Refinery Operational Excellence

Refineries face persistent challenges in improving energy efficiency, ensuring crude availability, and implementing process safety, with excessive energy consumption being particularly difficult to address. This book explores the integration of chemical engineering principles with Industrial Internet of Things (IIoT) technologies, including artificial intelligence (AI), to optimize refinery operations. This book is organized into four sections - Introduction, Equipment Twin, Instrumentation, and Refinery Application. This book emphasizes the use of digital tools and engineering fundamentals to enhance equipment design and operational efficiency. Key Features: - Focuses on the intersection of chemical engineering, refinery operations, and digital technologies, particularly IIoT and Digital Twin (DT) applications. - Explains setup procedures, process simulation with feed characterization, thermodynamic model selection and equipment specification. - Reviews current refinery challenges such as energy efficiency, predictive maintenance and decarbonization goals. - Details the development of IIoT applications for three refinery units: sour water stripper unit, amine regeneration unit, and crude and vacuum distillation unit. - Includes case studies and first-principle-based simulation strategies. This book is intended for engineering graduate students, chemical engineering researchers, and refinery professionals.

Ashwani Malhotra is the Project Director at the Centre of Excellence for Process Safety & Risk Management (CoE-PS&RM), IIT Delhi. The primary focus of the Centre is on developing expertise and knowledge in process safety, building awareness, and providing consultancy services to the industry. Prior to joining CoE-PS&RM at IIT Delhi, he served as Chief General Manager in the Process Department at Engineers India Limited (EIL), with additional charge as Executive Director of the Safety and Environment Departments. He brings over 38 years of experience in process design and engineering for refineries and onshore/offshore oil & gas facilities. His career at EIL also included roles in the Equipment and R&D divisions. He has led the process design of numerous Crude and Vacuum Distillation Units, along with other refinery units-covering both grassroots developments and revamp projects. He has also been involved in the development of Industrial Internet of Things (IIoT) applications for Crude and Vacuum Distillation Units to enhance efficiency and support decarbonization efforts. He holds a Ph.D. in Chemical Engineering from the Indian Institute of Technology Delhi, where he also completed his bachelor's degree in the same field. Anil K. Saroha has been engaged in "Teaching & Research" in Chemical Engineering Department, Indian Institute of Technology, Delhi, for the last 25 years. He has been actively working on "Wastewater Treatment" using novel approaches and has completed several transformational research projects on industry relevant problems. He has guided 13 Ph. D. students and 45 M. Tech. students. He is currently Coordinator (Professor in-charge) of Centre of Excellence on 'Process Safety and Risk Management' operating at IIT Delhi. He is reviewer to many leading scientific journals. He is Fellow of The Royal Society of Chemistry (UK), Indian Institute of Chemical Engineers, Indian Chemical Society and Institution of Engineers (India). He was the Honorary Editor of 'Indian Chemical Engineer', flagship journal (published by Taylor & Francis, UK) of Indian Institute of Chemical Engineers (IIChE) for 07 years (01 Jan.2009 to 31 Dec.2015). He has been actively involved with professional societies and has held many responsibilities in IIChE which is a national body of professional chemical engineers with 32000 members across the country with 46 regional centres and 182 student chapters. He was the Honorary Treasurer, Joint Secretary, Secretary, Vice-Chairman and Chairman of Indian Institute of Chemical Engineers (Northern Regional Centre). He was President of Indian Institute of Chemical Engineers for the year 2023.

1. Introduction to IIoT 2. Introduction to Digital Twin 3. Centrifugal Pump Operation 4. Distillation Column Internals Operation 5. Fired Heaters. 6. Heat Exchanger 7. Instrumentation 8. Sour Water Stripper Unit 9. Amine Regeneration Unit 10. Crude and Vacuum Distillation Unit