Crude Oil Distillation Research Articles

Rock-to-Pharma: Characterization of Shale Oil-Based Nonbiological Complex Drugs along the Production Process by High-Resolution Mass Spectrometry.

Antibiotic resistance has become a primary concern in medicine because of the overuse and misuse of classical pharmaceuticals. Recently, nonbiological complex drugs (NBCDs) have gained interest for their complex pharmacological profiles. Bituminosulfonates, which have lately been tentatively allocated toward NBCDs, are pharmacologically well-studied and show low potential in resistance development. However, molecular composition knowledge is limited. With this work, we present a comprehensive approach to investigate the manufacturing process of complex pharmaceuticals like bituminosulfonates on a molecular level via Fourier-transform ion cyclotron resonance mass spectrometry. The application of various hyphenations and ionization techniques comprehensively covers the entire mass and polarity range of the matrix, and the high sensitivity enables the identification of significant and minor chemical alterations caused by the multistep manufacturing process. The distillation of the shale crude oil eliminates highly aromatic PAH and PASH constituents. ESI(-) revealed strong PAH- and PASH-sulfonate formation after reacting the shale oil distillate with sulfuric acid. Increasing alkylation reduced the sulfonation yield, instead causing oligomerization side reactions, as observed by APPI analysis. Furthermore, multidimensional gas chromatography coupled with high-resolution mass spectrometry verified core structural motifs. With this work, we demonstrate the high potential of FT-ICR MS in NBCD process analysis. The results also give valuable information for future pharmacological investigations focusing on specific compound classes or properties.

Vacuum pyrolysis of Tamanu seed (Calophyllum inophyllum): Fuel properties, distillation, and composition study of the pyrolytic oil

BackgroundThe pyrolysis of Calophyllum inophyllum seeds holds significant potential for producing biofuels and value-added chemicals. Research aims to identify optimal process conditions for maximum yield of oil, and evaluate its properties and composition for fuel application. MethodsIn this study, vacuum pyrolysis of extractive-rich biomass such as Tamanu seed (Calophyllum inophyllum) was performed at 25 °C min−1. The composition, fuel properties, and distillation of oil confirmed its application as fuel which is compared with various non-edible seed pyrolytic oils. Significant FindingsThe resulting pyrolysis oil, constituting 69.53 % of the seed, boasted a calorific value of 42.78 MJ kg−1, 10 % water content, and a viscosity of 12.9 cSt. Its flashpoint and pour point were measured at 42 °C and 7 °C, respectively. Distillation exhibited a broad range of fractions, mimicking crude oil distillation, with 55 % comprising diesel-range fractions. GC–MS analysis identified 46 hydrocarbon compounds, indicative of fatty acid, cellulose, and hemicellulose degradation, producing alkanes, alkenes, esters, nitriles, acids, amides, and amines. Notably, the oil contained significant levels of oleic acid, palmitic acid, and stearic acid. The mechanism involved radical reactions, yielding diverse hydrocarbons and oxygenates, albeit with minimal aromatic formation. This elucidates the potential of Tamanu seed pyrolysis for sustainable biofuel production and value-added chemical synthesis.

Development of a New Method to Optimize Operations of an Existing Crude Unit

A nonlinear optimization method working with the Simplex Method was developed to find optimum operating conditions of a crude oil distillation unit subject to defined process constraints, product specifications and prevailing market conditions. Then the method was applied to a commercial crude unit. This crude unit was modeled using Aspen Hysys V12.1 process simulation software. Two sets of market scenarios designated as the maximum gasoline scenario and minimum gasoline scenario were applied to the simulation model. It was found that the model minimized naphtha production and maximized kerosene production for minimum gasoline scenarios where the price of kerosene and diesel products were higher than naphtha products. Similarly, the model maximized the naphtha product yield for the maximum gasoline scenario where the naphtha price exceeds the mid-distillate product price. The iterative procedure developed for the study monotonically converged to optimum operating conditions for both market scenarios. It was observed that the optimization scheme developed in this study could generate a significant profit increase in the conventional crude unit investigated in this study without and capital investment.

