Efficient Modeling and Simulation of Crude Oil Stabilization Processes: Integrating RSM and ASPEN HYSYS for Energy-Saving Modifications.

Abstract The process of crude oil stabilization involves removing highly volatile hydrocarbons (methane, ethane, and propane) while increasing the fraction of heavier hydrocarbons in the fluid. After production, the dissolved gas in the crude oil must be eliminated to prevent shrinkage in storage tanks. Maintaining the Reid vapor pressure (RVP) within a range of 10-12 psia at atmospheric temperature is imperative. This study demonstrates the stabilization of crude oil through the recycling of condensate into the separator feeds. From a typical production, the fluid composition and process conditions were obtained on a real-time basis. Employing a data-driven methodology, Response Surface Methodology (RSM) and Aspen Hysys simulation software were utilized to optimize the stabilization process efficiently. The Aspen Hysys model accurately reproduces thermodynamic and mass transfer phenomena, providing the foundation for these investigations. Leveraging RSM's experimental design capabilities, key operational parameters such as flow rate, temperature, and pressure were systematically influenced by both energy consumption and RVP. Statistical analysis of RSM-generated data unveils intricate interdependencies and optimal parameter configurations, aiming to minimize energy consumption while meeting stringent product specifications. The integrated RSM-ASPEN HYSYS approach establishes a robust framework for optimizing crude oil stabilization. A Reid vapour pressure of 7.752 psia was obtained. Moreover, it boosts the economic competitiveness of the oil and gas industry by aligning practices with sustainability objectives.