Overview of Refinery Process: Crude Oil Distillation 29th September – 4th October, 2025

Course Overview

This 5-day course provides an in-depth understanding of crude distillation, one of the most fundamental processes in petroleum refining. Participants will learn the principles of crude oil distillation, the design and operation of distillation columns, and the factors affecting separation efficiency. The course covers key concepts such as tray and packed columns, heat integration, and troubleshooting, aimed at improving the performance and energy efficiency of crude distillation units (CDUs). The course is suitable for refinery engineers, operations staff, and technical professionals involved in the crude distillation process.

Course Objectives

By the end of this course, participants will be able to:

1. Understand the fundamental principles and importance of crude oil distillation in refinery operations.
2. Identify the key components and equipment in a crude distillation unit (CDU).
3. Analyse the factors affecting separation efficiency in distillation columns.
4. Optimise distillation column performance through energy integration and operational control.
5. Troubleshoot common issues encountered in crude distillation operations.
6. Implement best practices for the maintenance and operation of distillation units.

Target Audience

• Refinery engineers and operations professionals involved in crude distillation.
• Process engineers working on distillation or other separation technologies.
• Operations managers overseeing CDU units.
• Technical staff and supervisors engaged in maintaining and optimising distillation columns.
• Environmental and safety officers in refining environments.

Daily Agenda

Day One: Introduction to Crude Distillation

• Overview of Crude Distillation: Understanding the role of crude distillation in refining, and its impact on the entire refining process.
• Crude Oil Composition and Characteristics: The role of different fractions in crude oil and their significance in refining.
• Principles of Distillation: The theory of distillation, including vaporisation and condensation.
• Distillation Column Basics: Key components of a distillation column, including trays, packing, and reboilers.
• Crude Distillation Unit (CDU) Configuration: Common configurations of CDU and associated equipment.
• Distillation Principles in Refining: How crude distillation separates crude oil into fractions.

Day Two: Distillation Column Design and Operation

• Tray Columns vs. Packed Columns: Comparison of tray and packed distillation columns, advantages and limitations.
• Design Considerations for Distillation Columns: Factors affecting column design, including pressure, temperature, and flow rates.
• Reboilers and Condensers: The function of reboilers and condensers in the distillation process.
• Operational Aspects of CDU: Understanding the operating parameters such as reflux ratio, column pressure, and temperature profiles.
• Heat Integration: Introduction to heat integration techniques for energy efficiency, including preheating and heat exchangers.
• Hands-on Exercise: Column design basics and layout planning.

Day Three: Separation Efficiency and Performance Optimisation

• Separation Efficiency in Distillation: Factors influencing separation efficiency, including relative volatility and column internals.
• Column Performance and Tray Design: The role of tray design in performance, including weeping, flooding, and entrainment.
• Energy Efficiency in CDU: Methods for improving energy efficiency in crude distillation, such as energy targeting and heat recovery.
• Optimisation of Distillation Conditions: Adjusting temperature, pressure, and flow rates for improved separation and performance.
• Column Simulation and Modelling: Using software tools to model column performance and optimise operating conditions.
• Case Study: Improving the energy efficiency of a CDU in a real refinery setting.

Day Four: Troubleshooting Crude Distillation Issues

• Common CDU Problems: Identifying common issues such as fouling, pressure fluctuations, and poor separation.
• Operational Troubleshooting: Diagnosing and solving operational problems related to reflux ratios, flooding, and capacity limitations.
• Troubleshooting Column Internals: Understanding and resolving issues with tray design, packing, and other column internals.
• Impact of Feedstock Variations: How variations in crude oil feedstock affect distillation performance.
• Troubleshooting Heat Integration Systems: Identifying and resolving heat integration issues in distillation operations.
• Group Exercise: Troubleshooting a simulated crude distillation column scenario.

Day Five: Maintenance and Best Practices for CDU Operations

• Routine Maintenance for CDU: Key maintenance activities for ensuring reliable operation of distillation columns.
• Preventative Maintenance Strategies: Best practices in preventive maintenance to avoid unplanned shutdowns and improve column lifespan.
• Instrumentation and Control: Overview of instrumentation and control systems used to monitor and optimise CDU performance.
• Safety Considerations in CDU Operations: Identifying and mitigating safety hazards related to distillation operations.
• Environmental Considerations: Addressing emissions and waste management in CDU operations.
• Future Trends in Crude Distillation: Innovations in distillation technology, including advanced separation techniques and energy-saving strategies.
• Final Assessment: Practical troubleshooting and operational optimisation in a real-world CDU scenario.

Why Choose this Course?

This course offers a comprehensive understanding of crude distillation, from fundamental principles to advanced operational techniques. Participants will gain practical knowledge of improving efficiency, troubleshooting common problems, and implementing best practices in crude distillation units. The course provides a blend of theoretical knowledge and practical, hands-on exercises to ensure participants can apply what they learn in real refinery settings.

Learning Outcomes

Upon successful completion of the course, participants will:

1. Gain a solid understanding of the crude distillation process, including the key components and operating principles.
2. Be able to optimise distillation column performance and efficiency through process control and energy management techniques.
3. Troubleshoot common operational issues and apply corrective actions to improve CDU performance.
4. Understand the maintenance needs of distillation units and implement best practices for long-term operational reliability.
5. Be equipped to improve the safety and environmental performance of crude distillation operations.