Advanced Refinery Process Modeling Using Aspen HYSYS

Name: Advanced Refinery Process Modeling Using Aspen HYSYS
Rating: 4.8 (35 reviews)

Mastering Simulation Techniques for Enhanced Refinery Efficiency and Optimization

Created bySarah Zayan

Last updated 8/2025

English

English [Auto],

What you'll learn

Atmospheric Crude Column Simulation
Vacuum Tower Simulation
Aspen HYSYS software
Atmospheric Crude Column Optimization
Oil Refinery Simulation

Course content

5 sections • 40 lectures • 4h 26m total length

Fluid Package2:57
This lecture shows how to start a new Aspen HYSYS case, import an assay to create a fluid package, select Peng-robinson for refinery hydrocarbon modeling, and rename the petroleum package.
Add Petroleum Assay Manually10:14
Petroleum Assay plots2:56
Import Petroleum Assay from Library3:12
AspenTech Petroleum Assay library4:32
Import a petroleum assay from the embedded library to attach to a crude material stream, then enter temperature, pressure, and molar flow in the simulation environment.
Load manually added Petroleum Assay2:31
Stream Analysis - Petroleum Assay6:49

Atmospheric Distillation Process Overview1:25
Distillation Column – Refluxed Absorber- Article1:45
Distillation Column - Refluxed Absorber14:28
Distillation Column, Inlet, Outlet, Degree of Freedom, Converge
Atmospheric Gas Oil Side Operation12:56
Atmospheric Gas Oil Side Stripper and Pump Around
Diesel Side Operation7:25
Diesel Side Stripper and Pump Around
Kerosene Side Operation12:22
Kerosene Side Stripper and Pump Around
Trim Duty11:08
Learn how to implement trim duty in an atmospheric distillation column using an energy stream to dynamically adjust reboiler duty and column operating conditions in Aspen HYSYS.
Cut Point for Distillation Products0:27
Naphtha and Kerosene Cut Point18:09
Controlling the quality of Naphtha and Kerosene instead of the quantity produced.
Diesel and Atmospheric Gas Oil Cut Point4:44
Controlling Diesel and AGO quality by setting a cut point instead of fixing the flow rate

Vacuum Distillation Process1:26
Vacuum Distillation Column12:00
Model a vacuum distillation column fed from atmospheric residue, heated by a vacuum heater, with steam and pump around reflux, producing light and heavy vacuum gas oil under pressure profile.
Converged Vacuum Column4:34
Implement Side Operation10:42
Implement a second bumper round in the vacuum column to handle heavy and light vacuum gas oil, adjusting flow rate and duty within side operation settings.
Stream Heat Integration13:30

FCC Process Description1:24
FCC Template12:41
FCC Feed6:11
Import vacuum gas oil as the FCC feed from the library, configure essay lumps, and set top and bottom cut points, then review feed properties before defining the catalyst.
Lump Model0:39
FCC catalyst introduction1:24
FCC Catalyst8:51
FCC Operation1:16
FCC operation10:12
Set the FCC operation by defining feed flow, temperature, and pressure in the riser, specify steam and regenerator conditions, then review yields and heat balance.
FCC Quiz

Hydrocracking Process0:53
Hydrotreater Template6:20
Create a hydrocracker template in Aspen HYSYS, configure two reactors with two and three catalyst bits, add a high-pressure separator, and set calibration options for future integration.
Component list and Fluid Package4:47
Define a component list and the float package for the hydrocracker template. See how the hcr fluid package uses base components and abbreviations such as C6 to model feeds.
Hydrocracker Components Legend1:13
HCR Feed9:15
HCR Operation11:51
Hydrocracker Calibration - Definition0:57
HCR Calibration operation & Product12:14
Learn to calibrate the hydrocracker in Aspen HYSYS using calibration factors, input operation measurements, feed data, and product specifications, and interpret calibration results from the worksheet and linked Excel sheet.
Calibration Control7:22
Set up calibration parameters and objective function for a hydrocracker in Aspen HYSYS, define bounds and initial values, run pre-calibration, review results, and save calibration factors for simulation.
Simulate the Hydrocracker into Refinery Plant9:14
Push calibration data into the hydrocracker simulation, activate the reactor solver, and review hydrocracking results and yields. Save the hydrocracker as a template and integrate it into a refinery model covering desalter, distillation, and heavy vacuum gas oil feed.

Requirements

Chemical Engineering Background ( Refinery )

Description

Welcome to the Advanced Refinery Process Modeling Using Aspen HYSYS. This comprehensive program is designed for professionals and students seeking to deepen their understanding of refinery process simulation and optimization using one of the industry’s leading software tools, Aspen HYSYS.

In this course, participants will engage in hands-on simulation exercises that cover a wide range of essential refinery processes. The curriculum includes the following key modules:

Petroleum Assay Simulation:
- Learn how to utilize fluid packages and explore various methods to input petroleum assay data, including manual entry, extraction from the assay library, and stream analysis.
Atmospheric Distillation:
- Gain insights into the operation of atmospheric distillation columns, including the design and function of refluxed absorbers. Participants will also examine side operations such as pump-arounds and side strippers, as well as the determination of cut points and trim energy optimization.
Vacuum Distillation:
- Delve into vacuum distillation processes, focusing on column design, side operations, and the principles of heat integration to enhance efficiency.
Fluid Catalytic Cracking (FCC):
- Explore the FCC template, including feed, lump model, catalyst selection, and operational conditions. This module emphasizes the importance of accurate modeling for optimizing catalyst performance and refinery yields.
Hydrocracking Process Simulation:
- Introduce the hydrocracking (HCR) template and engage in simulations that illustrate the hydrocracking process. Participants will learn about calibration techniques to ensure model accuracy and reliability.

Throughout the course, participants will engage in practical exercises and case studies that reinforce theoretical concepts and enhance software proficiency. By the end of this course, you will be equipped with the skills necessary to model complex refinery processes effectively, optimize operations, and contribute to the overall efficiency and sustainability of refinery systems.

Who this course is for:

Chemical Engineer
Process Engineer
Operation Engineer

Advanced Refinery Process Modeling Using Aspen HYSYS

What you'll learn

Explore related topics

Course content

Petroleum Assay Data7 lectures • 33min

Atmospheric Distillation Column10 lectures • 1hr 25min

Vacuum Distillation Column5 lectures • 42min

Fluidized Catalytic Cracking (FCC)8 lectures • 43min

Hydrocracker Reactor10 lectures • 1hr 4min

Requirements

Description

Who this course is for: