Abstract

Crude oil refining in compact units has become crucial for developing economies due to the soaring demand for refined products and the prohibitive costs of large conventional refineries. Many countries find it challenging to build and maintain these massive plants, leading them to adopt cost-effective, simplified distillation units. This study specifically analyzes the design of a small-scale crude oil distillation column with 12.5 barrels per day (bpd) capacity, forming part of a broader refinery design initiative. The study utilized Aspen HYSYS software to simulate a simplified crude oil atmospheric distillation unit, serving as a preliminary step towards its full design and construction. The 2011 assay of Bonny Light crude oil was analyzed to determine its properties, such as API gravity, sulfur content, and pour point, categorizing it as medium sweet crude. Simulation results indicated recovery volumes for various fractions: off gases and liquid petroleum gas at 0.94 L/h, naphtha at 25 L/h, kerosene at 19.6 L/h, diesel at 16.45 L/h, and atmospheric residue at 8.37 L/h. Furthermore, the simulation results suggested feasible dimensions for constructing the distillation column, demonstrating the practicality of using process simulation software for designing cost-effective, small-scale refining units.

Key words: Bonny Light 2011, crude distillation, simulation, 12.5 bpd throughput, Aspen HYSYS.