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ADAPTING PETROLEUM REFINERY TECHNOLOGY FOR NATIONAL DEVELOPMENT: THE AHMADU BELLO UNIVERSITY EFFORTS

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BY

Prof. I. A. MOHAMMED-DABO MINIREFINERY DEVELOPMENT RESEARCH TEAM

DEPARTMENT OF CHEMICAL ENGINEERING

AHMADU BELLO UNIVERSITY, ZARIA, NIGERIA

0803 361 1734/ 07055671304 iroali@mail.ru iamdabo@abu.edu.ng

Paper presentation at 25TH COREN ASSEMBLY

International Event Centre (The Dome), Akure

August , 2016

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PRESENTATION OUTLINE

•INTRODUCTION

•BRIEF ON REFINERY OPERATIONS

•NIGERIAN REFINERIES CAPACITY UTILIZATION

NIGERIAN vs. AFRICAN REFINERIES

•ILLEGAL REFINERY OPERATIONS

•ABU REFINERY DEVELOPMENT

•CHALLENGES

•CONCLUSION

•REFERENCES

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INTRODUCTION Any country that strives to develop technologically should try to

domesticate the technology of its manufacturing industry.

It should be noted that in reality “TECHNOLOGY IS NEVER TRANSFERRED” ONLY

ITS COMPONENT CAN BE TRANSFERRED.

TECHNOLOGY IS EITHER ACQUIRED OR “STOLEN”.

HOWEVER, AN EXISTING TECHNOLOGY CAN BE ADAPTED TO SUIT THE NEEDS OF A NATION OR REGION

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TECHNOLOGY DEVELOPMENT

HE WHO IS AFRAID AND ALWAYS THINKING OF FAILURE WILL NEVER SUCCEED

EXPERTS BUILT THE TITANIC BUT IT SANK

LOCAL CARPENTERS BUILT NOAH’S ARK

AND IT WITHSTOOD THE FLOAD

BECAUSE:

NEVER BE AFRAID OF DEVELOPING A TECHNOLOGY

Be with those who encourage you and not

those who discourage you

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NIGERIAN POTENTIALS NIGERIA IS BLESSED WITH BOTH MINERAL AND HUMAN RESOURCES

POPULATION: 173.6mln(2013)

CRUDE OIL RESERVE: 37 trillion barrels DAILY PRODUCTION CAPACITY: 2.3 MBPD

NATURAL GAS RESERVE: 187 Trillion Cubic Feet (TCF)

ANTICIPATED RESERVE: As high as 800TCF

REFINERIES INSTALLED CAPACITY: 445,000 BPD +1,000BPD

Daily consumption capacity: 250,000BPD @60% Production(267,000BPD) – No importation None of the refineries produce at near 50% capacity

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BRIEF ON REFINERY OPERATIONS Petroleum refinery A highly complex manufacturing sector for handling complex mixture

of HCs.

It uses crude oil and processes it into various end products, some

of which can be used as ready made products while others serve as

the starting raw materials for other chemical and petrochemicals

industries.

Refinery Processes Separation; Cracking; Upgrading; Recombination; Treatment

Types of Petroleum refinery Simple -Topping

Complex

Fuels direction

Fuels & Lubes direction

Fuels, Lubes and Petrochemicals

Mini, Small & Mega

Cost of a Refinery: $500 mln – $20bln

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FUEL DIRECTION REFINERY PROCESS FLOW CHART FUEL DIRECTION OF REFINERY FLOW CHART (SOURCES OF REFINER GASES)

