Chapter 6 - Modern Refinery Layout

Transcription

1 Chapter 6 - Modern Refinery Layout Introduction Refinery processing units can be classified into the following main categories: 1. Physical Separation. 2. Desulfurization. 3. Product upgrading. 4. Finishing. 5. Heavy residue processing. 6. Supporting facilities and Utilities. Refinery schemes are determined by: 1. Crude oil characteristics (S, API, Aromatic/Naphthenic content). As more crude oil is produced and less is remaining, the quality of crude is expected to worsen over time. Lower API heavier crudes more atm. and vac. residue (harder to process cost more). Higher S more hydrotreating units are required. 2. Product demand (e.g. shift of demand from heating oils and FO to LNG & LPG) 3. Capital/Operating Cost (How much money is available to invest). 4. Process equipment available. Allowance exists for production flexibility to meet market demand. (i.e. maximizing/minimizing certain products and shifting production). Optimum flow pattern for any refinery is dictated by economic considerations which is changing with product prices this can be determined only by optimization Software. CDU & VRU HS Residue H-Oil or Isomax CDU HS Residue ARDS LS Residue RFCC HS vac resid hydrocracking configuration (SHU) LS atm resid catalytic cracking configuration (ZOR) CDU HS Residue ARDS LS Residue VRU LS Residue VGO Delayed Coker CGO HCR Coke LS vac resid thermal cracking configuration (MAA & MAB) Figure 6-1. The three basic refinery configurations 6-1

2 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Fahaheel Expressway MAB Refinery white black SHU Refinery white black MAA Refinery North Figure 6-2 The three KNPC refineries are interconnected through Inter Refinery Transfer Lines for receipt and supply of Intermediate/Finished products (in addition to sulfur, coke and LPG) Figure 6-3. Product shipping facilities. 6-2

3 Table 6-1: Comparison of the Units (Process and Utilities) and their Capacities in Kuwait Refineries. MAA refinery (466,000 MBPD) MAB refinery (270,000 BPD) ZOR refinery (615,000 MBPD) Processing Units MBPD Processing Units MBPD Processing Units MBPD Crude 3 Crude 4 Crude Crude 01 Crude Crude Crude Crude Eocene ARDS 41/42-81/82 2X32.95 ARDS 12 2 X 33 ARDS Isomax Vacuum Rerun Vacuum 13 2 X 78.4 Bitumen Unit Hydrocracker 84 FCC 86 Kerosene Desulfurization Unit 43 Gas Oil Desulfurization Unit FCC LPG Merox ATK Merox Naphtha Merox FCC naphtha Merox Gasoline Merox 94 Hydrogen 48/49-88/89 H 2 Recovery Sulfide Unit 50 H 2 Recovery 98 Acid gas Sweetening TGT TGT 54/55/93 Acid Gas Removal 20, 21 Acid Gas Enrichment Flare Gas Recovery Unit 05 Flare system 62 Gas Plant 30, 31, 32, 33 Regeneration Gas Sweetening C3 Stream COS Removal Propylene Recovery & Equate Stream Handling /300 FCC LPG Treating FCC LPG Splitting Sulfur Recovery 20, Sulfur Recovery 51/52-91/92 Sulfur Handling 64 Sour Water Stripper 20 Sour Water Treatment 56/96 Thermal Incinerator 20 Acid Condensate Sweetening H 2S Recovery 90 Sulfuric Acid 47 CCR Reforming MTBE 45 Alkylation 46 Waste Water Treatment 63 Tankage & Off-sites 60 & 61 Fuel Oil Supply 68 Fuel Oil System 73 Fuel Gas System 74 Cooling Water System 75 Desalination Plant 27 N2 System 71 Plant & Instrument Air System X Hydrocracker Naphtha HTU 17 Kerosene HTU 18 Diesel HTU 19 Coker 20 Naphtha Merox 22 4X Hydrogen 18 Hydrogen 03 H 2 recovery 19 Gas Handling & LPG 18 Tail Gas Treating 24 2X18 Sulfur Recovery 23 Sulfur 05 Sour Water Stripper 26 Amine Regeneration X 41 2 X X 48 δ X 36 Ψ 3 X 270 Ψ 140 Ψ 2 X 1045 ζ 3 X 1400 ζ Naphtha HTU Kerosene HTU Diesel HTU Hydrogen Gas treating Acid gas removal Boilers 20 Sulfur Recovery Amine treating unit Ammoniacal water treating Water Demineralizer Utilities and Offsites Utilities and Offsites Utilities and Offsites N 2 generation Unit 21 1,580 Foul water treating Plant & instrument air Cooling water system Inert gas Sea cooling water Coke handling API separator Utility block and Flare systems Inst. & plant air systems Waste water treatment systems Fuel gas system air pollution monitoring stations 195,000 lbs/hr Flare system 900 psi steam boilers X3 (each) 210,000 lbs/hr Off-sites, tank farm & 150 psi steam 14 MM bbls Shipping area Tank Farm Sea Island Ψ T/SD ζ GPM δ MMSCFD all other in MBPSD δ δ δ Ψ ζ ζ 6-3

