Refinery Configuration & Technology Selection
Transcript of Refinery Configuration & Technology Selection
March 2020
Refinery Configuration & Technology Selection
About Phasis Oil Refinery Project
TR has been engaged by Phasis Oil Company to carry out a Configuration Study for selecting
the best Refinery scheme for producing Gasoline & Diesel Euro VI Quality.
CPC Blend Crude Oil: 45,3° API and 0,56 % Sulphur.
The refinery goal was to reach the maximum conversion and maximizing Gasoline yields at
expenses of Middle Distillates.
• Atmospheric Distillation
• Gas Processing
• Naphtha and Middle Distillates Hydrotreaters
• Catalytic Reforming
• Isomerization
• Atmospheric Residue Upgrading Unit
• Hydrogen Production
As a first approach, the new 94500 BPSD Refinery includes at least the following
Process Units:
The Study compares four (4) Configurations for Residue Upgrading Unit and analyzes the convenience in terms of Product Yields, Product Quality and Investment Cost:
The study was carried out with the information received from reputable Licensors of the main Process Units, as well as Técnicas Reunidas know-how for “Open Art Process Units” and wide experience in Oil & Gas Engineering fields.
Configuration 1:
Atmospheric Residue Hydrocracker
Configuration 2:
Atmospheric Residue Fluid Catalytic Cracking.
Configuration 3:
Vacuum Residue Hydrocracker Unit & VGO FCC Unit
Configuration 4:
Vacuum Residue Hydrocracker Unit & VGO HCU Unit
About Phasis Oil Refinery Project
Configuration Study
Overall Block Schemes, Material Balances, Utilities Consumption and CAPEX Estimation were developed to a degree of definition sufficient to select the optimum Configuration.
About Phasis Oil Refinery Project
The discussions and the comparison tables supplied in the report, together with the investment and operating cost enables to select the scheme which best suits Phasis Oil needs.
The economic assessment is not in the scope of work of this study. Overall economics shall be calculated based on the cost of feedstocks, value of products and operating costs.
About Phasis Oil Refinery Project
Main Process Units Licensors
Crude Distillation
Hydrotreating
Hydrocracking
Fluid Catalytic
Cracking
Alkylation
Naphtha Isomerization
& Catalytic Reformer
About Phasis Oil Refinery Project
Other Process Units Licensors
Gas Processing Unit
Hydrogen Production
Unit
Amine Regeneration
Unit
Sour Water Stripping
Unit
Sulphur Recovery Unit
Utilities & Off-sites
Next stage (Haldor Topsoe, Technip, …)
Next stage (Kinetic Technologies, Jacobs, …)
With the aim of reducing the CAPEX of the refinery, the configuration was frozen for maximizing Middle Distillates at expenses of Gasoline.
About Phasis Oil Refinery Project
The reduction on the Overall Refinery CAPEX in conjunction with the gasoline pool optimization and the surplus in the Hydrogen production, brings TR to consider Axens approach as the best choice for the Naphtha Complex and the construction of the Project in one (1) stage.
