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Reducing crude oil quality affects the refinery capacity, quality for downstream units, and overall economics. The thermoeconomic model of a refinery can show that the effects of faults generally propagate through the whole process and affect the behavior of several components, resulting in induced malfunction in typical components. This study aims to estimate the primary source of inefficiency and, therefore, the main reason for the increase in irreversibility and entering feed into the refinery due to changes in some operating conditions. Operating conditions in 2013 and 2023 are defined as base mode and operating mode, respectively. The results of exergy cost analysis show that Liquefied Petroleum Gases (LPG) unit and H 2 S removal unit have the greatest impact on reducing the overall performance of the refinery in 2023, while this unit is one of the units with the least exergy destruction in the base year. The share of the environment and fuel oil unit, LPG unit, H 2 S removal unit, and kerosene treating unit in increasing the irreversibility of the utility unit is 4,898.18, 1200.67, 935.15, 642.73, and 624.45 GJ/day, respectively. The share of the Crude Distillation Unit (CDU) in the reduction of the irreversibility of the utility unit is 7,316.67. The results show that the total resource consumption has increased by 168 MJ/day. Therefore, in order to reduce resource consumption in 2030 (operational mode), the impact of LPG and H 2 S removal units on utility irreversibility should be controlled.

Exergy cost accounting thermoeconomic analysis of an oil refinery operating at off-design conditions