Assessing the rheological properties of bio modified asphalt cement

The production of asphalt cement binder in Iraq is conducted through the distillation of crude oil. The byproduct of such distillation is the asphalt cement which does not practice any further processing further processing of the binder is considered vital to control its physical properties and chemical composition. The implementation of bio-modifiers before using such asphalt cement binder for paving work is a sound practice to enhance its sustainability and reserve the required rheological properties. In the present study, the asphalt cement binder was modified by implementation of extender oil (used diesel engine oil) and scrap tire rubber. The aim of this work is to improve and provide a sustainable and proper rheological quality of the binder for paving work. Various percentages of scrap tire rubber and extender oil have been tried to optimize the modifiers which can exhibit a suitable control on the required rheological properties of the asphalt binder such as the stiffness modulus, its temperature susceptibility in terms of penetration index and penetration viscosity number, and temperature of equivalent stiffness of the binder. The stiffness of asphalt cement binder was digested at hot, moderate, and cold environments. It was observed that the implementation of extender oil was able to reduce the penetration index (PI) by 36.3%, 54.5%, and 27.2% when 15%, 10%, and 5% of extender oil by weight of the mixture were added respectively to the control binder. The addition of scrap tire rubber to the binder-oil mixture was able to reduce the PI up to 10% of rubber content and exhibited further control of the temperature susceptibility of the binder. It can be revealed that the extender oil increases the negative values of penetration viscosity number (PVN) while the scrap tire rubber can improve the PVN of the binder. When high percentage of extender oil 15% is implemented, the stiffness of the binder declines by 50%, 90%, and 75% when the testing temperature change from 4 to 25, and 60 ℃ respectively. It was concluded that implication of 15% of scrap tire rubber and 15% of extender oil into the asphalt cement binder produced by Qayarah oil refinery is recommended to provide a sustainable binder for pavement, control its temperature susceptibility, and provide a binder with lower prone to pavement distresses.

Optimization and design of a new column sequencing for crude oil distillation at Basrah refinery

Abstract The utilization of distillation stands as a predominant separation method within the chemical and petroleum industries, prominently influencing operational costs and environmental impact due to energy consumption. Enhancing energy efficiency holds paramount significance in elevating the sustainability and overall efficacy of distillation operations. Within this study, we introduce an innovative approach termed “marginal vapor flow (MVF)” to optimize the distillation column sequence for crude oil processing, focusing on the third distillation unit at the Basra Refinery. This research evaluates diverse column designs through streamlined simulations using Aspen HYSYS V11 software. The study determines total energy consumption as a benchmark, comparing it against the optimal sequence recommended by the MVF methodology. A novel application of the downward reduction equation to crude oil guides the selection of light and heavy components. Key findings from this comprehensive analysis showcase the potency of combining MVF with Aspen HYSYS for optimizing crude oil distillation column sequences. Aspen HYSYS, a widely recognized process simulation tool, accurately represents distillation processes. Simultaneously, MVF facilitates the determination of optimal column sequences based on marginal vapor flow rates. Notably, the results reveal that within the studied sequences, sequence 9 exhibits the lowest total MVF of (1393.4 kmol/h), signifying its optimality, while sequence 2 displays the highest total MVF of (4827.3 kmol/h), representing the least favorable scenario. Simulation of the optimal sequence derived through the MVF approach exhibits a remarkable 35% reduction in energy consumption compared to real-life operations. Conversely, simulating the least favorable sequence demonstrates a substantial 32% increase in energy consumption compared to actual operations. This study underscores the pivotal role of MVF methodology in optimizing distillation sequences for enhanced energy efficiency, providing actionable insights for refining operations to significantly reduce energy consumption and operational costs while advancing sustainability goals.

ANN and RSM Modelling and Optimization of Paraffins and Aromatics in Crude Oil Distillation Products’ Properties in Iraq

Back-Propagation neural networks, as well as RSM-DOE techniques, were used to predict the properties of various compositions of Iraqi oil, which were presented in this study. Paraffin and Aromatics’ effect on petroleum properties, e.g., yield, density, calorific value, and other essential properties, were studied. The input-output data to the neural networks were obtained from existing local refineries in Iraq. Several network activation functions to simulate the hydrocracking process were tested and compared. the network function that gave satisfactory results in terms of convergence time and accuracy was adopted. The data were divided into training and testing parts. The results of the trained artificial neural network models for each one of the tested functions have been cross-validated with the experimental data. The network that compared well against this new set of data (i.e. testing data), with an average percent error always less than 3% for the various products of the hydrocracking unit were chosen for the study. Aromatics showed to have more profound effect on the Octane number at low concentrations of paraffin, while, for specific gravity and calorific value they have similar effects. As for boiling points and sulfur contents, aromatics have almost no effect at lower levels of paraffin.