PRODUCT YIELDS
FEEDSTOCKS tons/h
CRUDE OIL 500
BUTANE 5
MTBE 6,9
PRODUCTS tons/h %
SULPHUR 2,85 0.56
OFFGAS 3,86 0.75
C3/C4 2,7 0.53
GASOLINE 216,3 42.25
KEROSENE 115,6 22.58
DIESEL 162,6 31.75
RESIDUE 6,1 1.20
HYDROGEN 1,9 0.38
Block Flow Diagram of Final Refinery ConfigurationPropane
GPUGas
Processing(20 TPH)
ARU
AmineRegeneration
(90 TPH)SRU
Sulphur Recovery(66 TPD)
Desalted
Crude
Off Gas + LPG6 TPH
RichAmine
SRNaphtha171 TPH
H20.2 TPH
Diesel 123 TPH
Reduced Crude123 TPH
DHTMiddle Distillates
Hydrotreater(36552 BPSD)
H2
0.5 TPH
Lean Amine
Rich Amine LPG3 TPH
Lean Amine
SWSSour Water
Stripper(50 TPH)
SourWater
HPUHydrogen Plant
Natural Gas
H2
Strippedwater
H2S
Residue6 TPH
Sour Water
Sour Water
Sour Water
CDU
Crude Distillation
Unit(94500 BPSD)
Heavy Naphtha139 TPH
H2
3 TPH
HCU Naphtha33 TPH
Reformate107 TPH
Sulphur3 TPH
500 TPH
Diesel162 TPH
H2S + NH3
H2 Rich Gas
6 TPH
Off Gas1 TPH
Off Gas2 TPH
Kerosene76 TPH
Kerosene115 TPH
NHTNaphtha Hydrotreater
Naphtha Splitter(42506 BPSD)
CCRCatalytic Reformer
(23265 BPSD)
Isomerate62 TPH
HDS Reactor effluent to common fractionation section
Fuel Gas3 TPH
Light Naphtha63 TPH
H2
0.6 TPH Off Gas2 TPH
Off Gas + LPG8 TPH
Heavy Naphtha24 TPH
Butane11 TPH
Propane3 TPH
Heavy Naphtha116 TPH
Total Naphtha204 TPH
Butane
Crude Oil Storage
Tank
Isomerate
Reformate
Heavy Naphtha
Kerosene
Diesel Fuel
Residue
ISO Isomerization(14041 BPSD)
HCKHydrocracker(20325 BPD)
Atmospheric Residue Hydrocracking& Middle Distillates Hydrotreating
Naphta HydrotreatingCatalytic Reforming
Isomerization
Crude DistillationGas Processing
Amine RegenerationSour Water StrippingUtilities & Off-sites
Licensors Selected as Technology Providers
The most Modern Refinery in the area
Optimization for Gasoline Pool by Axens
Clean Fuels on top of Euro VI Quality Standards
96,6%Gasoline plus Middle distillates
Maximization
ISOIsomerization
GPUGas
Processing
Heavy Naphtha116 THP
NHTNaphtha
Hydrotreater &Naphtha Splitter
CCRCatalytic Reformer
ImportedButane
Light Naphtha63 TPH
Heavy Naphtha24 TPH
Reformate107 TPH
Butane11 TPH
Isomerate62 TPH
Butane5 TPH
MTBE7 TPH
Naphtha204 TPH
ImportedMTBE
GASOLINE POOL
216 TPH
UNIT UNIT DESCRIPTION TIC
SECTION A Capacity UoM (USD Million) Licensor
1 CDU Crude Distillation Unit 500 Ton/h Feed 115 TR
2 NHT Naphtha Hydrotreater 204 Ton/h Feed 32 Axens
3 DHT Middle Distillates Hydrotreater 200 Ton/h Feed - Shell
4 HCK Hydrocracker 123 Ton/h Feed 245 Shell
6 + 7 ISO Isomerization + CR Catalytic Reformer 179 Ton/h Feed 123 Axens
8 GPU Gas Processing 20 Ton/h Feed 70 TR
9 HPU Hydrogen Plant 24600 Nm3/h product 82
Total SECTION A 666
SECTION B Following Units to be added to SECTION A
10 ARU Amine Regeneration 90 Ton/h Feed included (SRU)
11 SWS Sour Water Stripper 50 Ton/h Feed included (SRU)
12 SRU Sulphur Recovery 66 Ton/day product 122 TR
Total SECTION B 122
TOTAL DIRECT COST (ISBL+Utilities) 787
TOTAL COST OSBL (Estimated) 236
TOTAL DIRECT COST (ISBL+Utilities+OSBL) 1023
CAPEX Estimation
Overall Plot Plan optimized to comply with safety distances and minimize piping routing
12 Process Units blocks
+7 Utilities & Off-sites Units
+28 Tanks
The new Phasis Refinery compares well with refineries of similar size on a global basis
Nelson Complexity Index
Benchmark with refineries with size 100 to 140 kbd(10 refineries between two vertical lines)
Georgia oil products demand compares more than well with any reference.
Phasis Oil Refinery is the cornerstone of oil products in Georgia.