`

Stabilizer Saturates Gas Plant

Isomerizer

Alkylation

Unsaturates Gas Plant

MTBE Plant

Polymerizer

Visbreaker

Coker

Thermal Cracker

Dist. H-cracker

Cat Cracker

Reformer

G

A

S

O

L

I

N

E

B

L

E

N

D

I

N

G

GO Treater

Kero Treater

Splitter

ADU

VDU

75 -1800C

180 -2400C

240 -3500C

Crude Oil

<1800C

>3500C

Atm. Residue

C3/

C4

Butanes

SRG

Alkylate

Isomerate

Reformate

Kerosene

FCCG

MTBE

TCG

Coker Gasoline

Coke

Fuel Oil

VBG

GO/Diesel

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NIGERIAN REFINERIES CAPACITIES AND PRODUCTS SLATES

S/N Refinery Units Capacity (bpd)

KD Warri PH-1 PH-2 Ogbelle Eleme PC

1 Crude unit 1 (fuels) 60,000 125,000 60,000 150,000 1,000

2 Crude unit 2 (lubes) 50,000

3 Vacuum unit 1 (fuels) 15,200 34,200 54,000

4 Vacuum unit 2 (lubes) 23,000

5 FCC 21,000 40,000

6 Catalytic reformer 17,500 21,000 6,000 33,000

7 Naphtha hydrotreater 24,000

8 Kerosene hydrotreater 17,500 15,800

9 Distillate hydrotreater 33,000

10 Propane deasphalter 7,860

11 Furfural extraction 12,450

12 MEK dewaxer 5,300

13 Wax deoiler 1,050

14 Wax hydrofinisher 75 t/d

15 Sulphur recovery 10 t/d

16 Bitumen unit 6,000

17 LAB unit 30,000mta

18 Isomerization 3,600

19 Alkylation 2,850 7,020

20 LPG Unit 6,000

21 Carbon black 18,000mta

22 Olefin 483,000mta

23 Polypropylene 35,000mta 80,000mta

24 Polyethylene 250,000mta

25 Total capacity 110,000 125,000 210,000 1,000

26 Year Established 1980 1978 1965 1989 2013 1995

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Nigerian Refineries vs. other African Refineries COUNTRY/

CAPACITY

POPULATION

REFINERY NAME TYPE OWNER/OPERATOR Capacity (MB/D)

ALGERIA

450,000BPD

39.21mln

(2013)

Algiers Refinery Simple Sonatrach 60

Arzew Refinery Simple Sonatrach 60

Hassi Messaoud Refinery Simple Sonatrach 30

Skikda Refinery Simple Sonatrach 300

EGYPT

677,700BPD

82.06mln

(2013)

Amerya Refinery Simple Egyptian Gen. Pet. Corp. 47

Asyut Oil Refinery Simple EGPC 78

Cairo Ref. Co . Mostrod Simple EGPC 145

Cairo Refinery Co.Tanta Simple EGPC 35

El Mex Refinery Simple EGPC 100

El Suez Refinery Complex EGPC 99.3

Suez Petroleum Processing Co Simple EGPC 66.4

MIDOR Refinery Complex Mid-East Oil Ref.Co., Alexandria 100

Wadi Feran Refinery Simple EGPC 7

LIBYA

343,000BPD

6.202mln

(2013)

Azzawiya Simple Government of Libya 115

Ras Lanuf Simple Government of Libya 220

Sirte Oil Co. Simple Government of Libya 8

Sidi Kacem Refinery Simple Société Cherifienne des Petroles 30

NIGERIA

445,000BPD

173.6mln (2013)

Kaduna Refinery Complex NNPC 110

Port Harcourt I & II Complex NNPC 210

Warri Refinery Complex NNPC 125

SOUTH AFRICA

489,000BPD

52.98mln (2013)

Calref Complex Chevron - Texaco 110

Engen Refinery

Complex Petronas, Worldwide African

Investment Holdings (Pty) Ltd

105

Natref Complex Sasol Ltd, TOTAL- SA. (Pty) Ltd 109

Sapref

Complex Shell & BP S/A Petrol. Ref. Ltd 165

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CONSEQUENCES OF INSUFFICIENT

REFINED PETROLEUM PRODUCTS

(FUELS)

Importation/(Subsidy???)