Application of Regression Models on the Prediction of Corrosion Degradation of a Crude Oil Distillation Unit

Abstract The crude distillation unit is the most critical elements in the refining process. Moreover, most of the equipment in the distillation unit are made of general carbon steels. Data analysis models, machine learning techniques can predict corrosion degradation rates. We used Pearson’s correlation coefficient and multiple linear regression, to predict the impact of process parameters. Altogether, we have analysed 84 channels of technological parameters, and 22 different types of crude oils. Among the corrosion agents, the chloride content strongly affected the weight loss of coupons, where the highest coefficient was 0.68. The most influential parameter is found to be the pH value. Thus, an estimation method of the pH value is set up to predict the corrosion degradation rate. The regression correlation for estimating the pH value is 0.53 if the corrosion agents are not used, which can be improved to 0.76 if the corrosion agents are also used in the regression analysis.

Concentrated solar heat for the decarbonization of industrial chemical processes: a case study on crude oil distillation

A novel strategy for the decarbonization of crude oil distillation was proposed considering two distillation columns located in Sicily that were simulated by adapting the equipment datasheet of the refinery Raffineria di Milazzo (RAM). The proposed approach consists of the integration of the topping section with a concentrating solar power (CSP) plant to decrease the carbon dioxide emissions and the consumed fossil fuels in the furnaces of the distillation columns. Three hypothetical scenarios of applicative interest were considered. In that most economically sustainable, the use of solar heat allowed a decrease of CO2 emissions of 54.2 kt/year corresponding to a reduction of about 11% of the greenhouse gas emissions joined with the saving of 19.9 kt/year of methane with a rate of return of investment (ROROI) of 16.2%. As a comparison, if the land surface occupied by the CSP plant is used for photovoltaic production of green hydrogen considering an energy consumption of the electrolyzer of 4.70 kWh/Nm3, just 24.6 and 9.0 kt/year of CO2 and methane respectively can be saved and the ROROI decreases to 8.5%.This study indicates that solar heat can be effectively and economically integrated in crude oil distillation to achieve a significant decarbonization of refineries.

Production of Light Naphtha by Flash Distillation of Crude Oil

The escalating global demand for sustainable, renewable energy sources has catalyzed research into advanced refining processes, particularly focusing on the generation of essential raw materials like light naphtha. This paper delves into the production of light naphtha via the flash distillation of crude oil, underlining its critical role in fulfilling the petrochemical industry's requirements. The research delineates the fundamentals of flash distillation, incorporating both physical and mathematical models, with a specific emphasis on Raoult's Law, to demystify the hydrocarbon separation process in crude oil. The mathematical framework encompasses material and energy balances, coupled with the application of liquid-vapor equilibrium equations, thereby shedding light on the thermodynamic principles steering this procedure. The progression of this study involved analyzing the distillation curve of the referenced crude oil and identifying the pseudo-components representative of the involved hydrocarbons. Utilizing the DWSIM commercial simulator, the flash distillation process of Nemba crude oil was simulated, taking into account diverse operational conditions and thermodynamic models. The outcomes were juxtaposed with industrial datasets, demonstrating a significant alignment and affirming the simulation's predictive efficacy. A parametric sensitivity analysis was conducted to refine light naphtha yield, elucidating the effect of variables like the temperature of crude oil feed and naphtha separator feed on the process efficiency. The response surface methodology underscored the feasibility of augmenting naphtha production under certain conditions. Furthermore, this study assessed the impacts of employing two distinct thermodynamic models – the Soave-Redlich-Kwong (SRK) and Peng-Robinson (PR) equations of state. This analysis revealed minimal discrepancies in physical parameters, confirming the simulation's robustness and the reliability of both models. The findings of this paper validate the efficacy of flash distillation in light naphtha production, with numerical simulation emerging as a potent tool for enhancing process optimization and predictive analysis. These insights not only contribute to a deeper understanding of environmental sustainability but also offer strategies for maximizing light naphtha production in the oil industry. In conclusion, the results from this investigation significantly advance our comprehension of phase equilibrium profiles and their relationship with the applied thermodynamic state equations, thereby enriching the quality of the results.