4 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering KNPC MINA ABDULLA REFINERY (MAB) Figure 6-4. Mina Abdullah Refinery Summary of History & main features Located in southern Kuwait about 60 KM from Kuwait City. The refinery was first built in 1958 by the American Independent Oil Co. (AMINOIL). It contained one crude oil distillation unit with a capacity of approximately 30,000 BPD. Old MAB refinery facilities were installed between 1962 (Crude Distillation Unit) and 1967 (Isomax, Hydrogen and Sulfur Units) its refining capacity rose to 145,000 BPD. Main product was residual fuel oil from neutral zone crude oils (Ratawi-Burgan mix. 20 API). Mina Abdullah Refinery became a State property, following a transition period during which the refinery was managed by the national company Wafra Oil Company. Ownership of the refinery was transferred to KNPC in Mina Abdulla Refinery (MAB) Refinery Modernization Project (RMP) - Upgrading the old units. - Increasing the throughput by MBPSD by adding new units. - Integration of the old and new units in the refinery. - Integration of MAA, SHU, MAB refineries for optimum flexibility and utilization. Ultimate refinery scheme was based on linear programming. The entire design, engineering material procurement and construction activities of the project were entrusted to Kuwait Santa Fe Braun (KSB) the new refinery was commissioned the refinery throughput was raised to 256 MBPSD. Further debottlenecking raised the throughput to 270 MBPD Total area covered by its installations is million m

5 MAB Refinery consists of the following main units: Atmospheric and vacuum distillation units. Distillate Hydrotreaters (for Naphtha, Kerosene & Diesel). Atmospheric Residue Desulfurization units. Hydrocracker unit to upgrade Gas oil. Delayed Coking Units to upgrade vacuum residue. Supporting units (Hydrogen Production, Sulfur Recovery, Utilities, etc). Table 6-2 The Main Units at Mina Abdullah Refinery Crude Distillation Units No. Of Units Total Capacity Crude Distillation Units 2 270,000 bpd RCD UNIBON Unit 1 35,000 bpd Atmospheric Residue Desulphurization Units ARDS 2 84,000 bpd Vacuum Re-Run units 2 150,000 bpd Hydro-Cracker unit 1 42,500 bpd Kerosene Hydro-Treating unit 1 40,000 bpd Diesel Hydro-treating unit 1 40,000 bpd Naphtha Hydro-Treating unit 1 7,500 bpd Delayed Coker 2 90,000 bpd Merox unit 2 3,200 bpd Hydrogen Plant million cu ft/d Old Hydrogen plant unit 1 26 million cu. ft/d Hydrogen Recovery unit 1 26 million cu. ft/d Sulphur Recovery units MT/D Tail Gas Treating unit MT/day 6-5

