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    The substantial energy requirement of crude oil distillation columns is met partly by
    costly utilities, such as steam and fuel for red heaters, and partly by heat recovered
    from the process, using process-to-process heat exchange. Energy savings, therefore,
    demand not only a distillation column that is energy-ef
    cient, but also a heat exchanger 5131
    network (HEN) which minimizes utility costs by maximizing heat recovery. A new crude oil
    distillation design procedure is presented which considers the column, the HEN and their
    interactions simultaneously, to minimize utility costs. Pinch analysis is used to determine
    minimum utility costs prior to the design of the HEN. In this method, the column is
    decomposed into a sequence of simple columns, which enables appropriate distribution of
    stages and simpli
    es analysis. Modi
    cations, which further increase the ef
    ciency of the
    process, are proposed: these are the installation of reboilers, rather than stripping steam, and the
    thermal coupling of column sections. The detrimental effects of these modi
    cations on the heat
    recovery opportunitiesof the process are analysed for a distillation tower with side-strippers. A
    new step-by-step design procedure is derived from this analysis, and is applied to a case study.
    In the case study, the resulting design offers nearly 20% savings in utility costs over the base
    case design. The vapour ¯ ow in the column is reduced by a similar amount, offering capital
    savings, additional ¯ exibility or the opportunity to increase throughput. The new integrated
    design procedure considers the column and its associated HEN simultaneously, aiming to
    minimize operating costs by obtaining the best t between the process and the available
    utilities.
    Keywords: pinch analysis; preheat train; distillation design1. INTRODUCTION
    Crude oil distillation is an energy-intensive process,
    consuming as fuel 1 to 2% of the crude oil processed
    (Klenner
    1
    ). The process is highly complex and has changed
    relatively little since its inception 70 years ago (Miller
    2
    ).
    Crude oil distillation design is usually governed by
    experience, design guidelines and simulation trials. How-
    ever, published design procedures are not systematic and do
    not consider concurrently the design of the heat exchanger
    network (HEN).
    Energy costs are highly relevant to the crude oil
    distillation process, especially since fuel combusted is
    product lost from this process. Furthermore, saving energy
    has the side bene
    ts of reducing site emissions and
    stretching further our limited crude oil reserves. The heat
    duties of a distillation process can be reduced signi
    cantly
    by designing an energy-ef
    cient system. In addition, crude
    oil distillation lends itself to heat recovery through process-
    to-process heat exchange since it requires heat addition and
    heat removal over a wide range of temperatures. Simply
    increasing the energy-ef
    ciency of the distillation column
    gives smaller utility savings than if the energy-ef
    ciency
    is improved while also maximizing the potential for energy
    recovery in the context of the process and the utility
    system.
    1.1 Process Description
    A typical crude oil distillation column consists of a main
    tower with side-strippers. The crude oil fed to the distillation
    tower generally comes from storage at ambient temperature
    and is heated in a heat exchange network (preheat train) and
    a furnace. In the preheat train, heat is transferred from hot
    process streams to the crude oil feed, generally raising its
    temperature to 270 to 290 C. The pressurized crude oil is
    heated further, using a furnace, to about 350 to 370 C. This
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