Abstract
Crude oil fouling is a complex process caused by multiple mechanisms. This study examined fouling's environmental impact on a distillation unit's heating tubes and heat exchangers, proposing optimal pollution levels to reduce emissions and achieve sustainability goals. The study evaluated five crude oil blends in terms of API, sulphur, salt content, and other physical properties. Contaminated water was analyzed through biological and chemical means, while CO2, NOx, and SOx emissions were calculated from actual fuel and power consumption. Solid and sludge sediments were observed throughout all plate heat exchangers, consisting primarily of iron hydroxides and manganese oxides. Rationalizing energy use reduced the burden on the environment and fuel consumption by 7 %, with a 2 % reduction in energy needed to refine crude oil feeding units when fouling is removed after maintenance. By optimizing pollution levels and reducing energy consumption, the environmental impact of fouling can be mitigated.