Impact of petroleum expulsion and evaporation losses on shale oil assessment using pyrolysis techniques

Shale reservoirs contain petroleum that undergoes losses through oil expulsion and evaporation, with uncertain implications on shale oil reserves and mobility evaluation. This study focuses on understanding the influence of these losses on open‐system pyrolysis, the primary method for assessing shale oil content and mobility. Comprehensive analyses were performed on 26 lacustrine shale samples from the Chang7 Member, encompassing total organic carbon (TOC), programmed pyrolysis, solvent extraction, and gas chromatography–mass spectrometry (GC–MS). The research examines the impact of petroleum losses on petroleum fractions, the oil saturation index (OSI), and multi‐step pyrolysis outcomes. The findings indicate that Chang7 shale with TOC content above 7% experiences more substantial petroleum losses than those with TOC below 7%. Petroleum losses result in significant fractional distillation of crude oil in the shale, leading to the deterioration of shale oil properties and a notable reduction in free oil content in S1, ultimately causing a decline in OSI values. As a result, Chang7 shale with TOC below 7% demonstrates a higher potential for shale oil recovery, whereas Chang7 shale with TOC exceeding 7% should be considered more significant as a hydrocarbon source rock. Moreover, multi‐step pyrolysis is not suitable for assessing petroleum mobility in shale with low free oil content (OSI values below 100 mg/g). This limitation arises from the loss of free low‐boiling components in Chang7 shale, and the currently detected low‐boiling pyrolysis products may predominantly exist in an adsorbed state.

Boiling point modeling for petroleum speciation data

An empirical model is presented for generating the boiling curve of a petroleum sample based on parameters that are experimentally available using typical speciation techniques. The approach estimates the boiling point distribution of the detected components and allows a comparison with the simulated distillation profile of the sample. The model is shown to predict the boiling behavior of the speciation-derived average components in crude oil distillation fractions, which match the measured average distillation temperature of the fractions. The model is then applied to generate boiling distributions, based on mass spectrometric and gas chromatographic speciation data, which match the measured simulated-distillation curves with less than 20 °C difference. The model is also applied to the isolated fraction of saturated compounds, where the modeled boiling profile matches well with the measured distillation profile of the entire sample. This confirms that the model, although built using Fourier transform ion cyclotron resonance mass spectrometry data of aromatic compounds, extends to data obtained using comprehensive 2-dimensional gas chromatography, and also describes the boiling behavior of saturated compounds speciated by field desorption time of flight mass spectrometry. Consequently, the modeled boiling distribution enables an assessment of how well a speciation measurement describes the sample, and provides an estimation of lower and higher-boiling portions that have been omitted in the data set.

Solution-processable polytriazoles from spirocyclic monomers for membrane-based hydrocarbon separations.

The thermal distillation of crude oil mixtures is an energy-intensive process, accounting for nearly 1% of global energy consumption. Membrane-based separations are an appealing alternative or tandem process to distillation due to intrinsic energy efficiency advantages. We developed a family of spirocyclic polytriazoles from structurally diverse monomers for membrane applications. The resulting polymers were prepared by a convenient step-growth method using copper-catalysed azide-alkyne cycloaddition, providing very fast reaction rates, high molecular weights and solubilities in common organic solvents and non-interconnected microporosity. Fractionation of whole Arabian light crude oil and atmospheric tower bottom feeds using these materials enriched the low-boiling-point components and removed trace heteroatom and metal impurities (comparable performance with the lighter feed as the commercial polyimide, Matrimid), demonstrating opportunities to reduce the energy cost of crude oil distillation with tandem membrane processes. Membrane-based molecular separation under these demanding conditions is made possible by high thermal stability and a moderate level of dynamic chain mobility, leading to transient interconnections between micropores, as revealed by the calculations of static and swollen pore structures.

Experimental and numerical simulation verification of depositional characteristics of NH4Cl particles under variable conditions

ABSTRACT The primary cause of U-tube heat exchanger leakage and perforation is attributed to the deposition and corrosion of NH4Cl within the condensing pipeline located at the summit of the crude oil distillation tower. This paper aims to investigate the deposition law of NH4Cl in U-shaped tubes under variable operating conditions and the impact of diverse factors on the deposition features of NH4Cl. To achieve this objective, the study establishes appropriate experimental equipment, designs a 4-factor and 4-level orthogonal experimental table, and manipulates the variables of particle incidence velocity (v), relative humidity (RH), particle size (d), and temperature (T). The experimental results of each group are recorded and analyzed. The observed experimental data reveals that under the operational parameters of Group H (v: 7 m/s, RH: 50%, d: 0.7 mm, T: 140°C), particle accumulation peaks at the elbow outlet, resulting in a substantial volume ratio of 17.14%. Conversely, Group M (v: 10 m/s, RH: 1%, d: 0.1 mm, T: 140°C) demonstrated the minimal particle deposition in the angular sector between 30° − 60° of the elbow, yielding a minimal volume ratio of 0.22%. Further scrutiny suggests that environmental humidity and incident flow velocities significantly influence particle deposition, whilst ambient temperature and particle size exert less substantial effects. A multivariate linear deposition equation between NH4Cl deposition and v, RH, d, T was derived through linear regression, yielding an Rc2 of 0.913, indicating a high level of concordance. A mathematical model was constructed, incorporating computational fluid dynamics (CFD), to simulate and analyze the flow characteristics of ammonium chloride particles in U-shaped tube bundles, which was subsequently validated with the experimental results obtained, the comparison results showed a good degree of coincidence, with an error of 4.41%.

