100,000 BPSD Crude Oil Refinery. Project Presentation Executive Summary. 1 st edition

Transcription

1 100,000 BPSD Crude Oil Refinery Project Presentation Executive Summary 1 st edition

2 , B P S D O i l R e f i n e ry

3 Table of Contents Contents 1 0 0, B P S D O i l R e f i n e r y 3

4 , B P S D O i l R e f i n e ry

5 1 Refinery Configuration Refinery Configuration 1 0 0, B P S D O i l R e f i n e r y 5

6 1. Refinery Configuration Overview The refinery has been in successful and profitable operation until Proper shut-down procedures have been implemented (de-commissioned by Foster Wheeler) Detailed equipment and process documentation have been properly maintained and preserved Detailed process simulation is being executed by KBC - crude oil suitability per customer request The refinery is currently stored at Famagusta, Cyprus free zone. All small sized equipment (pumps, motors etc) is already securely stored and lashed for shipping within 143 containers. The implementation of the relocation can be in one or more phases , B P S D O i l R e f i n e ry

7 The phased approach would allow for gradual integration with any existing facilities should this be the case. A project master plan will be devised to include all potential phases as well as future expansion/upgrade. The addition of a Fluid Catalytic Cracking (FCC) Unit and a Vacuum Unit are considered as most appropriate for the enhancement of the existing product pool. Such units are already available, dismantled and stored within the AMBER s yard in Houston. Refinery Capacity and Products Refinery Production Record ( ) Refinery Configuration 1 0 0, B P S D O i l R e f i n e r y 7

8 Utility Details Historical Data Major events, revamps and upgrades from commission to shut-down in 2004: 1. Historical Data Plant , B P S D O i l R e f i n e ry

9 Refinery Configuration 2. Historical Data Units Crude Distillation Unit (CDU) 1962 Commissioned at 68,500 BPSD capacity 1 0 0, B P S D O i l R e f i n e r y 9

10 1969 Debottlenecked to 100, 000 BPSD - Added second parallel preheat exchanger train - Doubled overhead cooling capacity - Installed booster feed pump Installed new desalter 1975 Modified tower internals removed two trays and replaced two others with section and bubble cap tray CDU EnCon Project Phase 1 - Installed 4 preheat exchangers (2 new, 2 idle) - Modified tower externals - Rasied gas oil draw 1994 CDU EnCon Project Phase 2-6 new preheat exchangers installed 1997 CDU Tower Modifications - Installed new sleeve trays at stripping section - Installed new stream distributors at stripping section - Installed new VEP type gravity liquid distributor - Removed random packing - Removed bubble cap tray no. 6. Installed new low drop de-entrainment tray, - Installed new HGO draw nozzles , B P S D O i l R e f i n e ry

11 Naphta Catalytic Hydrodesulphurisation (NCHD) Refinery Configuration 1962 Commissioned at 19,000 BPSD 1969 Commissioned and de- bottlenecked to 21,720 BPSD - Added preheat exchangers 1998 De-bottlenecking to 24,000 BPSD (3 new preheat exchangers installed) UNIT CAPACITY: 24,000 BPSD 158 m³/h CATALYST: Akzo KJ-752-3Q 7,560 kg Criterion C-488TL 7,780 kg Total 15,340 kg 1 0 0, B P S D O i l R e f i n e r y 11

12 Amine Treating Unit (ARU) Commissioned to treat 18,000 m³/hr fuel gas containing 26 kg moles/hr H2S. Specified to meet %vol H2S in fuel gas (-2 tons/day) UNIT CAPACITY: 18,500 m³/hr Fuel Gas Sulphur Recovery Unit (SRU) 1995 Commissioned recover 20 tons/day Sulphur - Three-converter Claus plant, single train: 6.6 to 1 turn-down ratio. Incinerator but not tail gas unit. - Sulphur Recovery is 97% at SOR, 96% at EOR - SO2 emission < 1 kg mole/hr UNIT CAPACITY: 20 tons/day , B P S D O i l R e f i n e ry

13 Solid Sulphur Forming Unit Flaker 1995 Commissioned to process 30 tons/day liquid sulphur solid sulphur flakes Platinum Reforming Unit (PtR) 1962 Commissioned at 8,000 BPSD 1970 Installed spare capacity recycle gas compressor 1991 Expanded to 14,000 BPSD - Re-trayed stabilizer - 5 new exchanger added - New radial flow reactor added 1996 New recycle gas compressor shifted Refinery Configuration UNIT CAPACITY: 14,000 BPSD 92.3 m³/hr Six month 96 RON clear severity CATALYSTS: UOP R-62 (regenerated in October 2001) 1 0 0, B P S D O i l R e f i n e r y 13

14 Kerosene Catalytic Hydrosulphurisation Unit (KCHD) 1962 Commissioned at 8,000 BPSD 1969 Expanded to 12,000 BPSD 1988 Due to new diesel specification of 0.7%wt S, the unit was desulphurising gas oil at 10,000 BPSD max in blocked operation 1997 Dense loading of reactor performed. New distribution tray installed UNIT CAPACITY: 12,000 BPSD 79.5 m³/hr 10,000 BPSD m³/hr Liquefied Petroleum Gas Unit (LPG) 1981 Commissioned at 2,800 BPSD Designed for kerosene mild de-sulphurisation 1991 Expanded to 4,000 BPSD UNIT CAPACITY: 4,000 BPSD 26.5 m³/hr , B P S D O i l R e f i n e ry

