Assessment of a Mass and Energy-Integrated Gas Oil Hydrocracking Process via Water–Energy–Product Technical Indicators

The increasing demand for industrial resource optimization has driven the creation of integrated methodologies for the technical assessment of complex operations such as gas oil hydrocracking. This study examines the technical performance of a mass and energy-integrated gas oil hydrocracking process using the Extended Water–Energy–Product (E-WEP) methodology, which enables the quantification of 12 key indicators related to water, energy, and raw material usage. The research addresses the challenge of high demineralized water consumption in conventional hydrocracking processes. The findings show a production yield of 95.77% and a recycled hydrogen reuse rate of 67.99%, expressed as the Index of Reused Unconverted Material (IRUM). In terms of water use, fresh water demand decreased to 26.99 m3/h and wastewater discharge to 21 m3/h, although 77.79% of the total water processed is released as effluent, corresponding to the Wastewater Production Ratio (WPR). From the energy standpoint, total energy consumption increased to 2966.57 MMBTU/h, primarily due to the use of additional electrical equipment for mass integration. The Total Cost of Energy (TCE) reached 3,563,840.10 USD/day, with electricity (1630.82 kWh/t) as the dominant source, negatively influencing the process’s economic efficiency. Despite this energy drawback, the evaluated configuration achieves the most sustainable water use compared to conventional and integrated PVC production schemes, underscoring the importance of adopting holistic evaluations that jointly address technical efficiency, environmental impact, and economic feasibility.