European Refinery Uses Aspen HYSYS and EDR to Cut Heat Exchanger Fouling Costs

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European Refinery Uses Aspen HYSYS and EDR to Cut Heat Exchanger Fouling Costs

Case study shows how INEOS modeled fouling in heat exchangers with Aspen HYSYS and EDR to reduce downtime and save $4 million annually.

Published

June 4, 2026

Read time

3 min read

Source

INEOS implemented an automated fouling monitoring application using Aspen HYSYS and Aspen Exchanger Design and Rating to track heat transfer coefficients across its vacuum distillation units. By comparing clean versus fouled performance in real time, engineers created optimized cleaning schedules that reduced unplanned outages. The solution integrates with Aspen InfoPlus.21 and Microsoft Excel for visualization and has been rolled out to additional units and sites.

Key takeaways

Fouling monitoring via Aspen HYSYS and EDR identified performance loss early

Annual savings reached $4 million across vacuum distillation units

Optimized cleaning schedules reduced maintenance costs and downtime

Application integrated with existing Aspen InfoPlus.21 data historian

Methodology transferred to crude distillation unit and other global sites

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