Optimizing Crude Distillation Through Heat Integration: Insights From Krpc, Nigeria

Energy conservation remains a critical priority in process industries, particularly in oil refineries and petrochemical plants, where optimizing heat utilization can significantly enhance efficiency and sustainability. This study explores heat integration and retrofit analysis of Crude Distillation Unit-1 (CDU1) at the Kaduna Refining and Petrochemical Company (KRPC) to identify and implement energy saving strategies. Process data were extracted from the existing flowsheet, and a Pinch Analysis was conducted using Aspen Energy Analyzer to determine optimal energy targets. The analysis revealed that no additional heating was required, while the cooling demand was quantified at 2.475 × 108 kJ/hr. A minimum approach temperature of 13oC was selected, balancing capital and operational cost considerations, with an associated total cost index of NGN 42.46/s. A heat exchanger network (HEN) retrofit was designed and integrated into the process, incorporating 20 heat exchangers to maximize energy recovery. The proposed heat integration strategy offers an annual energy cost savings of NGN 1.38 billion, with a payback period of 2 years and 7 months. These findings demonstrate the potential for significant efficiency improvements in refining operations, reducing both energy consumption and associated environmental impacts.