A major oil refinery faced production constraints, and our optimization expertise unlocked significant operational gains.
Bottlenecks in the refinery’s distillation and catalytic cracking units limited output, hindering the ability to meet rising fuel demand. High energy use in aging infrastructure reduced efficiency, and any changes needed to maintain safety and comply with industry standards. The client required solutions that minimized operational disruptions to avoid production losses.
Through our Process Optimization and Debottlenecking service, we used Aspen HYSYS to model the refinery’s key units, simulating fluid dynamics and heat transfer to identify constraints. Our analysis revealed inefficiencies in heat exchanger configurations and flow rates. We proposed targeted upgrades, including resized exchangers and optimized control strategies, validated through dynamic simulations. Our Safety and Risk Analysis service ensured compliance with API standards for pressure relief systems. We provided on-site support during implementation, delivering detailed plans to ensure smooth execution by the client’s team.
The refinery significantly increased throughput, meeting market demand, and reduced energy consumption, enhancing efficiency. Implementation was completed without downtime, ensuring continuous operations. The optimized processes improved long-term reliability, allowing the client to maintain peak performance. The refinery now operates at enhanced capacity, strengthening its market position.
Our precise simulations and seamless execution empowered the refinery to overcome bottlenecks, boosting productivity and efficiency. By delivering compliant, disruption-free solutions, we enabled the client to meet demand and solidify their leadership in the oil and gas sector.
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