More throughput. Less energy. Better margins.
Practical refinery process optimization that finds hidden capacity, recovers higher-value products and cuts energy use in the units you already own.
Refinery Process Optimization
Hidden capacity, product value and energy savings in assets you already own
Every refinery has hidden opportunities. We find them with plant-calibrated process simulation and modeling, tray and packing hydraulic rating, and hands-on revamp experience.
We start with the cheapest fix: operating changes first, targeted revamps next, and new technology such as DWC Prime™ only when it pays.
Better Results Without Major Capital Projects
Many performance gains come from operating changes, better controls or targeted revamps rather than new units.
Increase throughput
Process more feed by removing the real capacity constraint.
Reduce energy use
Lower reboiler, steam and cooling duties through better separation.
Improve product quality
Tighter specifications at the same or higher recovery.
Increase product value
Turn low-value streams into saleable products.
Delay capital spending
Unlock capacity before investing in new equipment.
Where We Find the Value
Distillation is usually the largest source of lost capacity and excess energy, so most studies start there.
Distillation systems3
- Column debottlenecking: jet flood, downcomer backup and entrainment limits (see distillation troubleshooting)
- Product purity and recovery improvement
- DWC Prime™ and Dual DWC Prime™ retrofit evaluation inside existing shells
Naphtha processing3
- Naphtha splitter optimization and additional cuts
- Extra cuts such as isopentane for premium gasoline
- Benzene management with Ben Prime™
Isomerization2
- Deisohexanizer revamps for more feed capacity in light naphtha isomerization
- A fourth cut of food-grade hexane, RON unchanged
Refinery–petrochemical integration2
- Side cuts that feed the CCR, PX and aromatics units
- Propylene recovery revamps
Energy2
- Heat-pump-assisted distillation for close-boiling separations
- Multi-effect distillation, alone or paired with DWC Prime™
DWC Prime™ Revamps in Practice
How the optimization levers above look on real refinery sequences. Click any diagram to enlarge it.
Naphtha splitter sequence
Two DWC Prime™ columns in parallel inside the existing shells: about $3M instead of $15M, installed in a 20-day turnaround, with sharper cuts relieving the downstream ISOM and CCR units.
Propylene recovery
Depropanizer and propylene splitter combined in one DWC Prime™ column, with higher propylene recovery and lower RVP of the bottoms C4 product.
Isopentane recovery
A depentanizer revamp recovers isopentane at 90 wt% purity and 70% recovery for premium gasoline.
Naphtha splitter with C7 side cut
A C7 side cut to the CCR integrates the isomerization, CCR and PX units.
Reformate splitter with C6 side cut
A C6 side cut reduces feed to the aromatics extraction unit to 75%, debottlenecking it.
A Structured Optimization Process
- Analyze plant dataDCS and lab data, test runs and heat and material balance closure.
- Build calibrated modelsPlant-matched simulation and tray or packing hydraulic rating.
- Identify opportunitiesFlood margins, pinch points, recovery and energy.
- Quantify economicsCAPEX, OPEX and payback in a feasibility study.
- ImplementBasic engineering through start-up and PGTR support.
Solutions sized to refinery economics and turnaround windows.
Recommendations grounded in modeling and operating reality.
From optimization study to technology, engineering and start-up.
Refinery Process Optimization: Questions Clients Ask
What is refinery process optimization?
A structured engineering review of refinery units to find more throughput, lower energy use, better product recovery and higher margins, using plant data, process simulation, hydraulic analysis and economics.
Do optimization projects always need capital spending?
No. Many gains come from operating changes or control improvements; others need only a targeted revamp of column internals rather than new units.
Which refinery units benefit most?
Distillation columns, naphtha splitters, deisohexanizers and isomerization units, reformate splitters, depropanizers and propylene splitters.
How much extra capacity does a DWC Prime revamp add to a naphtha splitter?
Typically more than 40% additional capacity, by revamping only the column internals with little or no change to the reboiler, condenser or pumps.
Can a propylene splitter be debottlenecked without adding a new column?
Yes. A dividing wall column revamp of a depropanizer and propylene splitter sequence can add roughly 30% more throughput and higher propylene recovery inside the existing shell.
What is a dividing wall column (DWC) revamp?
A DWC revamp installs a vertical partition inside an existing distillation column, so one shell does the work of two columns, adding capacity, sharpening product cuts or recovering an extra product without major new equipment.
Looking for more throughput or better margins?
Send us your unit data. We’ll identify the most economical path to more capacity, value or energy savings.