6 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Mina Abdullah Refinery Modernization Project: (MAB-RMP) Mina Abdullah Refinery Modernization Project consisted of three parts. 1. to revamp the existing units (such as the crude distillation, hydrogen production units, Sulfur recovery units) and utilities at the refinery and increase their efficiency and capacity. 2. to construct 15 new process units and support facilities that use the best oil refining technology known at the time in order to produce high quality petroleum products and minimize volume of fuel oil in the ultimate yield. 3. to develop export facilities including the construction of an island (the Sea Island, MAB) to be used as an exporting point for the refinery products and to increase the efficiency of the North and South piers at Mina Al-Ahmadi Refinery. Upon the completion of its modernization project, Mina Abdulla Refinery became one of the world's most sophisticated and modern oil refineries. RMP-MAB further integrated the then existing MAB refinery with MAA and SHU refineries so that the three facilities were practically converted into one fully integrated refining complex that would provide a high degree of flexibility. The three refineries continuously exchange products for use in their various process activities or blending operations to create products that are ready for export. After Kuwait liberation, the product shipping and transfer facilities, damaged during the Iraqi Invasion, were rebuilt. Overall Scheme of Refinery Operation Kuwait Crude mix received from KOC in refinery storage tanks is separated into straight run fractions; naphtha, kerosene, diesel and atmospheric residue in the old and new crude units. Straight run Naphtha, kerosene and diesel are hydrotreated in separate hydrotreating units to meet the finished product quality criteria. The Hydrotreating units upgrade the quality of the raw distillates produced in various refinery process units. The residue, from both crude units, is sent to existing RCD Unibon (Isomax) Unit and the ARDS Unit for desulfurization to sulfur levels of 1.5 % and 0.5 % respectively. The naphtha stream from these units and distillate from RCD Unibon (Isomax) are sent to the hydrotreating units to improve their quality. The low sulfur residue product from RCD Unibon and ARDS units are supplemented by imported low sulfur atmospheric residue from MAA refinery to form the feed stock to the vacuum rerun unit (VRU). Part of the vacuum gas oil produced from these units is sent to the hydrocracker unit for conversion into more valuable distillates namely naphtha and ATK and also if required, LP diesel (low pour point diesel). Any remaining vacuum gas oil is exported to MAA refinery to feed the FCC unit. The vacuum residue from the vacuum units is fed to the delayed coker unit. Without a coker, the vacuum residue would be sold as heavy fuel oil (HFO) or asphalt, depending on the type of crude, for about 70 % of crude oil price. The delayed coker units converts this low value bottom of the barrel stock into valuable distillates such as naphtha, kerosene, diesel and gas oil and produce green coke as solid byproduct. The liquid streams from the delayed coker unit need further treatment before joining the finished product pools. - Light & part of the heavy naphtha is treated in a Merox Unit. - Heavy naphtha, kerosene and diesel streams are treated in the hydrotreating units. 6-6

7 Utilities & Offsites The process units are supported by facilities such as Hydrogen production, Hydrogen recovery, Gas handling, Amine regeneration, Sour water stripping, Sulfur recovery, Tail Gas Treating, Coke handling, Utility block and Flare systems (separate for hydrocarbon and acid gases). Also included are facilities such as waste water treatment systems, air pollution monitoring stations etc. For handling the products generated, a number of tanks are provided (total storage capacity of about 14 million barrels). The steam requirements for the refinery are met by three 900 psi steam generators each of 195,000 lbs/hr capacity and an existing 150 psi steam generator (Babcock Wilcox boiler) of 210,000 lbs/hr capacity. The water requirements (about 2,600 gpm) are met by imports from the Ministry of Electricity and Water (MEW). The power requirement (about 165 MW) is also met by imports, from MEW. The natural gas requirement (about 47 MMSCFD) is met by imports from KOC. Sea cooling water requirements for the refinery (peak 93,000 gpm) is met by Shuaiba Area Authority. Nitrogen gas is generated locally in a package unit and also received by trailers & pipeline from outside. Other requirements for utilities such as plant air, instrument air, Inert gas etc. are met by facilities built within the refinery. Flexibility The process units and product handling facilities incorporate adequate flexibility for varying the product pattern. These features permit uninterrupted overall refinery operation during scheduled/unscheduled shutdown of any one unit. Some of the units are designed for different modes of operation. The hydrocracker has two modes of operation 1. ATK mode: Maximizing ATK/kerosene production with no diesel production 2. Diesel mode: Producing low pour diesel additionally. The two reaction stages running normally in series can be operated in parallel mode. The Delayed coker can be operated with recycle ratio of % yielding different rates of distillate and coke production. The higher recycle ratio increases the production of coke and gas with corresponding reduction in the total volume of liquid products. However, the yields of high value products namely kerosene & diesel are better. 6-7

8 Isomax (RCD Unibon) Unit Mbpsd Old Crude Distillation Unit (CDU 01) 75 Mbpsd Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Tail Gas Treating and Hydrogen production units have spare capacity. Critical units such as Sulfur Recovery, Sour water stripper, Amine Regeneration are spared (have more than one train). Gases Naphtha to HTU Storage Tanks Kerosene to HTU H 2 Rich off Gas. Crude oil from Storage (KOC) Diesel to HTU Residue Naphtha Distillate Fractionator Bottoms Natural Gas From Oilfields (KOC) Old Hydrogen Unit 03 H 2 Utilities & Offsites Unit 06 Power Generation Unit 07 Sour Gases H 2 S Removal Unit 04 (now retiered) H 2 S Old Sulfur Recovery Unit 05 Sulfur Figure 6-5. Process scheme for MAB Old Refinery. 6-8

