost of $ 9.7 × 106 and an operating cost of $2.1 × 106 for the process configuration. The model results further investigate the constraints that maximise the overall energy consumption of the process and reduce the operational cost.
Highlights
Energy is one of the essential constituents of any socioeconomic structure, and its consumption directly affects economic growth [1, 2]
A complete petroleum production chain consists of geological surveys, extraction, refining, and transportation
The crude oil processing begins at the drilling wells when the crude is pumped out from the well and routed to the processing facility at certain pressure and temperature
Summary
Energy is one of the essential constituents of any socioeconomic structure, and its consumption directly affects economic growth [1, 2]. The oil reservoirs contain hydrocarbons, but many inorganic chemicals, including CO2, N2, H2S, etc These inorganic constituents must be removed to commercialise the petroleum products for different applications [11]. The oil facility’s overall production may change with time [18] due to the change in oil composition, gas, and water in the reservoir. Tran et al [23] performed simulations on Aspen HYSYS for techno-economic analysis of biodiesel production from grease trap waste and reported promising results. The presented study analyse process design, operation, and monitor process performance of up-stream oil-production facility. The optimisation and performance analysis incorporated with the economic analysis contributes to understanding the process constraints and their optimisation in oil and gas industries. These Production states classify the water and oil content in various proportions from production states 1 to 5 illustrates the consecutive increase in water content and a decrease in oil content with the last stage of production marks the maximum water content
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