Sustainable Refining: Enhancing Energy Efficiency in Crude Distillation Processes

Abstract

Crude oil distillation is a crucial separation process in the petroleum refining industry, where crude oil is fractionated into various components based on their boiling points. This energy-intensive industrial process significantly contributes to global energy consumption and greenhouse gas emissions. Given the magnitude and environmental implications of crude distillation operations, there is an urgent need to analyze energy usage patterns rigorously and identify opportunities for enhancing efficiency. This review explores the extensive efforts made by researchers to develop advanced models and techniques for the techno-economic evaluation of crude distillation systems. It begins by highlighting the considerable energy demands and emissions associated with conventional crude distillation units (CDUs). Emphasizing the necessity of comprehensive energy analysis, the paper discusses how optimization strategies can improve CDU operations and enable retrofits aimed at reducing both energy consumption and environmental impacts. Various modeling approaches are examined, including rigorous process simulations using tools like Aspen HYSYS and innovative exergy-based analyses, which provide deeper insights into the thermodynamic principles and operational factors influencing CDU performance. The review focuses on key areas such as distillation tower configurations, operating conditions, and heat exchanger network designs, all aimed at identifying energy-efficient modifications. Additionally, the paper discusses advancements in process intensification techniques, including Dividing Wall Columns, Hybrid Distillation, and reactive distillation. These methods not only enhance separation efficiency but also contribute to significant reductions in energy usage. The findings from numerous case studies are synthesized, demonstrating their effectiveness in improving overall efficiency.