Towards low-carbon refinery
Future Upgrading: CO2 Capture & Utilisation
March 2020
Towards low-carbon refinery
Future Upgrading: CO2 Greenhouse Application
TR is a global leader in the design and build of complex industrial plants
Tecnicas Reunidas is a company specialized in the design and management of the execution of industrial plant projects throughout the world, with almost 60 year of experience.
Tecnicas Reunidas has designed and managed the construction of more than 1,000 industrial plants in over 60 countries. Its clients include many of the major national and multinational oil companies.
Main Markets
Saudi Arabia, UAE,Kuwait, Bahrein,Oman, Algeria,Singapur, Indonesia, Malaysia, Turkey, Russia, Poland, Finland, UK, Azerbaijan, Peru, Chile, Mexico, Canada, US, China, Australia
+9,000 professionals of
over 70 nationalities
+$50 billion in projects in the last 10 years
More than 1,000 industrial
plants
60 countries where we have
operated
2019 Backlog, M€ 10,026
Sales, M€ 4,700
Employees +9,000
60 years of continued
growth
Safety Performance / Zero Incident
Target
$4 billion per year in
purchasing and subcontracting
Engineering Hour/Year
Construction Hour/Year
> 195,000,000 > 9,000,000
About Técnicas Reunidas (TR)
DOWNSTREAMTrack record/highlights
• 421 Refining Units
• 150 Petrochemical Units
• Top Ten International contractor
• Worldwide leader in Heat Transfer,
Nitric Acid, Ammonium Nitrate and
Hydrometallurgy Technologies
UPSTREAM & GASTrack record/highlights
POWER & WATERTrack record/highlights
• Oil & Gas Fields Development
• World Leader in LNG terminals
• Pipelines & Storage
• Thermal plants
• Gas Turbine
• Conventional
• Reciprocating
• Biomass and Waste to Energy
• Nuclear Experience
• Water Treatment
• Desalination
• Effluent Treatment (WWTP)
• Drinking Water Treatment
TR covers almost the whole energy value chain
0,28
0,45
0,280,23
0,070,12 0,15
0,10,03 0,029 0,02 0,01 0,02 0,036 0,03 0,01
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
LTIR
TR is committed to maintain the highest safety and environmental standards for the Employees, Clients and Suppliers
Safety and Environment
TR Safety Performance / Zero Incident Target
HORSEHEAD
FERTILIZANTES
TALARA
PETRONAS
SOCAR
FADHILI
JAZAN
SASOL
SADARA
GASCO
NESTE / VEOLIA / BOREALIS
TEESSIDE TUROW
ASHUGANJ
PEMEX
KNPC AL ZOUR
KNPC GT5
TOUATGAZ
RAS TANURA
TIERRA MOJADA
BAPCODUQM
HARADH
BAKU
ADNOC LNG
BU HASA
NOVA
GAZPROMNEFT
CKPC
HASSI MESSAOUD
SAUDI KAYAN
KEMYA
PETROKEMYA
BOROUGE
HAMRIYAH
LUKOIL — Vacuum Gasoil Deep Conversion Complex
AOC — Khabarovsk Refinery Expansion
LUKOIL — H-oil Residue HCK Facility
MARJAN
HAMRIYAH
EXXON
UPER ZAKUM
TR have executed some of the most emblematic projects of the industry
Executed projects 2009-2019
50 B$
Upstream & gas
Refining
Petrochemical
Power & Water
TR Technology
One of the 35 reference companies in the Spanish Stock Exchange
Founder37%
Treasury stock
4%
Institutional investors
49%
Backlog, M€
TR has a strong shareholder structure, and an impressive history of growth
5.3876.205 6.377
8.412
12.136
10.5829.870
8.981
10,026
2011 2012 2013 2014 2015 2016 2017 2018 2019
Split by Products
Downstream
Upstream
Power & Water
48%
48%
4%
0
50
100
150
200
250
300
350
400
450
500
196
1
196
6
1970
1974
1978
198
2
198
6
199
0
199
4
199
8
200
2
200
6
2010
2014
2018
Recurrent customers
New customers
50% of recurrence of customers in terms of awarded projects
# of projects
TR has renowned and recurrent clients, ongoing investors in energy infrastructures