This study investigates improving the energy efficiency of two key refining processes: the Crude Distillation Unit (CDU) and the Residue Cracking Unit (RCU). The research methodology followed the ‘targeting before design’ approach. The CDU is a ‘tightly pinched’ system, with limited opportunities for further energy savings. The RCU actual ΔTmin is around 55 ℃ indicating a low level of current heat recovery. The Total-Site analysis shows that theoretically 18MW of heat could be transferred from the RCU to the CDU, reducing CDU requirements by 40% for a new or grass roots design. RCU retrofit designs were developed to increase steam generation by up to 35% and in line with targeting estimates would appear to have economic potential. The alternative CDU-RCU retrofit design was developed to decrease CDU hot utility use. Although the Total-Site profile demonstrated strong potential for heat integration, this retrofit design is not commercially attractive, as the decrease in CDU fuel does not offset the cost of reduced steam generation. This demonstrates the need to consider the different fuel and steam costs in the Total-Site analysis.

Heat Integration Retrofit Design Heat Exchanger Networks Pinch Analysis Crude Distillation Residue Catalytic Cracking Energy Recovery

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