Advanced Distillation in Petroleum Refineries Training Course

Advanced Distillation in Petroleum Refineries Training Course

Introduction

Advanced Distillation in Petroleum Refineries Training Course is designed to equip petroleum refining professionals with advanced technical knowledge and practical skills in crude oil distillation, fractionation technology, process optimization, and refinery performance improvement. Distillation is one of the most critical operations in petroleum refining, influencing product quality, energy consumption, throughput, and overall profitability. This comprehensive training explores the engineering principles of atmospheric and vacuum distillation units, thermodynamic modelling, vapor–liquid equilibrium, crude assay interpretation, fractionation efficiency, column hydraulics, tray and packing design, and advanced process control. Participants will learn how to optimize refinery distillation systems using process simulation, data-driven decision-making, digitalization, energy efficiency strategies, and predictive analytics to improve separation performance and minimize operational bottlenecks.

The course also focuses on modern refinery challenges, including fluctuating crude oil quality, energy cost reduction, fouling mitigation, corrosion management, emissions reduction, and increasingly stringent fuel specifications. Through practical exercises, engineering simulations, troubleshooting workshops, and industry-based case studies, participants will develop the expertise to diagnose distillation inefficiencies, improve heat integration, optimize reflux and steam consumption, and maximize valuable product recovery. The programme emphasizes refinery digital transformation, advanced process control (APC), real-time performance monitoring, process safety, and sustainable refining practices. By the end of the course, participants will be better prepared to implement technically sound and economically viable distillation improvements, enhance operational reliability, increase refinery margins, and support continuous improvement across modern petroleum refining operations.

Course Duration

10 days

Course Objectives

By the end of this course, participants will be able to:

1. Master advanced distillation engineering principles and their applications in modern petroleum refineries.
2. Analyze crude oil assays to optimize feed selection, unit performance, and product yield.
3. Evaluate vapor–liquid equilibrium and thermodynamic models for accurate separation predictions.
4. Optimize atmospheric distillation unit (CDU) operations for improved throughput and product recovery.
5. Improve vacuum distillation unit (VDU) performance while minimizing thermal cracking and coke formation.
6. Apply Aspen HYSYS, Aspen Plus, and process simulation techniques to model and optimize refinery distillation systems.
7. Diagnose column hydraulic limitations, including flooding, weeping, entrainment, and pressure-drop problems.
8. Optimize reflux ratios, stripping steam, pumparound circuits, and operating temperatures.
9. Implement advanced process control (APC) and real-time optimization strategies to stabilize refinery operations.
10. Develop effective fouling prevention, corrosion control, and equipment reliability improvement programmes.
11. Enhance energy efficiency through heat integration, heat recovery, and reduced furnace fuel consumption.
12. Apply process safety, hazard identification, and risk-based operational management principles.
13. Conduct techno-economic evaluations to quantify yield improvement, energy savings, and refinery profitability.

Target Audience

1. Petroleum refinery process engineers and chemical engineers.
2. Distillation unit operators, shift supervisors, and control-room personnel.
3. Refinery operations managers and production superintendents.
4. Process design, simulation, and optimization engineers.
5. Refinery technical services and performance improvement specialists.
6. Instrumentation, automation, and advanced process control engineers.
7. Inspection, maintenance, reliability, and equipment integrity professionals.
8. Energy management, technical consulting, and refinery project development specialists.

Course Modules

Module 1: Fundamentals of Advanced Petroleum Distillation

• Principles of vaporization, condensation, and fractional separation.
• Thermodynamic fundamentals of multicomponent hydrocarbon mixtures.
• Vapor–liquid equilibrium (VLE) and phase behavior of petroleum fractions.
• Relative volatility, boiling-point distribution, and separation efficiency.
• Case Study: Evaluating separation performance in a refinery crude distillation column processing mixed crude feedstocks.

Module 2: Crude Oil Characterization and Feedstock Optimization

• Crude oil assay interpretation and laboratory characterization.
• API gravity, sulfur content, viscosity, and distillation curves.
• True boiling point (TBP) analysis and simulated distillation techniques.
• Crude blending strategies and their impact on refinery product yields.
• Case Study: Optimizing crude blends to improve middle-distillate recovery while controlling refinery operating costs.

Module 3: Advanced Atmospheric Distillation Unit Operations

• Configuration and operation of the crude distillation unit (CDU).
• Desalter performance and feed preparation requirements.
• Furnace outlet temperature and flash-zone operating conditions.
• Side-draw product recovery, stripping steam, and pumparound optimization.
• Case Study: Improving CDU throughput and reducing off-specification kerosene and diesel production.

Module 4: Vacuum Distillation and Heavy Residue Processing

• Vacuum distillation principles and reduced-pressure operation.
• Vacuum column design, flash-zone configuration, and vapor handling.
• Steam injection, ejectors, and vacuum system performance.
• Minimizing thermal cracking, coke formation, and heavy-residue degradation.
• Case Study: Increasing vacuum gas oil recovery while maintaining acceptable vacuum residue quality.

