Investigation of the Opportunity of Heat Integration in a CDU in Egypt

Mohamed Kishk, Wael M. El-Maghlany, Abdelhamid Attia, Yehia A. Eldrainy


Energy integration is a critical solution for crude oil distillation units to reduce fuel consumption and environmental impacts. There are several proposed innovations for the networks of the heat exchanger, in addition to optimising operations in recent decades, for the purpose of enhancing the energy and economic efficiencies of the system of distillation of crude oil. However, retrofitting is often constrained by the constraints of maintenance, safety, and the topology of the process, but revamping managers prefer to exploit the existing equipment. Retrofit aims to reuse the existing equipment more efficiently to achieve various objectives, such as reducing utility consumption and minimising CO2 emissions. This study introduces an optimal operation modification for the purpose of enhancing the energy savings of the existing unit of crude oil distillation. First, a detailed process operation is explained, simulated, and analysed with ASPEN HYSYS software, and then two modifications are proposed. The proposed modifications aim to achieve higher energy savings while retaining the economic gain than conventional approaches and without any additional investment in a retrofit in an industrial case, especially up to 28% of the reduction of energy. It is also equivalent to a 23.38% reduction of CO2 emissions every year.


Aspen HYSYS; CDU; Heat exchanger network; Pinch analysis; Retrofitting

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