Process Simulations and Analysis of Optimal Naphtha Hydrotreating Operating Range Parameters: A Case Study in Basra Refinery

The hydrogenation process is crucial in the petroleum industry for improving the quality of petroleum products by eliminating sulfur and minerals, resulting in increased cleanliness and decreased toxicity. This study utilizes Aspen Hysys software to mimic the Naphtha Hydrotreating reactor (NHT) and does a thorough sensitivity analysis. The ideal operational parameters for the NHT are determined by examining key aspects such as feed temperature, pressure, flow rates, reactor diameter, catalyst quantity, and hydrogen power factor. The reactor feed, preheated in the charge heater, undergoes hydrogenation processes on the catalyst at a temperature range of 280–310 °C and a pressure of 28.5 bar. The effluent from the reactor, following heat exchange and condensation in the reactor effluent air condenser and trim condenser, is introduced into a product separator. To prevent the buildup of ammonium chloride in the air cooler pipes, it is advisable to introduce water to the air condenser. The results suggest that the ideal temperature is 310 °C, the hydrogen power factor should be 0.3, and the optimal hydrogen flow rate is 377.5 kg/hr. Crucially, the study results are consistent with data obtained from a refinery in the Basra Governorate, confirming the numerical model’s accuracy and practical applicability.