"Optimization of a real crude oil atmospheric distillation process using process simulation and statistical methods"
optimization, distillation column, crude oil, simulation, Response Surface Method.
The increasing global demand for energy has caused a rise in energy prices and has required the search for techniques that enhance the efficiency of processes in industries. Furthermore, in the environmental context, increasing energy efficiency plays a key role in reducing greenhouse gas emissions, contributing to sustainable development. This work was developed with the objective of optimizing the energy consumption of the top condenser of an atmospheric petroleum distillation tower, installed in one of the largest refineries in Brazil. The optimization consisted in the determination of optimum conditions for the stripping steam and feed temperature, which minimize the condenser energy consumption, according the product specification requirement and the equipment operational limits. The working methodology developed includes the steps of modeling, sensitivity analysis, factorial design and Response Surface Method (MSR). This was possible with the aid of the commercial simulator Petro-SIM® and the softwares STATISTICA© and Excel®. The results demonstrate that the refinery operates at operational conditions close to optimum values, but significant gains can still be reach by adjusting the stripping steam flowrate and feed temperature. The change in the steam flowrate to 280.00 t/d and the feed temperature to 363.64°C can generate a reduction of 0.81% in the overall thermal load and a monthly savings of R$ 341,733.00. It is also worth mentioning a monthly reduction of 2,148m³ of water for the production of steam. Thus, in addition to the possibility of real gains, this methodology developed from existing methods is able to be an optimization tool to improve energy efficiency, even in complex processes such as petroleum distillation.