Queues for petroleum products at filling stations Granting Licenses to construct more refineries

Illegal refining

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2002 LICENSED PRIVATE REFINERIES IN NIGERIA

S/N REFINERY

NAME

TYPE OWNER/

OPEATOR

LOCATION/

STATE

CAPACI-

TY (BPD)

REMARKS

1 Amakpe

Refinery

Topping

(H/skimming)

Amakpe Int. Refinery

Inc.

Eket, AKWA IBOM 12,000 -

2 Ikot Abasi

Refinery

Complex Resource Petroleum &

Petrochem. Int. Inc.

Ikot Abasi, AKWA IBOM 100,000 Designed completed

awaiting DPR review

3 Iwopin

Refinery

Complex

(mini),

Antonio Oil Iwopin, OGUN 27,000 Civil works started on

site in 2010

4 Ipokia Complex Gasoline Assoc. Int. Ltd. Ipokia, OGUN 100,000

5 Ikang

Refinery

complex Amexum Corporation, Ikang, CROSS RIVERS 100,000

In 4 phases, each

with 25,000 BPD

6 Ologbo

Refinery

Topping (H/-

skimming)

Ologbo Refinery Comp.

Nig. Ltd.

Ologbo, EDO

12,000

Designed completed

awaiting DPR review.

(Future plan 18,000)

7 Immingiri

Refinery

Topping Rehoboth Natural

Resources Limited

Immingiri, BAYELSA 12,000 -

8 Sapele Ref. Complex Sapele Petroleum Ltd. Okpe-Sobo, Sapele, DELTA 100,000 -

9 Ogbelle

Refinery

Modular.

Topping

Niger Delta Petroleum

Resources

Ogbelle, RIVERS

($600mln)

1,000

Completed and

operational(Diesel)

TOTAL CAPACITY 464,000

Dangote Refinery/Petrochemicals/Fertilizer plants

10 Dangote

Refinery

Complex Dangote Group

($9Bln)

OK-LNG Free Trade Zone,

between Ogun and Ondo

states.

400,000 To be completed in

2017

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The Federal Government had granted LTC to 22 private investors in 2002 but later cancelled the licenses for non-performance. However, the affected investors had cited non-deregulation of the downstream sector as the reason for their non-performance. In reality, lack of proper financial backing was the cause of their non-performance

REVOCATION OF 2002 LICENSES

COMPANIES GIVEN PRELIMINARY APPROVAL TO CONSTRUCT PRIVATE REFINERIES IN 2012

S/N Company

1 Akwa Ibom Refining and Petrochemicals Ltd

2 Badagry Petroleum Refinery Ltd.

3 Clean Waters Refinery

4 Ilaje Refinery and Petrochemicals

5 Niger – Delta Refinery and Petrochemicals

Company Ltd.

6 NSP Refineries and Oil Services Ltd.

7 Ode-Aye Refinery Ltd.

8 Orient Petroleum Resources Ltd.

9 Owena Oil and Gas Ltd.

S/N Company

10 Rivgas Petroleum and Energy Limited

11 Sapele Petroleum Ltd.

12 Southland Associates Ltd.

13 Southwest Refineries and

Petrochemicals Company

14 Starex Petroleum Refinery Ltd.

15 The Chasewood Consortium

16 Tonwei Refinery

17 Total Support Refineries

18 Union Atlantic Petroleum Ltd.

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FIRST NIGERIAN PRIVATE REFINERY

Plate 1.View of the 1000BPD Ogbelle Refinery. Plate 2. Products Line of the Ogbelle Refinery

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SECOND NIGERIAN PRIVATE REFINERY UNDER CONSTRUCTION

Plate 2.View of the Second 1000BPD Modular Refinery.

