Integrated Advanced Process Control & Real-Time Monitoring System Based on Preliminary Study of Effect of API Gravity, True Boiling Point Curve & Sulphur Content on CDU Light Fraction

Crude oil refining efficiency is largely influenced by key factors such as API gravity, sulfur content, and the True Boiling Point (TBP) curve. This study aims to explore the effects of API gravity, Sulphur content and TBP characteristics on crude distillation unit fractions especially naphtha (lightest fraction), using Aspen Plus simulation to model various refining scenarios with various crude assays and propose best control approach that can be made to optimize the CDU with varying crude oil properties. Analysis on API gravity and TBP curve, and the distribution of sulfur across distillation fractions was also done and related with flowrate of Crude Distillation Unit Fractions (especially naphtha). Results show that higher API gravity increases the yields of lighter fractions and TBP curve shape (less steepness) enhances the separation efficiency even more, while sulfur distribution shows heavier cuts have more Sulphur supported by its high boiling point. The findings highlight that best control approach is integrated Advanced Process Control & Real Time Monitoring System which uses Model Predictive Control that has the ability to predict future and adjust before it happens & inferential modeling and soft sensors provide real-time estimation of crude properties, reducing reliance on delayed laboratory analyses with addition of cut-point optimization that minimize the off-spec production. All these systems can be integrated in Distributed Control System (DCS) that will allow smooth operations with minimal disturbance and optimum efficiency. Future research should focus on implementation of said approach to analyze and optimize it.