Innovative Processing Techniques for Boosting Light End Fractions in Crude Oil Distillation

Abstract

Processing heavy Antan crude oil in conventional refineries is constrained by its high viscosity, low API gravity, and elevated sulphur content, which result in poor light distillate recovery and excessive residue formation, limiting its economic viability. This study investigates the upgrading of Antan crude through blending with Oso condensate using a newly assembled, innovative distillation column. Various blend ratios were experimentally evaluated, with a 40:60% (Antan crude oil + Oso condensate) composition selected for detailed analysis. In parallel, a MATLAB-based design and optimization framework was developed to enhance yield prediction and process efficiency. Atmospheric distillation of pure Antan crude produced negligible light fractions. In contrast, the 40:60 blend significantly improved product recovery, yielding 25.60% naphtha, 15.37% kerosene, 12.49% diesel, and 45.50% residue, demonstrating the effectiveness of condensate-assisted upgrading. Computational optimization further enhanced performance, increasing yields to 34.11% naphtha, 24.26% kerosene, and 18.87% diesel, while reducing residue to 22.38%. This represents gains of 8.51%, 8.89%, and 6.38% in naphtha, kerosene, and diesel, respectively, alongside a substantial reduction in residuum. The model accurately captured process behaviour and outperformed conventional experimental approaches. Economic analysis shows that the optimized blend improves Gross Product Worth (97.2 $/bbl) and Net Refinery Margin (7.7 $/bbl) relative to Antan crude alone (89.9 $/bbl GPW; 1.9 $/bbl NRM). Profitability indicators confirm strong economic viability, with annual profit reaching 254.1 M$, positive NPV (+962.4 M$), and IRR of 18 – 20%, compared to negative returns for unblended Antan crude. The integration of blending strategies with computational optimization provides a robust pathway for upgrading heavy Nigerian crude oils. This approach enhances light product recovery, reduces processing risk, and improves refinery profitability, offering a practical and scalable solution for maximizing the value of challenging feedstocks.