Simulation of Vacuum Distillation Unit in Oil Refinery: Operational Strategies for Optimal Yield Efficiency

Oil refineries play a crucial role in meeting global energy demands, and optimizing the efficiency of critical processes is vital for economic feasibility and environmental sustainability. Simulation is an essential tool for the optimization of valuable products. This work presents the rigorous simulation of a vacuum distillation unit (VDU) based on actual data from the vacuum distillation processes using Aspen HYSYS V10. The Peng–Robinson fluid package is used in this simulation, and an input assay with a standard density of 29 API_60 (879.8 kg/m3) is employed. True boiling point (TBP) assay data are the type that is being used. Methane, ethane, propane, i-Butane, n-Butane, i-Pentane, and n-Pentane are the components listed in the simulation. The research determines that achieving a yield capacity of 685 tons/h requires thirty stages in the atmospheric distillation unit and twelve stages in the vacuum distillation unit while operating at 420 °C temperature and 9 kPa pressure. Adjustments in the flash section temperature (FST) and steam flow rate (SFR) are proposed to enhance operational efficiency. Increasing the FST from 370 °C to 400 °C and adjusting SFR from 10 tons/h to 26 tons/h increases the Light Vacuum Gas Oil (LVGO) yield by 7.2% while elevating the FST from 400 °C to 430 °C and adjusting SFR from 10 tons/h to 26 tons/h enhances the High Vacuum Gas Oil (HVGO) yield by 7.4%. These optimization strategies offer a practical and effective approach for refineries to improve the economic benefits of vacuum distillation units. The implications of this research can act as a computational thinking exercise for higher education students considering the case study where only through changing the operational strategies can the yield be enhanced by 10.81% in the vacuum distillation unit of the oil refinery.