Impact of Mass Integration on the Technoeconomic Performance of the Gas Oil Hydrocracking Process in Latin America

The gas oil hydrocracking process is a cornerstone of modern refining, enabling the conversion of heavy fractions into high-value fuels such as diesel, kerosene, LPG, and naphtha. However, despite its economic significance, its considerable water requirements for cooling, washing, and steam generation lead to high utility costs, which may undermine profitability, representing the problem of the study. This study addresses the issue through a techno-economic assessment and resilience analysis of an industrial-scale, mass and energy-integrated gas oil hydrocracking process, utilizing the novel FP2O methodology. The process was modeled in Aspen HYSYS® V14.0 with a capacity of 1.94 Mt/year, assuming a feedstock cost of USD 350/t and a primary product (diesel) price of USD 1539/t. The total capital investment (TCI) was estimated at USD 175.68 million, while utility expenses reached USD 1312.18 million/year, representing nearly half of the total product cost (TPC) of USD 2692.20 million/year. A set of twelve techno-economic and three financial indicators was determined, yielding a gross profit (GP) of USD 97.69 million, profitability after tax (PAT) of USD 64.96 million, and a net present value (NPV) of USD 229.62 million. The payback period (PBP) was 1.41 years, with a depreciable payback period (DPBP) of 2.99 years. The return on investment (ROI) was 36.97%, and the internal rate of return (IRR) reached 44.81%, evidencing strong profitability relative to comparable petrochemical operations. Resilience analysis highlighted sensitivities to fluctuations in product prices, feedstock costs, and normalized variable operating costs (NVOC), identifying a critical NVOC of USD 1435/t against the current operation at USD 1384.74/t, which suggests a narrow buffer before profitability deteriorates. Overall, the findings confirm that mass and energy integration enhances resource efficiency but does not fully mitigate exposure to feedstock and utility price volatility. This work constitutes the first application of FP2O to a mass and energy-integrated gas oil hydrocracking facility, establishing a benchmark for holistic techno-economic and resilience assessments in complex petrochemical systems.