Oil refinery optimization

All major process in refineries are based on thermal intensive reaction and partial separation

New environmental standards have brought about challenging requirements for large capital expenditures and increased hydrogen usage for low sulfur fuels. This set of new regulations requires plants to reduce air pollution emissions (NOx), leading to costly equipment retrofits and upgrades. This means that you must be aware of safety, emissions and cost reduction issues such as improving unit and refinery reliability, refinery energy conservation and product loss reduction.

Obtaining efficiency, reliability and safety

Heat, pressure and chemical reactions transform crude oil into hundreds of refined products. You need measurement devices and automation solutions that allow you to control and operate complex refinery processes. In addition to answering environmental concerns, you must also address the issue of resource conservation. With our offering you can optimize oil refinery processes to improve:

  • Plant efficiency & availability

  • Plant safety & security - HSSE Environmental control

Zoom in refinery operation processes and applications

Process map of a refining process ©Endress+Hauser

The refining process

Process map of a distillation column in a refinery ©Endress+Hauser

The distillation column

Process map of hydro-desulfurization ©Endress+Hauser


Process map of steam process ©Endress+Hauser

Steam application process

Control the core processes and meet your production targets

Distillation columns of a refinery

Measurements in crude distillation columns

Getting an accurate and reliable measurement at the distillation column is critical for yield accounting, meeting production targets, planning and scheduling. You need to maximize the feed rate while ensuring the mixture of crude types meets environmental specifications. Troubles could lead to costly shutdowns. This is why our experienced team of engineers can help design and select the right devices for your critical measuring points e.g. guided wave radar (Levelflex).

  • Greater process availability and reliability

  • Safety risks are minimized

  • Lowest total cost of ownership

Desulfurization application, prevent channeling & hotspots in the hydrofiner

Desulfurization, prevent channeling & hotspots in hydrofiner

Due to environmental regulations, the sulfur content in oil products has to be limited, and this can only be achieved by catalytic desulfurization in a Hydrofiner. Proven in use in many applications around the world, the multipoint temperature assembly MultiSens Flex contains individual temperature sensors mounted in an individual nozzle. Your vessel requires only a minimum number of nozzles and openings to provide enough temperature measuring points for 3D monitoring.

  • Thermocouples can be retracted and changed during vessel operation, avoiding an unplanned shut down

  • Fully engineered solution for your needs

  • Increased efficiency, reliability and safety

Continuous cost reduction by monitoring the fuel usage or boiler efficiency

Monitoring the efficiency of steam boilers pays off

A typical steam boiler often consumes many times the initial capital expense in fuel usage annually. The investment cost for a boiler can easily be five times lower than the yearly fuel consumption. Consequently, a difference of just a few percentage points in boiler efficiency between units will result in substantial fuel savings. Our smart scale energy solutions for steam systems help you to monitor your boiler's efficiency.

Browse through our portfolio!


As a refinery operator, you are under ever-increasing pressure to minimize costs, safety risks, downtime, and emissions while maximizing performance. Therefore you need a reliable partner that is here for the long haul. Our experienced team of engineers can help design and select the right devices for all of your critical measuring points to optimize your oil refinery process, while drastically eliminating the human risk factor.

  • 50%

    total cost of ownerships savings offered by the electronic dP.

  • Up to 50

    measuring points per process connection can be freely directed in the fixed-bed reactor. As a result, you are aware of the real process optimization potential and you are able to predict catalyst life times.

  • 5 to 15%

    estimated savings generated from remote energy management solutions