9 The major processing, treating, and support units are as follows: 1- Crude Oil Distillation Unit (U-11) The refinery has two crude distillation units with a total capacity of 270,000 bpd ( BPD new CDU & 80,000 BPD existing CDU). Crude from the Kuwaiti oil fields is distilled in a distillation tower under atmospheric conditions to obtain preliminary petroleum products such as gas, naphtha, kerosene and diesel, while the bottom residues are sent to other units for further treatment under different temperature and pressure to upgrade the specifications of the primary petroleum products from the distillation column to conform with international specifications. 2- The Delayed Coker Units: Is the first such unit to be constructed in the Gulf area. There are two identical trains with a total design capacity of 76,000 BPSD (38,000 BPD each). Delayed coking is a thermal cracking process, which upgrades the heavy residues into valuable distillate products like light coker naphtha, heavy coker naphtha, kerosene, diesel, gas oil, green coke. The design of the unit is based on the full thermal cracking of the residuum from the vacuum rerun unit, as well as processing the entire refinery slop oil. The coke product forms porous solid after cooling in special drums, which is then removed by using a cutting tool equipped with high pressure water jets. The production capacity of the solid coke is 600,000 tons per year. 3- ARDS (Atmospheric Residue Desulfurization Units) The unit is designed to process 65,900 BPSD of high sulfur atmospheric distillation unit bottoms (HSFO) in two trains with one common fractionator. One train can be operated while the other is down for catalyst replacement. The primary object is to reduce the sulfur content of atmospheric residue to 0.5% in the presence of hydrogen over a fixed catalyst bed reactor, in addition to the removal of Nitrogen and metal compounds. A project revamp of the ARDS using On Stream Catalyst Replacement (OCR) technology to increase the capacity of each train from 33,000 BPD to 42,000 BPD. 4- Sulfur Recovery Unit To recover elemental sulfur from refinery sour gas such as the amine regenerator acid gas, sour water stripper overhead gas and the recycle gas from the Tail Gas Treating Unit (TGT). The recovered molten sulfur is degassed and sent to flaking facilities located in MAA. The tail gas will be sent to the TGT for further processing. The unit consists of three identical trains, with a 400 MT sulfur per stream day (99.5wt% purity) utilizing the Oxygen Enrichment Technology. 5- Central Control System (CCR) The CCR is a prime example of the modern technology applied in Mina Abdulla Refinery. The CCR consists of a system of video consoles, grouped workstations. There are ten workstations including one spare intended for training. Each workstation consists of 3-4 monitors associated with digital distributed control system (DCS). Process indications along with a variety of informative displays required for control and monitoring of refinery operations are available on the screens apart from providing a graphic display of the plant itself. 6-9

10 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering The state of the art technology includes reliance on microprocessors, digital equipment and use of a Distributed Control System (DCS) together with a computer to apply advanced control strategies to refinery operations. Process units can be remotely controlled and operated from about 5,000 ft away. The workstation associated with the tank farm displays tank gross and net volumes. Another provides a graphic display of tanks and interconnecting valves and means to control oil movement by sequentially opening valves remotely from the workstation. A report printers are associated with the process computer to provide plant status reports. Figure 6-6 CCR (central control room). Figure 6-7 MAB Sea Island. 6- Coke Handling Facilities The coke produced at the delayed coker unit is carried by conveyor belts to the boundaries of Mina Abdullah Refinery where it is then carried in carts to the boundaries of Shuaiba Refinery for storage in warehouses with a capacity of 70,000 tons of coke. Eventually, the coke is carried to Shuaiba Port on conveyor belts for export. To avoid air pollution by dust emitted from the transport and storage of coke, the coke is washed several times prior to storage and is kept under diffused pressure at night to prevent the leakage of coke dust outside the warehouses. A coke calcination unit was added later to mina Abdulla refinery to improve coke quality. 7- The Sea Island Located approximately 5 km offshore. It consists of two loading berths for exporting liquid petroleum products and importing fuel oils in case of any emergency. The seaward berth can receive tankers ranging from 25 to 276 MDWT (metric dry weight tons) Landward berth can receive tankers ranging from 25 to 140 MDWT. Each berth is provided with six loading arms, four for white oil products and two for bunker/fuel oil products. There are six submarine pipelines; each is dedicated for the transfer of a product. The products transported through these lines are naphtha, kerosene, export gas oil (EGO), high speed diesel (HSD), marine diesel oil (MDO) and high sulfur fuel oil (HSFO). All submarine pipelines are 24 diameter except MDO which is 12. The shipping facilities are designed for loading a cargo of 80,000 MT of white oil products in 36 hours and black oil products in 40 hours. 6-10

