Case Study: INEOS achieves $4M per year savings and predictable heat-exchanger performance with Aspen Technology (Aspen HYSYS & EDR)

European Refiner Tackles Heat Exchange Issues and Saves Millions in the Process

INEOS, a European refiner processing over 410,000 barrels per day across 76 facilities, struggled with fouling in its heat exchange system that disrupted operations and reduced productivity. To tackle this, INEOS worked with Aspen Technology, leveraging Aspen HYSYS and Aspen Exchanger Design and Rating (EDR) to model the heat exchange network and simulate fouling behavior.

Aspen Technology implemented an automated fouling-monitoring application (using Aspen HYSYS, Aspen EDR and Excel visualization) that compared clean and fouled heat-transfer coefficients and enabled smart tube-cleaning schedules. The solution improved predictability and uptime, reduced maintenance and downtime, and delivered $1.5–$2.0 million savings per VDU (about $4 million per year total), with the approach being expanded to other units and sites.

INEOS

Pierre Sere Peyrigain

INEOS