55,000 BPSD Crude Oil Refinery. Project Presentation Executive Summary. 1 st edition

Transcription

1 55,000 BPSD Crude Oil Refinery Project Presentation Executive Summary 1 st edition

2 2 5 5, B P S D O i l R e f i n e r y

3 Table of Contents Contents 5 5, B P S D O i l R e f i n e r y 3

4 4 5 5, B P S D O i l R e f i n e r y

5 1 Introduction History Introduction - History 5 5, B P S D O i l R e f i n e r y 5

6 Introduction History The purchase of the CENCO refining facility in late 2005 was concluded after detailed investigation. The CENCO refinery had begun operation in the late 1950s. Over 90% of production was light products, including reformulated gasoline, CARB diesel, EPA diesel, jet fuel, butane and propane. Modernization in the 1980s allowed the refinery to produce petroleum coke. Three major periods of refinery expansion occurred; late1950's, and early 1980's. Summary With the exception of the catalytic naphtha reformers and one of the two crude units, CENCO's major processing units were constructed either early 1970s or The Fluid Catalytic Cracking Complex expansion in was centered around a new FCCU but also included a Gas Concentration Unit, FCC Merox Unit, Vacuum Distillation Unit, Naphtha Hydrotreater, and an HF Alkylation Unit. A Heavy Oils Upgrade in 1982 included a new Delayed Coker, a Hydrocracking Unit, plus a Hydrogen Plant, Kerosene Hydrotreater, Gas Oil Hydrotreater, Amine Unit, Sour Water Stripper, Sulfur Recovery Units and a Tail Gas Unit , B P S D O i l R e f i n e r y

7 The Reformulated/Clean Fuels Project in 1994 consisted of a Penex Plus (benzene saturation/isomerization) Unit, Reformate Splitters, Gasoline Splitter, additional 600 lb steam capacity and offsite facilities. Numerous other upgrades were performed to improve operability and reliability. 1 Introduction - History The refinery suspended crude oil refining in July 1995, at which time the entire facility was de-commissioned, mothballed in accordance with industry standards and maintained under nitrogen pressure. Special care was taken to passivate all austenitic stainless steel equipment to protect against polythionic and chloride stress corrosion cracking. An ongoing effort to maintain the equipment in a preserved condition has been in effect since It should be noted that until 1995 the facility operated profitably and the company was planning another major expansion. In 1998, the refinery was sold for USD 180M to a US investment group, seeking to restart the refinery after extensive investment to reduce emissions in line with new Californian air pollution standards. 5 5, B P S D O i l R e f i n e r y 7

8 However, soon after the refinery was sold again to a major commodity trading and investment company. When this company incurred heavy losses from speculative trading activities, the refinery was put up for sale once again in 2003/04. Based on our information, all shut-downs and maintenances were duly scheduled and executed while no serious incidents or malpractices that degraded the equipment have ever occurred , B P S D O i l R e f i n e r y

9 2 Refinery Configuration Refinery Configuration 5 5, B P S D O i l R e f i n e r y 9

10 Refinery Configuration Refinery Capacity and Final Products The current facility as it was in profitable operation, consists of a series of units that guarantee the capacity and product mix shown below while allowing for improvements that can lead to profit maximization depending on the local market needs. At the moment and until the end user is in position to modify the process variables, the refinery consists of the units as shown in the next page and in detail further in this section in the relevant table. Refinery Capacity: 50,000 BPSD Product Mix after Refurbishment Gasoline Jet Fuel Auto Diesel Heat Diesel Fuel Oil LPG Asphalt , B P S D O i l R e f i n e r y

11 Refinery Units When the current configuration was purchased an international team of experts was immediately set up and employed to closely follow the project in all its aspects. One of the first tasks was to retrieve and assemble all available 2 Refinery Configuration documentation, review, evaluate and sort it accordingly in order to create the refinery s virtual Data Room that is currently accessible through the internet. Parts of the crucial documentation were the above units history regarding maintenance; revamps etc. and an abstract of those can be found in the Data Room. 5 5, B P S D O i l R e f i n e r y 11