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LABORATORY SCALE DISTILLER (KRPC/UNIPORT)

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Causes of illegal refining:

1. High demand for petroleum

products (esp. fuels)

2. Insufficiency of the products

3. Unemployment among the

Niger Delta youth

ILLEGAL refinery

OPERATIONS

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SOME PICTURES OF ILLEGAL

REFINERY OPERATIONS

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Plate 3. Part of the Illegal Refinery Plate 4. Improvised Condensers

20 20 Plate 5. Crude oil Siphoning

CRUDE OIL BUNKERING

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Plate 6. Heating fuel supply

Plate 7. Heating fuel supply

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DEATH OF AN OPERATOR

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Plate 9. Products Collection

Plate 10. Products Collection

ILLEGAL DISTILLATION

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Plate 11. Residue Disposal Plate 12. Residue Disposal

Uncondensed HC vapour

RESIDUE DISPOSAL

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Plate 13. Polluted abandoned site Plate 14. Polluted abandoned site

SITE POLLUTION

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Plate 17. Burnt site by JTF

JTF ACTIVITIES

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AHMADU BELLO UNIVERSITY EFFORTS IN

MINI-REFINERY TECHNOLOGY DEVELOPMENT & ADAPTATION

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LOCATION OF ABU MINIREFINERY

Boundaries: East --CERT ; North--Area A ; West-- Koraye Road ; SouthEast -- Waste dumping site

Located within the ABU Samaru Main campus

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AERIAL VIEW OF ABU MINIREFINERY

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ABU REFINERY DEVELOPMENT

WHY COUNTRIES DEVELOP TECHNOLOGIES

Most of the Developed countries were faced with the challenges of developing a technology for the product(s) they need. This could be due to many reasons, such as:

1. Need for self reliance. 2. No where to run to for such technologies. 3. Generate employment for their citizens. 4. Generate revenue by selling/supplying the

technology to other countries that may need it.

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Refineries are deliberately calibrated to

be sophisticated to make it difficult to

copy (Igwe,2012)

It is ONLY DIFFICULT but NOT IMPOSSIBLE TO COPY/ADAPT

INGREDIENTS FOR COPYING: Practical Experience Theoretical Background

OIL REFINERY- COMPLICATED PLANT

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HISTORICAL BACKGROUND OF THE PROJECT

YEAR EFFORTS

2001/2002 UG STUDENTS PRELIMINARY DESIGN TOPIC

2002 PROPOSAL TO UNIVERSITY FOR FUNDING. ==NO FUND.

2011 Prof. I. A. Mohammed-Dabo, the then Head of Department gave an MSc Research Topic titled “DESIGN, CONSTRUCTION AND OPERATION OF A 1000BPD (1BPD) CRUDE DISTILLATION UNIT (ADU & VDU)”.

2011 PROPOSAL TO UNIVERSITY MANAGEMENT/TETFUND

2012 FORMATION OF RESEARCH TEAM (FAC. OF ENGINEERING)

2013 DESIGN COMPLETION & FABRICATION

2013 INSTALLATION/TEST RUN

2015 DEVELOPMENT OF NHU & FCCU (RMRDC SPONSORED)

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STAGES OF

A.B.U. MINI-REFINERY TECHNOLOGY DEVELOPMENT

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SOME TEAM MEMBERS

I.A. Mohammed-Dabo S.M. Waziri A. Hamza P.C. Okonkwo

Muhammad Dauda S.A. Yaro N.S. Maina M. J. Abubakar

S. Bilal U. Abubakar A. Bukar O. Omorogbe

M. Abubakar A. Lawal I. Abdulkadir V.O. Samson

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1. BRIEF ENVIRONMENTAL IMPACT ASSESSMENT OF THE PROJECT

Members of the Research Team are quite mindful of the necessity to take into consideration effect of this projects on the environment. The Nigerian Government has enacted various acts regarding consideration of the environmental impact of any project or activity to be conducted, be it on land, in water or air. The Nigerian Environmental Act of 1992 specifically specified that for a chemical project to be undertaken, EAI must be carried out PROVIDED “capacity of such plant is up to 100tones/day (Environmental Impact Assessment Decree, 1992). Capacity of the project is 1barrel/day (0.14tones/day), which is not up to 1% of the required capacity for detailed EIA. However, since this is a chemical process plant, a brief EIA was carried out prior to commencement of the project.

