Connected Services Optimise Large-Scale Refinery Operations

Honeywell is implementing connected services and digital performance solutions at the Dangote Petroleum Refinery in Lekki, Nigeria. The deployment supports real-time monitoring, operator training, and process optimisation at one of the world’s largest single-train refineries.

 

Digital Monitoring for Process Optimisation

The refinery integrates Honeywell’s Performance+ Services with the Honeywell Forge platform to enable continuous monitoring of core processing units. These systems collect and analyse operational data to provide real-time insights into plant performance.

 

By identifying deviations and recommending corrective actions, the platform supports stable production of high-octane fuels from multiple feedstocks. This is particularly relevant in large-scale refining environments, where process variability can affect yield and efficiency.

 

Combining Automation and Domain Expertise

The deployment combines digital tools with engineering expertise from refining specialists, enabling a data-driven approach to process control. Advanced analytics enhance visibility into asset performance, supporting predictive maintenance and reducing unplanned downtime.

 

Such integration improves overall equipment effectiveness by aligning process conditions with optimal operating parameters, contributing to higher throughput and improved energy efficiency.

 

Operator Training Using Digital Twins

To support workforce development, the project includes operator training systems based on digital twin models of the refinery. These simulators replicate real plant conditions, allowing operators to train on realistic scenarios without affecting live operations.

 

Simulation-based training improves response to operational events, enhances safety, and enables testing of process adjustments in a controlled environment. This approach is particularly valuable in complex refining systems where process interactions are highly interdependent.

 

Supporting High-Capacity Refining Operations

The Dangote refinery is designed to produce Euro V-quality fuels, including gasoline, diesel, and jet fuel, as well as petrochemical products such as polypropylene. Its scale enables it to meet domestic fuel demand while supporting export capacity.

 

Digital performance monitoring and training systems are essential in maintaining consistent output at such scale, ensuring process stability and compliance with product specifications.

Edited by Romila DSilva, Induportals Editor, with AI assistance.

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