integration, CHP) cuts costs. Feedstock flexibility via hydro - cracking heavier streams extends catalyst life, while emis - sion controls (flaring reduction, carbon capture, utilisation, and storage [CCUS]) align with sustainability. Hydrotreating and hydrocracking : Optimise catalysts for diverse feedstocks, improve hydrogen management (H₂-saving catalysts, low-carbon sources), and upgrade reactor internals for better flow. Hydrocracking further relies on next-generation catalysts and efficient hydrogen use. Integrating renewable feeds and CCUS ensures long- term sustainability. Catalytic reforming : Requires high-performance cata - lysts (such as CCR reformers), optimised controls, and energy-efficient heat exchangers. Digital tools like APC and predictive analytics enhance real-time decision-mak- ing, while bio-naphtha co-processing and CCUS support decarbonisation. Hydrogen production: Optimise conventional steam meth- ane reforming (SMR) with advanced catalysts/hardware, maximise H₂ recovery via pressure swing adsorption (PSA), and integrate blue/green hydrogen. Digitalisation (IIoT, data analytics) improves reformer efficiency. Sulphur plants: Enhance acid gas removal (AGR) with selective solvents, improve Claus process efficiency via oxy - gen enrichment, and optimise tail-gas treatment. Energy recovery from waste heat and digital process control (APC, IoT) maximise output and reduce emissions. Finally, digital transformation will be pivotal. AI-driven blending, predictive maintenance, and automated inventory management enhance efficiency. Wearable tech and real- time safety monitoring improve reliability. Sustainability ini- tiatives, like CCUS and renewable integration, are essential for long-term competitiveness. By adopting these strate- gies, refineries can achieve higher throughput, lower costs, and improved sustainability, ensuring resilience in a rapidly evolving industry. Refinery digitalisation, IIoT, and AI Refinery digitalisation is rapidly transforming operations by strategically integrating advanced digital technologies, enhancing efficiency, safety, and profitability across the value chain. IIoT forms the core, connecting intelligent sensors, actu- ators, and devices throughout the refinery. These sensors capture real-time data from equipment, processes, and environmental conditions, providing unprecedented oper- ational visibility. Innovations like wireless sensor networks and edge computing enable localised data processing, reducing latency and accelerating decision-making. Digital twins, virtual replicas of physical assets, leverage this IIoT data for predictive analysis, scenario testing, and optimised control without impacting live operations. Artificial intelligence (AI) and machine learning (ML) act as intelligence engines, unlocking the true value of IIoT data across numerous refinery functions: • Predictive analytics : ML models analyse data to antici- pate equipment failures, predict catalyst deactivation, and forecast process upsets, enabling proactive maintenance and preventing costly unplanned downtime.
Pro tability
Sustainability
Flex i bility
• Sulphur plant: Incorporate advanced Claus catalysts for better conversion, apply process intensification to reduce pressure drops, and improve heat integration. While individual units become more efficient, increased crude processing complexity and product demands can offset some gains. Refineries are advancing towards sus - tainability via energy efficiency, operational optimisation, and environmental responsibility. Key innovations include digitalisation, AI-driven optimisation, waste heat recovery (such as pinch analysis), carbon capture, and green hydro- gen. These efforts aim to reduce energy consumption, cut emissions, and lower operational costs. A comprehensive energy management strategy focusing on high-throughput units, energy-efficient equipment, and advanced digital tools like the Industrial Internet of Things (IIoT) is crucial. Productivity increases In today’s refining environment, maximising unit productivity is key to profitability amid shifting demands, stringent regu - lations, and cost pressures. Leveraging innovative technolo- gies to optimise operations, reduce waste, and boost output enhances refiners’ bottom line and ensures sustainability. Unit-specific optimisations Crude distillation units (CDUs) : Boost productivity through process optimisation (adjusting conditions, seasonal mod- ifications, reduced reboiler duty) and hardware upgrades (furnace efficiency, advanced column internals, liquid-ring vacuum pumps). Heat integration, automation, and fouling mitigation (tube inserts, chemical additives, advanced mon- itoring) are crucial. Emerging technologies like progressive distillation, IoT, and AI-driven optimisation will future-proof operations. Coking units: Implement AI/ML-driven process optimisation, automated furnace/drum controls, and heat integration via pinch analysis. Improve equipment reliability with high-effi - ciency valves, advanced decoking, and waste-heat recovery through combined heat and power (CHP). Proactive digital maintenance and emissions control (such as fuel gas leak reduction) enhance efficiency and compliance. Fluid catalytic cracking (FCC) units: Benefit from AI-driven reactor optimisation, high-activity catalysts, and advanced process control (APC). Energy efficiency (fractionator heat Figure 1 Transforming refining strategies to meet profita - bility, sustainability, and flexibility
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PTQ Q4 2025
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