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2. DESIGN METHODOLOGY DETAILED LITERATURE DIGEST

PROCESS SELECTION

WORKING DRAWINGS (Mechanical Design)

DESIGN BASIS+RAW MATERIALS SELECTION

DESIGN CALCULATIONS (Material & Energy balances; Equipment design)

FABRICATION

INSTALLATION/PIPING/INSTRUMENTATION

TEST RUN

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Method Major Activities

Literature Digest Various related works globally

Process Selection 2-Stage Distillation

Design Basis Selection 1,000BPD (1BPD); Escravous crude

Design Calculations (Manual & Software)

Mat. &Energy balances; Temperatures (Flash Zone, Products Draw-off, Tower Top, Side Stripper, Products); Condenser Duty, Reflux Ratio; etc

Equipment Design Column Diameters, No. of Trays & Holes; Furnaces; Steam ejector; HEs; Reflux Drum; etc

Working Drawings Various views of the equipment with appropriate Dimensions

Materials Selection Various Grades of Stainless & Mild Steels

Fabrication Competent/Certified Fabricators engaged

Installation/ Instrumentation

Following the Plant Layout and Control Loops Diagrams

Test Run Testing for leakages/Plant workability

DESIGN METHODOLOGY (Contd.)

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PLANT LAYOUT

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INSTALLATION,

PIPING,

INSTRUMENTATION

& TEST RUN

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Plate 18. ADU Colum Installation Plate 19. ADU and VDU Columns Erection

INSTALLATION

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Plate 20. Installation Plate 21. Piping

INSTALLATION/PIPING

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Plate 22. Cooling Tower Installation Plate 23. Furnace and Hot Air Generator

COOLING TOWER/FURNACE

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INSULATION

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Plate 24. Overhead Water Tower Plate 25. Products Line

OVERHEAD WATER/PRODUCTS LINE

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Plate 26. ADU Instrumentation Plate 27. VDU Instrumentation

INSTRUMENTATION

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Plate 28. Control Panel in Control Room

CONTROL ROOM

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Plate 29. System Steam Flushing

SYSTEM STEAM FLUSHING

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Plate 30. Atmospheric Distillation Unit Plate 31. Vacuum Distillation Unit

ADU & VDU

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50 50

51 51

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PICTORIAL VIEW OF THE DEVELOPED PLANT UNIT

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PLANT VIEW AT NIGHT

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IMMEDIATE FUTURE PLANS

S/N

UNIT STATUS

1 NAPHTA HYDROTREATER (NHU)

Installation Stage

2 FLUID CATALYTIC CRACKER (FCC)

Installation Stage

3 KERO HYDROTREATER (KHU)

Design Stage Completed (No Funding)

4 CATALYTIC REFORMING Design Stage Completed (No Funding)

5 DIESEL/DISTILLATE HYDROTREATER (DHU)

Design Stage Completed (No Funding)

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Plate 35. View of the FCC Heat exchangers and Tanks

Plate 37. View of the proposed FCC units

PROPOSED FCC UNIT

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V-01 P-01 E-01 H-01 E-02 R-01 V-02

Surge

Drum

Pump Exchanger Fired

Heater

Cooler Reactor Separator

Figure 2. Process Flow Diagram of the proposed Naphtha Hydrotreating Unit

PFD OF PROPOSED NHU

ENGINEERS AT WORK (ABU REFINERY)

NH Unit FCC Unit

FCC & NH Units installation in progress

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INSTALLATION STAGE OF NAPHTHA HYDROTREATING UNIT

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FCCU CONVERTER COUPLING STAGE

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UTILIZATION OF

MINIREFINERY FOR

TEACHING &

RESEARCH

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STUDENTS TAKING LECTURES AT THE MINIREFINERY SITE

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IMPact of THE PROJECT

1. Demonstration of the Nigerian local

capacity to design, fabricate and

operate mini-petroleum refinery units

2. Creation of Hands-on training facility

for both undergraduate and

postgraduate students.