Corrosion in Crude Oil Distillation Units (CDUs) and a Study of Reducing Its Rates by Changing Chemical Injection Sites

The injection of chemicals is one of the most important treatment steps used to reduce the effect of corrosion factors in crude oil distillation units in oil refineries. As a result of the availability of suitable conditions for the formation of the main corrosion agents, namely acids (HCI, H2S). It has become necessary to neutralize the effect of these factors in distillation units and towers by changing the sites of adding chemicals, where oil refineries use anti_ corrosion film and caustic soda (NaOH) as well as neutral amine to control and limit the effect of chloride ion, iron rates, salts and the (PH) values. As a result, the research paper is interested in developing a study of adding and changing chemical injection areas (points) of adding chemicals, especially (caustic soda and neutralizer amine) at different specific points, and as it is well known, crude oil passes through a number of different heat exchangers to raise its temperature in preparation for refining. It was found that changing the addition of the neutral amine in the striper tower area of the kerosene section (drops that are returned to the main refinery tower) has a significant effect in controlling the stabilization of pH values between (5.5-6.5) and reducing the iron ion concentration at a rate of (1% ppm), While the injection of caustic soda depends on the temperatures of the crude oil, so it is changed into two lines. The first is before the heat exchangers, that is, when the temperature of the crude oil is (20-35) c̊, and the second line is after the crude oil reaches the temperature (65-90) c̊, it has a significant effect in reducing the concentration of the chloride ion at a rate of (1-5 ppm) present in the form of chloride salts dissolved in the crude oil.

Will the carbon neutrality target impact China's energy security? A dynamic Bayesian network model

Efforts to reach the target of carbon neutrality create uncertainty about future energy security in China. This paper predicts the future state of energy security on the path to achieving carbon neutrality. A dynamic Bayesian network model is proposed to describe the dynamic causal relationship between China's energy security and its influencing indicators, including a carbon neutrality factor. The results reveal that, under the carbon neutrality scenario, energy security is expected to be in a Poor state in 2030, with improvement to a Poor+ state in 2040, 2050, and 2060. The energy security state is expected to remain in a Poor state in 2030, 2040, 2050, and 2060 under the existing policy scenario. Carbon neutrality has a small negative impact on energy security in the short term, and a positive impact in the long term. The energy security state is not expected to be fundamentally improved under carbon neutrality scenario because the four dimensions of energy security may not achieve balanced development. These dimensions include availability, applicability, acceptability, and affordability. Crude oil distillation capacity, crude oil price, and coal price are expected to have the greatest impact on energy security.

Maintenance Strategy of a Preheat Train of a Crude Oil Distillation Unit Based on Exergy and Exergoeconomic Analysis

Abstract Established or create new ones to plan the cleaning tasks of the heat exchangers. In this work, a maintenance strategy is developed for a preheating train under the Maintenance Centered on Energy Efficiency (MCEE) methodology, where it is sought to integrate the information of the principles of the second law of thermodynamics with economic variables to use parameters. The modification of the maintenance justification parameter (J) is proposed, adding two new maintenance indicators (W and X). Each one seeks to evaluate an essential criterion for the maintenance area: economic viability, technical feasibility, and benefits, toward the other exchangers in the network after cleaning a specific component. A criticality diagram and a criticality matrix are used. The heat exchangers are grouped into subassemblies, with the leading group consisting of the key heat exchangers (KHEX), the elements of which have a significant impact on the efficiency of the preheat train. For their part, the regions are composed of components whose performance is less considerable than that of the KHEX. In total, 34 maintenance activities will be carried out, distributed among the 25 interchanges of the network. The planning of a program of cleaning activities according to the maintenance strategy based on the methodology of the MCEE establishes a substantial scientific contribution due to the almost null existence of exergetic studies applied to the management of maintenance tasks and focused mainly on the preheating of trains.