15 1 0 0, B P S D O i l R e f i n e r y 15 Refinery Configuration

16 EXPANDED FACILITY FLOW CHART (with the proposed addition of FCCU and Vacuum-not included in the original refinery) , B P S D O i l R e f i n e ry

17 2 Process Operational Records Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 17

18 CRUDE OIL THROUGHPUT (in 000 Metric Tons) , B P S D O i l R e f i n e ry

19 CUT (ASTM end point C) Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 19

20 STANDARD YIELD DATA , B P S D O i l R e f i n e ry

21 EQUIPMENT LIST - Exchangers Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 21

22 EQUIPMENT LIST - Exchangers , B P S D O i l R e f i n e ry

23 EQUIPMENT LIST - Exchangers Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 23

24 EQUIPMENT LIST - Towers , B P S D O i l R e f i n e ry

25 EQUIPMENT LIST - Drums Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 25

26 EQUIPMENT LIST - Drums , B P S D O i l R e f i n e ry

27 EQUIPMENT LIST - Reactors Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 27

28 EQUIPMENT LIST - Pumps , B P S D O i l R e f i n e ry

29 EQUIPMENT LIST - Pumps Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 29

30 EQUIPMENT LIST - Pumps , B P S D O i l R e f i n e ry

31 EQUIPMENT LIST Air Coolers Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 31

32 EQUIPMENT LIST Air Coolers , B P S D O i l R e f i n e ry

33 EQUIPMENT LIST FCCU (not in ATAS site) Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 33

34 EQUIPMENT LIST FCCU (not in ATAS site) , B P S D O i l R e f i n e ry

35 EQUIPMENT LIST FCCU (not in ATAS site) Process Operational Records 1 0 0, B P S D O i l R e f i n e r y 35

36 EQUIPMENT LIST FCCU (not in ATAS site) , B P S D O i l R e f i n e ry

37 3 Refurbishment Plan Refurbishment Plan 1 0 0, B P S D O i l R e f i n e r y 37

38 PHASE 1 Data Room and Documentation 1. Data Room BEI/METALLON has established an experienced team to review and evaluate all available on site documentation, including: All available equipment documentation such as operating manuals, drawings, maintenance records, inspection log books etc. All available production documentation such as production planning sheets and log books, feedstock records etc. 2. Site Verification and 3-D Laser Scanning BEI, has assigned LEICA along with an engineering team to survey with state of the art instrumentation the whole facility, in detail: Laser scanning of the installed units and all relevant utilities in the as is condition prior to dismantling. Creation of a 3-D cad model including all relevant data to facilitate as a base for further detailed engineering. Data such as equipment tag numbers, piping line lists and steel structures parts lists are included and easily accessible or generated. Also included all P&IDs, foundation and supporting structures drawings. PHASE 2 Process 1. Process Simulation KBC was awarded a contract to execute a complete, detailed simulation of the refurbished facility. A detailed Petro-Sim model will be prepared based on verified and confirmed by site investigation data. Current and refitted condition will be taken into account. In detail the following are included: Development of a base Petro-SIM simulation of the refinery using the present crude blend of 75% Urals/25% Tengiz. Development of a Petro-SIM simulation of the refinery using Arab Medium crude. Developments of a detailed Petro-SIM simulation of the refinery, including replacement of generic models with specific information as various parts of the refinery are being refurbished. This simulation will provide all details needed for a Refinery Process Design Information Package , B P S D O i l R e f i n e ry

39 PHASE 3 Site Activities Refurbishment Plan 1. Dismantling Detailed plans are prepared and approved prior to commencement of works on any item. Cold cutting is the main means of dividing single pieces (if needed) All safety measures are implemented in order for asbestos removal. The job is being executed by certified personnel. 2. Refurbishment Works BEI, with its vast experience in the industry is in charge of all refurbishment works. The various procedures are governed by the relevant ITP which is a material attachment to the Contract. Works are executed according to ASME codes and standards. Third Party certification at all stages (by internationally acknowledged firm). Equipment is considered finished only after corresponding Third Party Release Note. All Repair Plans are being evaluated and approved by METALLON and Third Party before execution. METALLON site supervision by experienced ASME certified welding engineers and level II and III inspectors , B P S D O i l R e f i n e r y 39

40 Deliverables 1. Refurbished ATAS Refinery Equipment 2. FCCU All units as shown in the relevant lists in certified refurbished condition. Initial equipment list may slightly deviate from final. Unit owned by BEI and reserved for incorporation in the current facility. The production will be greatly enhanced towards high added value products. All items as shown in the relevant list. Most already refurbished. Completion before the end of the year. The unit is being incorporated in KBC s process design along with the current facility. 3. Vacuum Unit Specific unit has already been identified in order to be incorporated in the current facility , B P S D O i l R e f i n e ry

41 4. Other Units Utilities BEI has various equipment reserved in different sites available upon customer request to assist in concluding and upgraded refinery production. 5. Data Room Complete, easy access, internet based Data Room including all available and useful documentation from previous operation and all data generated during refurbishment period (i.e. inspection reports, Release Notes, 3-D facility model, P&I drawing etc.) Process detailed simulation model by KBC, based reports on alternative feedstocks. Additional simulation relevant reports that derive from the executed runs and will support further process design or expansion plans. The certified quality level of the work executed the specific project team structure and the relatively well preserved condition of the available equipment guarantee a successful result. Refurbishment Plan 1 0 0, B P S D O i l R e f i n e r y 41

42 TIME SCHEDULE , B P S D O i l R e f i n e ry