3. Such plants can serve as a bridge

for Industry-Academia Collaboration.

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FUNDING

CRUDE SUPPLY

BELIEVING IN OURSELVES COLLECTIVE ENCOURAGEMENT

CHALLENGES

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A mini crude oil distillation (atmospheric and vacuum) unit with a designed throughput of 1,000BPD (but scaled down to 1.0BPD) was successfully designed, constructed, installed and operated .

The ADU consists of column, side strippers, condenser, reflux drum, valves and

piping system while the VDU consists of column, TPA, BPA heat exchangers, steam ejector and piping system.

The plant is controlled by both manual and automatic modes. A utility and

safety systems were provided. Preliminary test runs indicated that the plant produces products such as Light

and heavy naphtha, kerosene and diesel fractions, and light and heavy vacuum gasoils.

The plant is currently used as teaching aid to students of Faculty of Engineering, Ahmadu Bello University Zaria.

CONCLUSION

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Engineers should pay more attention to practical aspects in addition to theory.

Federal Government should vigorously encourage practical researches with a view to domesticating various manufacturing technologies.

Institutions of Higher Learning should identify a specific technology and challenge their Engineers and Scientists to develop it.

RECOMMENDATION

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MY FELLOW ENGINEERS, WE CAN ALL DO IT

BUT NEVER BE AFRAID OF STARTING AND STOP THINKING OF FAILURE

EXPERTS BUILT THE TITANIC BUT IT SANK

LOCAL CARPENTERS BUILT NOAH’S ARK

AND IT WITHSTOOD THE FLOAD

BECAUSE:

NEVER BE AFRAID OF DEVELOPING A TECHNOLOGY

Engage those who will encourage you

68

Bagajewicz, M. & Ji, S. (2001), Rigorous Procedure for the Design of Conventional Atmospheric Crude

Fractionation Units. Part I: Targeting: Ind. Eng. Chem. Res. 40.

Environmental Impact Assessment Decree 1992. http://www.nigeria-law.org/EnvironmentalImpact

Assessment DecreeNo.086 201992.htm

Igwe, G. (2014). Modular Refineries: Nigeria Should Try the Idea. Elombah.com A Nigerian Perspective

on World Affairs. Available at : www.elombah.com/index.php/special-reports/20816-modular-refineries-

nigeria-should-try-the-idea

Kalu, I.K. (2012). Presidential Committee Report on Petroleum Refining in Nigeria

Mohammed-Dabo, I.A. Safieva, R.Z. and Syunyayev, R.Z. (2008). Recycling of Used Industrial

Lubricating Oil through its Joint Refining with Crude Oil. Petroleum Training Journal (PTJ) Vol.3 No.2,

July, 2008

Mohammed-Dabo, I.A. Bugaje, I.A. Zakari, B.Y. and Yakubu, S. (2008). Upgrading the product

potentials of Antan Crude Oil through its Joint Refining with Oso Gas Condensate. Journal of Research

in Engineering, Vol 5, No. 4, pp.94-99

NNPC (2009). Nigerian National Petroleum Corporation

NPC (2001). Nigerian Population Commission Report

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Research Publications, Volume 5, Issue 6, June 2015 1 ISSN 2250-3153 www.ijsrp.org

Oniwon, A.O. (2011). The Nigerian Oil and Gas Industry and the Global Economy. Paper presented at

the Ahmadu Bello University 35TH Pre-Convocation Lecture Series. November 23, 2011

Rao, B. (1990), Modern Petroleum Refining Processes, 1st ed. New Delhi, India.

Sinnott, R. N. (2006), Coulson and Richardson’s Chemical Engineering Series, Vol. 6, 4th Ed.: Elsevier

New Delhi.

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REFERENCES

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THANK YOU

FOR YOUR

ATTENTION