12 The complete concise list of all available equipment can be found in the Data Room accompanied by all relevant details. Furthermore, various technical evaluations executed by the partners and depending on the end user s specific needs, indicate that additional equipment could be incorporated. Such a list could be made available upon request and only for informational reasons as the precise detailed equipment list will only derive from the Detailed Design that the end user will conduct. According to calculations executed by KBC on the Nelson Complexity Index, it was proved that the current configuration is between 7,5 to 8,5 on the Nelson scale. Comparing this number to the global variations of the index as shown below, one can easily recognize the superiority of this facility and its inherent ability to generate profitable revenues , B P S D O i l R e f i n e r y

13 2 Refinery Configuration Units Details (initial Design Capacities) 5 5, B P S D O i l R e f i n e r y 13

14 Flow Chart FLOW CHART Refinery detailed process flowcharts as deriving from the process simulation model , B P S D O i l R e f i n e r y

15 3 Refurbishment Progress Refurbishment Progress 5 5, B P S D O i l R e f i n e r y 15

16 Refurbishment Progress Overview A professional and expedited refurbishment process was initiated based on available documentation escorting the purchased equipment and the deep industry experience of its partners. All equipment were transported after dismantling to BASIC Engineering Inc. facilities in Houston and has since received a high standard of workmanship governed by the relevant ASTM and API standards. The main pillars of the activities are the follows: , B P S D O i l R e f i n e r y

17 The choice of the partners: BASIC Engineering Inc., as the main contractor, with deep experience in the industry, very significant shop and manufacturing facilities and an array of the best specialty subcontracting companies in USA METALLON Technologies SA, as the focal technical and engineering consultant, supervising both site activities, engineering and documentation KBC Advanced Technologies Inc., as the refinery process consultant, TUV Rheinland, as Third Party 3 Refurbishment Progress On site (Houston) continuous supervision of all involved parties and tasks Application of a preaggreed Project Inspection & Test Plan (ITP) governing all refurbishment activities taking place Activities scheduling and real time Progress Measurement Creation and regular maintenance of a virtual Data Room, including all available and newly generated process, engineering, equipment and historical documentation including P&IDs, Equipment Operation Manuals, Inspection and Repair Books etc. When in cases the initial documentation can not be retrieved, its recreation was achieved. 5 5, B P S D O i l R e f i n e r y 17

18 Detailed scanning/survey of the Cenco facility using state of the art laser photogrammetric equipment, before dismantling. The result of the scanning is a detailed 3-D CAD model of the refinery that besides the actual pieces of equipment includes all instrumentation and piping from 4 and up. The model creates drawings in full detail along with all the relevant parts lists and line lists to support further design or procurement activities. 3D models of all units are included in the Data Room. Detailed Process Simulation using state of the art modeler software tools that supplement the equipment with almost any information the end user may possibly need in order to make crucial decisions regarding his investments , B P S D O i l R e f i n e r y

19 Close cooperation and open line communication with all involved parties in order to resolve issues in the most beneficiary way for the end user regarding the integrity and agility of the equipment 3 Refurbishment Progress Concise Procedure Description In order for any piece of equipment to undergo any refurbishment work and receive the relevant certification, the following stages are mandatory and thus closely monitored: Initial Assessment: The Third Party is invited to proceed to physical verification of the item by a general visual inspection, providing indications regarding the general status. A relevant report [Initial Assessment Report] is issued and distributed to the parties for information and further action accordingly. Documentation Review of existing records: Contractor and Third Party proceed with the review of retrieved documentation. Third Party submits relevant report to METALLON/OWNER indicating availability of data and/or any other issue requesting further attention. 5 5, B P S D O i l R e f i n e r y 19

20 Initial Inspection and Issue of Repair Plan: Each item prior to any work is being prepared (cleaned etc) by the Contractor for initial inspection by METALLON and Third Party who also issues the relevant report. Contractor draws the Repair Plan, which is reviewed and approved by METALLON and Third Party. Therein the repair process is described in detail, the required tests and the technical documentation [reports etc] to be issued. In all cases the applicable ITP and the documents referenced therein delineate the necessary requirements which the repair items shall comply to. Implementation of Repair Plan and Final inspection: The Contractor implements the remedial actions as per the approved Repair Plan issued or proceed with the typical repairs required in all other cases while closely monitored by METALLON. The final result of the refurbishment process, as well as any required intermediate repair work, is inspected by Third Party as required by the ITP. Review of Final Documentation Package and Issue of Release Notice: Prior to any release for shipment of refurbished equipment, the Contractor submits to Third Party for review the equipment s final documentation file which includes all useful documentation from previous services [i.e. previous Certificates and Authorized Inspector s Reports etc], as well as all generated documentation during refurbishment [i.e. Initial Inspection Report, Repair Plan, TUV Inspection Reports, drawings where necessary etc]. Third Party issues the Release Notice and only then the item is transferred to the shipment area , B P S D O i l R e f i n e r y

