Optimization of AGO and DPK Production in an Industrial Modular Refinery Operation

Abstract Optimization of automotive gas oil (AGO) and dual-purpose kerosene (DPK) production in an industrial modular refinery operation was conducted using a case study of a facility (Company A) located at Ohaji-Egbema Local Government Area, Imo State, Nigeria. The system was modelled using the Aspen HYSYS version 11.0 simulation tool. A daily input of 5,000 barrels of crude oil per day was characterized and introduced into the distillation system operating at 101.3 kPa. The distillation column consisted of 22 trays for the collection of five target products: Off-gas, Naphtha, DPK, AGO and residue. The flowrate of the target products, DPK and AGO, under the initial process conditions (Condenser: 44 oC, Stage 8: 163 oC, and Stage 16: 254 oC were determined to be 662.3 b/d and 431.40 b/d, respectively. The process was repeated at varied condenser temperatures in the range of 45 - 48 oC, and the Stage 8 temperatures were raised by 0.5 oC (163 oC -168.5 oC), while Stage 16 temperatures were increased by 4 oC (254 - 298 oC). Temperatures were recorded at each increment in condenser temperature, and the flow rates (yields) of the desired products were documented. The optimum production of AGO was observed at a condenser temperature of 48 oC, with a yield of 51.26%, at a stage 16 temperature of 270 oC (543.15k). The maximum yield of DPK was achieved at condenser temperature of 44 oC and a stage 8 temperature is 168.5 oC (441.65k), with a yield of 22.24%. Beyond the temperature of 48 oC for AGO and 44 oC for DPK, errors were encountered, and the DPK output decreased. This study identifies the precise conditions that optimizes the production of AGO and DPK, offering insights for enhanced oil refinery efficiency of the distillation process and sustainability in petrochemical engineering Top of Form.