Module 5: Distillation Column Design and Internals Optimization

• Tray column and packed column design fundamentals.
• Selection of trays, structured packing, and random packing.
• Column diameter, height, stage efficiency, and theoretical stages.
• Hydraulic performance, liquid distribution, and vapor–liquid contacting.
• Case Study: Retrofitting column internals to increase capacity without constructing a new distillation tower.

Module 6: Advanced Thermodynamics and Process Simulation

• Selection of appropriate thermodynamic property packages.
• Equation-of-state models and hydrocarbon phase-equilibrium calculations.
• Development of rigorous distillation column simulation models.
• Sensitivity analysis of pressure, temperature, reflux, and feed conditions.
• Case Study: Using Aspen HYSYS or Aspen Plus to identify optimal operating conditions for a refinery fractionator.

Module 7: Distillation Column Hydraulics and Troubleshooting

• Identification of flooding, weeping, entrainment, and downcomer backup.
• Pressure-drop analysis and column differential-pressure monitoring.
• Diagnosis of foaming, maldistribution, and liquid carryover.
• Interpretation of temperature profiles and operational trends.
• Case Study: Investigating a sudden loss of separation efficiency caused by hydraulic limitations in a high-throughput distillation column.

Module 8: Reflux, Stripping Steam, and Product Recovery Optimization

• Principles of reflux ratio and separation efficiency optimization.
• Stripping steam requirements and steam-to-feed relationships.
• Optimization of side strippers and pumparound heat removal.
• Balancing product purity, recovery, energy consumption, and throughput.
• Case Study: Reducing stripping steam consumption while meeting diesel flash-point and product quality requirements.

Module 9: Heat Integration and Energy Efficiency

• Distillation energy balances and major heat-consumption drivers.
• Crude preheat train optimization and heat exchanger network analysis.
• Furnace efficiency, excess oxygen, and stack heat-loss reduction.
• Pinch analysis and opportunities for process heat recovery.
• Case Study: Reducing crude unit fuel consumption through preheat train optimization and improved heat integration.

Module 10: Advanced Process Control and Digital Refinery Technologies

• Fundamentals of advanced process control (APC) and model predictive control (MPC).
• Integration of distributed control systems (DCS) with refinery optimization platforms.
• Real-time optimization (RTO) and automated operating constraint management.
• Digital twins, soft sensors, and predictive process analytics.
• Case Study: Implementing model predictive control to stabilize column temperatures and improve product recovery during feed variations.

Module 11: Fouling, Corrosion, and Equipment Reliability

• Mechanisms of heat exchanger fouling and crude preheat degradation.
• Corrosion risks associated with sulfur compounds, naphthenic acids, and chloride contamination.
• Monitoring heat-transfer coefficients and exchanger pressure drop.
• Preventive maintenance, inspection planning, and reliability-centred maintenance.
• Case Study: Investigating declining furnace and preheat train performance and developing a targeted fouling mitigation strategy.

Module 12: Product Quality Control and Refinery Specifications

• Quality requirements for naphtha, kerosene, diesel, and gas oil streams.
• Distillation endpoints, flash point, density, and volatility control.
• Online analyzers, laboratory testing, and process quality monitoring.
• Product blending and downstream unit feed-quality coordination.
• Case Study: Correcting off-specification kerosene by adjusting fractionation conditions and coordinating with downstream blending operations.

Module 13: Process Safety and Environmental Compliance

• Process hazard analysis (PHA), HAZOP, and risk assessment.
• Overpressure protection, relief systems, and emergency shutdown principles.
• Management of change (MOC) for distillation unit modifications.
• Energy-related emissions, flare minimization, and environmental monitoring.
• Case Study: Conducting a HAZOP review for a proposed increase in crude distillation unit throughput.

Module 14: Advanced Troubleshooting and Operational Performance Improvement

• Root cause analysis (RCA) for recurring distillation problems.
• Performance benchmarking and key performance indicator (KPI) development.
• Operating envelope optimization and constraint identification.
• Turnaround planning, equipment upgrades, and operational best practices.
• Case Study: Diagnosing declining atmospheric column performance using process trends, mass balances, and equipment inspection findings.

Module 15: Techno-Economic Optimization and Refinery Profitability

• Refinery margin analysis and product value optimization.
• Yield accounting and identification of high-value recovery opportunities.
• Capital expenditure (CAPEX) and operating expenditure (OPEX) evaluation.
• Economic assessment of energy-saving projects and distillation retrofits.
• Case Study: Evaluating the financial returns of a vacuum column revamp against continued operation under existing constraints.

Training Methodology

• Interactive lectures and presentations.
• Group discussions and brainstorming sessions.
• Hands-on exercises using real-world datasets.
• Role-playing and scenario-based simulations.
• Analysis of case studies to bridge theory and practice.
• Peer-to-peer learning and networking.
• Expert-led Q&A sessions.
• Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@datastatresearch.org or call +254724527104 

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

 We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to DATASTAT CONSULTANCY LTD account, as indicated in the invoice so as to enable us prepare better for you.