ENG. ANDREW OMWENGA
Chemical & Process Simulation Engineer • Thermodynamic Specialist
Refinery Crude Preheating & Energy Recovery Network
Section 1.0 — Simulation & Facility Metadata
Section 2.0 — Executive Summary
Pinch analysis and heat exchanger network (HEN) retrofit for a crude distillation unit to maximize cross-stream heat recovery.
Section 3.0 — Problem Statement & Operating Bottlenecks
High utility costs due to sub-optimal heat exchange between hot CDU residue/side-draw streams and cold crude feed.
Section 4.0 — Objectives & Rigorous Simulation Methodology
Pinch analysis target calculation followed by full rigorous shell-and-tube sizing and hydraulic validation in Aspen HYSYS.
Section 5.0 — Simulation Results & Thermodynamic Findings
The retrofit required adding only two shell-and-tube exchangers in series, demonstrating a payback period under 8 months.
Section 6.0 — Core Engineering Takeaways
Section 7.0 — Model Assumptions & Future Recommendations
Space constraints in existing crude unit layout were not physically constraint-checked.
Detailed 3D piping routing and pressure drop optimization.
Section 8.0 — Consultant Conclusion & Verification Sign-off
Pinch analysis combined with Aspen HYSYS simulation reveals high-ROI energy recovery opportunities in legacy refinery assets.