21 3 Refurbishment Progress 5 5, B P S D O i l R e f i n e r y 21

22 UNIT Progress , B P S D O i l R e f i n e r y

23 Comments on Unit Progress i. The In progress Items, are in the great majority (over 90%) already well in their refurbishment activities thus allowing for all quality related issues to be revealed, addressed and resolved as per the valid ITP and relevant industry standards. This means that surprises, regarding refurbishment activities, are a limited possibility. 3 Refurbishment Progress ii. The common method of the Punch List is being utilized, to facilitate as an additional monitoring tool to the ones already established by the project management system. Their (punch lists) life line is approximately monthly and their implementation is governed by weekly action plans followed-up on a daily basis. The activities in total are being monitored on a daily basis and recorded in a data base created specifically for this reason so that not only the comparison between planned and actual is easy but also reports over time vs. specific task or item are generated. A snapshot of the progress reporting system is shown in the next page. 5 5, B P S D O i l R e f i n e r y 23

24 Progress Reporting System DATA , B P S D O i l R e f i n e r y

25 4 Refurbishment Plan Process Simulation Process Simulation 5 5, B P S D O i l R e f i n e r y 25

26 Process Simulation Current Status KBC has successfully completed the detailed process simulation model using the PetroSim software modeller incorporating all of the refinery equipment and emulating the Cenco process schedule of proven operability and profitability. The basic approach was to model each unit based on the corrected PIDs and then build in the constraints of actual equipment sizing data, performance and ratings. Product qualities have been developed based on historical Powerine operating data. From the resulting quality products data the European AUTO OIL IV specifications are easily fulfilled , B P S D O i l R e f i n e r y

27 The result of the above is the development of a detailed Petro-SIM flowsheet incorporating: rigorous distillation towers, pumps, compressors, shell and tube heater exchangers (STHE), Air and Water coolers. 4 Process Simulation The simulation results deriving from the above provide rigorous equipment models required for equipment evaluation and also stream compositions, operating conditions (temperature and pressure), and stream rates. In order to provide an initial assessment on the suitability of alternative crude feedstocks originating from Angola, an LP was simulated based on the above model. The product split results shown here below prove that Cabinda crude looks like an excellent choice: 5 5, B P S D O i l R e f i n e r y 27

28 The quantities produced are more likely to increase (crude rate above 50,000bpsd). On the product specification side the very low sulphur content supports high quality end products without additional equipment PRODUCT ESCRAVOS-CABINDA (BPSD) PALANCA-NEM (BPSD) Crude 49,000 37,000 LPG 1,520 2,370 Naphtha 3,710 2,910 Mogas 17,030 16,270 Kero + Diesel 13,690 9,410 Asphalt 4,470 NA Fuel Oil 8,600 5,920 Simulation Results and Observations Crude slate 100% Urals 33 API gravity 1.32 wt% Sulfur Crude Units A and B Products Naphtha D86 95% cutpoint set at F Fill both Reformers (10,420 BPD) Kerosene Flash Point Kerosene D86 95% cutpoint set at 475 F Maximum Sulfur 0.30 wt% for Jet production Flash 128 F (Penske Martin Closed Cup Method) Diesel D86 95% cutpoint set at 675 F Pour point less than 20 F , B P S D O i l R e f i n e r y

29 Vacuum Unit Combined Atmospheric Residue from CDU-A and CDU-B Some heater capacity remains Design 75 MMBTU/h SIM 60 MMBTU/h LVGO section has some heat removal capacity HVGO heat removal has no remaining capacity Pumparound pumps at maximum horsepower Vacuum Residue cutpoint set to 950 F Control HVGO properties FCCU capacity 4 Process Simulation Naphtha Processing Unifiner Used HDS SIM model for reactor modeling; remove sulfur Produce LPG and Reformer feed #2 Platformer 2,900 BPD feed REF-SIM reactor model RON 94.3 #3 Platformer 7,500 BPD feed REF-SIM reactor model RON , B P S D O i l R e f i n e r y 29

