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Article

Multiobjective Sustainability Optimisation of a Delayed Coking Unit Processing Heavy Mexican Crude Using Aspen Plus

by
Judith Teresa Fuentes-García
* and
Martín Rivera-Toledo
*
Departamento de Ingeniería Química, Industrial y de Alimentos, Prol. Paseo de la Reforma 880, Álvaro Obregón, Mexico City 01219, Mexico
*
Authors to whom correspondence should be addressed.
Processes 2025, 13(10), 3151; https://doi.org/10.3390/pr13103151 (registering DOI)
Submission received: 3 September 2025 / Revised: 22 September 2025 / Accepted: 29 September 2025 / Published: 1 October 2025
(This article belongs to the Section Chemical Processes and Systems)

Abstract

The delayed coking unit (DCU) is a critical technology in Mexican refineries for upgrading heavy crude oil into lighter, high-value products. Despite its economic relevance, the process is energy-intensive, generates substantial emissions, and produces significant coke, challenging its sustainability. This study proposes a multi-objective optimization framework to enhance DCU performance by integrating Aspen Plus® v.12.1 simulations with sustainability metrics. Five key indicators were considered: Global Warming Potential (GWP), Specific Energy Intensity (SEI), Mass Intensity (MI), Reaction Mass Efficiency (RME), and Product Yield. A validated Aspen Plus® model was combined with sensitivity analysis to identify critical decision variables, which were optimized through the ϵ-constraint method. Strategic adjustments in reflux flows, split ratios, and column operating conditions improved separation efficiency and reduced energy demand. Results show GWP reductions of 15–25% and SEI improvements of 5–18% for light and heavy gas oils, with smaller gains in MI and trade-offs in RME. Product yield was preserved under optimized conditions, ensuring economic feasibility. A key limitation is that this study did not model coking reactions; instead, optimization focused on the separation network, using reactor effluent as a fixed input. Despite this constraint, the methodology demonstrates a replicable path to improve refining sustainability.
Keywords: delayed coking; multiobjective; sustainability indicators delayed coking; multiobjective; sustainability indicators

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MDPI and ACS Style

Fuentes-García, J.T.; Rivera-Toledo, M. Multiobjective Sustainability Optimisation of a Delayed Coking Unit Processing Heavy Mexican Crude Using Aspen Plus. Processes 2025, 13, 3151. https://doi.org/10.3390/pr13103151

AMA Style

Fuentes-García JT, Rivera-Toledo M. Multiobjective Sustainability Optimisation of a Delayed Coking Unit Processing Heavy Mexican Crude Using Aspen Plus. Processes. 2025; 13(10):3151. https://doi.org/10.3390/pr13103151

Chicago/Turabian Style

Fuentes-García, Judith Teresa, and Martín Rivera-Toledo. 2025. "Multiobjective Sustainability Optimisation of a Delayed Coking Unit Processing Heavy Mexican Crude Using Aspen Plus" Processes 13, no. 10: 3151. https://doi.org/10.3390/pr13103151

APA Style

Fuentes-García, J. T., & Rivera-Toledo, M. (2025). Multiobjective Sustainability Optimisation of a Delayed Coking Unit Processing Heavy Mexican Crude Using Aspen Plus. Processes, 13(10), 3151. https://doi.org/10.3390/pr13103151

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