Incorporation of fuel cell in oil refinery a step to achieve net zero-carbon emission goal

The usage of fuel cells is growing rapidly in various industries, and employing it as an alternative power source in oil refineries which will assist many large oil firms in achieving the global energy transition. The present paper focusses on significant utilization of fuel cell in downstream refinery to reach sustainable energy pathway towards net zero emission. The combination of gas turbine technology with high temperature fuel cells provides a power generating platform with ultra-high efficiency, ultra-low emissions, and fuel flexibility. Advances in R & D helps in reducing the cost of fuel cell and are now being used to power fuel cell producing energy ranging from 1 Watt to 10 Megawatt. The auxiliary power supplies and heat energy needed in refineries can be replaced by the use of these fuel cell. Fuel cell can be used in conjunction with the gas turbine for power supply with greater efficiency and lesser use of hydrocarbon-based fuel especially in equipments such as hydrotreater, desalting unit, pump and compressor unit etc. The heat generation in the fuel cell is associated with voltage losses and this generated heat can be used in reformer for hydrogen production, for space heating and preheating the steam required for heating of crude in crude oil distillation unit, vacuum jet, power turbines etc. With virtually zero harmful emission, minimal amount of space and higher efficiency reaching up to 60 %, the fuel cell can be utilized for optimum energy distribution in auxiliary units used in refinery.

Process design Optimisation, heat integration, and techno-economic analysis of oil refinery: A case study

ABSTRACT This paper outlines a comprehensive analysis of the optimal design and simulation of a crude oil distillation system within a refinery process, including pre-treatment and blending of two crude oils to increase the refinery’s annual profit. This distillation process is currently in operation, and the desired amount of feedstock is obtained from Iraqi Basra light-2015 and Kirkuk-2011 crude oil. To improve the energy efficiency of the utilization rate of crude oil, an atmospheric distillation process unit in this refinery with a capacity of 150,000 barrels per day (bpd) is considered. Aspen HYSYS simulation is used to optimize the distillation unit configuration and its operating performance. This paper also deals with three scenarios by comparing the feedstock compositions to the distillation process and the produced product compositions to minimize utility consumption. A heat integration approach was applied to the 3rd scenario by recycling hot outlet streams to the heat exchangers to increase the temperature of the inlet stream of the distillation column. Results indicated that about £2.29 million per year (Mpy) could be saved from the heat integration systems. Economic analysis and cut yields were carried out for each scenario to investigate the cost-effective and economically viable. Based on the economic analysis, scenario three showed better performance with a comparatively high cumulative cash flow of £31,886 M.

Fouling monitoring of a heat exchanger network of an actual crude oil distillation unit by constrained extended Kalman filter with smoothing

A heat exchanger network (HEN) is fundamental for reducing industrial processes’ external heating and cooling utility consumption, leading to lower operational costs and environmental impacts. HEN efficiency depends on the conditions of the heat exchangers, whose performance is reduced over time due to the constant deposit of impurities over the heat exchangers’ wall. This deposit, known as fouling, generates heat transfer resistance and reduces the corresponding performance and heat recovery. Therefore, the real-time estimation of fouling resistance is a crucial operational issue. The main industrial problem for monitoring in real-time the fouling in a HEN of an industrial process is the lack of measurements (e.g. temperatures and flow rates) and knowledge of the oil’s physical-chemical properties. In this work, a constrained Kalman filter with smoothing is applied to estimate the unavailable measurements and the fouling resistance to overcome these problems. This technique is applied to a real case study of a refinery industry’s crude oil distillation unit preheating train. The results show that the technique efficiently estimates the desired variables, increasing the process monitoring capability.

Optimization design of crude oil distillation unit using bi-level surrogate model

Crude Oil Distillation Unit (CDU) is one of the most important separation installations in the petroleum refinery industries. In this work, a Bi-level Surrogate column model Aided Constrained Optimization Design (Bi-SACOD) is proposed for time-consuming objectives and constraints in the evolutionary optimization design of CDUs. The main components of Bi-SACOD include bi-level surrogate model construction (Bi-SMC), bi-level model management (Bi-MM), and particle swarm optimization (PSO) mixed-integer constrained evolutionary (PSO-MICE) search. Bi-SMC implements surrogate column model construction and feasible domain identification. Bi-MM combines surrogate column models with rigorous CDU simulations to perform model management, and PSO-MICE implements optimum search works. The optimization results of the CDUs indicate that Bi-SACOD outperforms the single-level surrogate column model approaches, and are more consistent with the rigorous CDU model optimization approach, whereas the evaluation numbers of the time-consuming rigorous models are significantly reduced.