30 Gas Oil Hydrotreater (FHT) o Feed Rate 14,360 BPD o HTR-SIM model Target product sulfur, 0.28 wt% Liquid Hourly Space Velocity (LHSV) 1.9 Hr -1 o Stripper Column Steam Stripped Bottom to Top tray pumparound Naphtha D86 95% point 458 F Flow 50 BPD Routed to Diesel HDS Fluid Catalytic Cracker Unit (FCCU) Feed rate 13,000 BPD FCC-SIM Reactor Model Conversion 76.5 Riser outlet 975 F Preheat 505 F Full Burn Regeneration Complete Gas Plant Modeled FCC Full Range Gasoline RON 91.4 RVP 7.35 Light Cycle Oil Rate 2,440 BPD API gravity, 16.1 Blended to Low Sulfur Fuel Oil (LSFO) Slurry Oil Blended to LSFO , B P S D O i l R e f i n e r y

31 ISOM (Butamer) Process all mixed C4 s in Butamer Gibbs Free Energy reactors for equilibrium reaction of nc4 to ic4 1,930 BPD Reaction Section Charge Produce 95 vol% pure ic4 4 HF Alkylation Unit Process all FCC C3 s and C4 s Purchase additional 370 BPD of ic4 Use ALK-SIM model Products Propane for sales nc4 for gasoline blending (not ISOM Feed, HF) Alkylate for blending, RON 92.0 Process Simulation Diesel Hydrotreater Simple HDS reactor model CDU diesel plus FHT naphtha (high endpoint) Target product sulfur 60 ppm wt Liquid Hourly Space Velocity (LHSV) 1.96 Hr SCF/Bbl Hydrogen consumption Diesel Stripper Naphtha routed to Naphtha Unifiner Diesel to blender 5 5, B P S D O i l R e f i n e r y 31

32 Hydrogen Circuit Hydrogen Plant production approximately 5.0 MMSCFD Supply pressure 180 PSIA 99.8 mol% purity Hydrogen Compressors modeled as 2 stages First stage Hydrogen Plant H 2 Second stage mix with Platformer H 2 Unifiner feed from Platformer 85 mol% H 2 to Diesel and Gas Oil HDS Units Purity, mol% Purges Rates, MMSCFD Unifiner Diesel HDS FHT Feeds Crude Isobutane Products Propane Total Butane Regular Gasoline Jet Diesel Low Sulfur Fuel Oil Total Sulfur 50,000 BPD 371 BPD 50,371 BPD 230 BPD 0 BPD 20,620 BPD 3,594 BPD 7,369 BPD 16,570 BPD 48,383 BPD 40 Short Tons/day , B P S D O i l R e f i n e r y

33 5 Product to Tank Product to Tank 5 5, B P S D O i l R e f i n e r y 33

34 Products to Tank Next Stage to Conclusion As the aim of the project is the product to tank moment, immediately after the currently proposed SPA contract for the refinery equipment is in place, the prudent customer should continue to source the rest of the necessary works and services particularly those that interconnect deeply with the equipment being purchased. In brief the following stages are: 1. Reach final decision after relevant market research on the feedstock to be utilized, the intended products and the targeted market. 2. Complete refurbishment based on specific location of refinery and detailed requirements of purchaser. Assign the Basic and the Detailed Design of the new refinery facility, including process design, civil, electrical/mechanical works and the rest of the ancillary structures that a complete refining facility needs including utilities, offsites etc. These tasks are aided strongly by the existing documentation that we have preserved and created regarding not only process but the refinery facility as a whole. Particularly supportive will be the 3-D CAD model that derived from the laser scanning before dismantling. 3. Define (through the Detailed Design results) the additional items (mainly supportive and ancillary equipment) and immediately order them. We can supply a complete and detailed list of the additional items. 4. Commence tendering process for EPC contractor. The above step (additional equipment ordering) could be included in the contractor s tasks, if desired. 5. If it is the intention to upgrade the refinery to 100k bpsd, it is strongly advisable that the Basic and Detailed Design already take into account this enlargement , B P S D O i l R e f i n e r y