Process optimisation to reduce operating costs
- thoroughly analyse existing processes and identify bottlenecks;
- carry out process modelling;
- select the optimum internals design based on the characteristics of the feedstock and the requirements for the final product, and issue design documentation;
- manufacture the developed equipment;
- provide professional installation;
- train the plant personnel.
Value for You
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Spliteks, an engineering company, implements integrated solutions aimed at process optimisation and improved energy efficiency at oil and gas, oil refining and chemical facilities. In today’s environment, minimising production costs is a critical factor in competitiveness. Process optimisation is a key tool for reducing energy intensity and improving economic performance. The company’s specialists apply proven process-optimisation methods that reduce energy consumption, improve saleable-product quality and extend equipment life.
Analysis of current processes
Every production challenge begins with an in-depth analysis of the current operating conditions. Spliteks specialists study hydrodynamics, heat balance and mass transfer in columns, reactors and separators. Diagnostic tools include digital modelling and rapid inspection without shutting down the equipment. Bottlenecks are identified, including uneven flow distribution, excessive hydraulic resistance and excessive energy consumption.
On the basis of this information, individual process-improvement methods are proposed.
Process development and optimisation involves switching to high-capacity designs: structured packing with low pressure drop, valve trays with an extended load range and efficient liquid distributors. The use of modern designs improves heat and mass transfer, reducing steam and electricity consumption by 10–25%.
Energy-efficiency improvement measures
The use of modern internals improves system energy efficiency and ensures operation under optimum conditions through correctly selected design geometry, effective phase separation and low hydraulic resistance, while eliminating undesirable phenomena such as stagnant zones, flooding, liquid weeping and the associated excessive energy consumption and increased production operating costs caused by inefficient internals. Reducing pressure drop directly reduces the load on compressors and pumps, resulting in proportional savings. This reduces operating costs and specific energy consumption in production.
Effect of implementing the solutions
Process optimisation delivers a tangible economic benefit through increased throughput, improved product quality and lower total costs. Process and hydraulic guarantees confirm the reliability of the proposed solutions. More than one thousand completed projects throughout Russia demonstrate the effectiveness of modern internals.
The result is not only improved energy efficiency, but also sustainable development that gives the industrial facility a long-term advantage.