Energy Optimization and Performance Enhancement of the LPG Recovery Unit in Refinery using Aspen HYSYS Simulation

Document Type : Research Article

Authors

1 Department of Chemical Engineering, Engineering Faculty, Velayat University, Iranshahr, Iran

2 Department of Mechanical Engineering, Engineering Faculty, Velayat University, Iranshahr, Iran

Abstract

Enhancing the energy performance of liquefied petroleum gas (LPG) recovery units presents a significant challenge for refineries aiming to achieve greater efficiency while minimizing their environmental footprint.  This study focuses on modeling and optimizing the LPG recovery unit at the Refinery using Aspen HYSYS. The aim is to assess its thermodynamic and operational performance.  The simulation included the real setup of the deethanizer, depropanizer, and debutanizer columns, utilizing the Peng–Robinson equation of state to ensure precise predictions of vapor–liquid equilibria.  The validation of the model against actual plant data demonstrated a high level of agreement, with deviations remaining within ±3% for key parameters such as temperature, pressure, and product composition.  Through sensitivity analysis, it was found that the reboiler temperature and column pressure play a significant role in determining the purity of LPG and the overall energy requirements.  By optimizing these parameters, a significant reduction in overall energy consumption was achieved, with a decrease of approximately 12% noted. At the same time, the purity of the LPG product remained above 97mol%, highlighting our commitment to efficiency and quality. The model that has been developed provides a reliable and flexible framework for the evaluation of processes, the integration of energy, and the optimization of operations within current refinery systems. The results play a crucial role in connecting process simulation with real-world industrial practices, resulting in energy management and sustainability efforts across the entire refinery.

Keywords

References

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Chemical Process Design
Volume 5, Issue 1
June 2026
Pages 122-133

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