11 6-11

12 Delayed Cocker Unit (DCU 20) Vaccum Rerun Unit (VRU 13) Hydrocracker (HCR 14) Atmospheric Residue Desulfurization Unit (ARDS 12) Crude Distillation Unit (CDU 11) Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Gases LPG to MAA Gas Handling & LPG Unit 18 Rich Amine Lean Amine Amine Regeneration Unit 25 H 2 S Sulfur Unit 23 Sulfur Storage Tanks Crude oil from Storage (KOC) Naphtha HTU Kerosene HTU Diesel HTU Atmospheric Residue Gases LPG Naphtha Light Ends Distillate Fractionator Bottoms LVGO HVGO Gases Naphtha Vaccum Gasoil TGT Unit 24 Gases Naphtha Gasoline LCO HCO Residue Naphtha Treated Water Sour Water Stripper Unit 26 SW from all units Vaccum Rsidue Gases lt Naphtha Hvy Naphtha Merox Unit 22 Natural Gas From Oilfields (KOC) Hydrogen Unit 18 H 2 to Catalytic Units Kerosene to HTU. Diesel to HTU Fuel Gas to Units H 2 Hydrogen Recovery Unit 19 H 2 Rich Off Gases From Catalytic Units CGO (Cocker gas oil) Coke Figure 6-8 Process Scheme for Mina Abdulla New Refinery. 6-12

13 KNPC MINA ALAHMADI REFINERY (MAA) Figure 6-9. Mina Al-ahmadi refinery Summary of History & key features 1949 KOC commissioned MAA refinery for local market needs Capacity Mbpsd Capacity raised to 190 Mbpsd Capacity raised to 250 Mbpsd Gas liquefaction plant was commissioned Rhenformer Units commissioned MAA was transferred to KNPC 1984 Refinery Modernization Project (MAA-RMP), to (1) produce low sulfur petroleum products, and (2) to reduce local dependence on gas as fuel, providing cheaper and more stable fuel oil (FO) to the country s power generation plants Further Upgrading Project (MAA-FUP) to produce export fuel FCC was commissioned 1997 FCC unit capacity increased to 40,000 BPD (revamp), as part of MAFR - PRU, MTBE, ALKAYLATION, and SAR units commissioning started A leak in gas condensate line led to a destruction of several facilities. Immediate rehabilitation took place to repair and replace the damaged facilities. New ATK MEROX unit was commissioned New GOD is commissioned in April. Currently Capacity 460 Mbpsd. The refinery contains 29 new units, in addition to the old units; including the crude distillation units, the Fluid Catalytic Cracking Unit, the Atmospheric Residue Desulfurization Units, the Vacuum Rerun Unit and the Sulfur Recovery unit. MAA total area of million m 2. The refinery is located 45 km to the South of Kuwait City on the Arabian Gulf. MAA & LPG plant employees about 1550 Staff. MAA has now become one of the world s modern refineries in terms of both refining capacity (460,000 bpd) and the advanced technology it employs. Following the establishment of KPC and the restructuring of the oil sector, ownership of the refinery was passed from Kuwait Oil Company (KOC) to Kuwait National Petroleum Company (KNPC) which became responsible for the oil refining and gas liquefaction operations in Kuwait in the early 1980 s as part of an overall plan. 6-13

14 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Figure 6-10 Main Units at Mina Al-Ahmadi Refinery Unit No. Of Units Actual Capacity Crude Distillation Units 3 466,000 bpd EOCENE Topping Unit 1 24,000 bpd Bitumen Production Unit (Asphalt) 1 11,000 bpd Atmospheric Residue Desulphurization Unit (ARDS) 4 132,000 bpd Naphtha Reforming Units 2 35,000 bpd Kerosene Desulphurization Units 1 20,000 bpd Gas oil Desulphurization Units 1 61,600 bpd Vacuum Distillation Unit 1 85,000 bpd Hydro Cracking Units (HCR) 1 40,000 bpd Fluid Catalytic Cracking Unit 1 40,000 bpd Hydrogen Recovery Unit 1 56,000 MMSCFD Hydrogen production Units MMSCFD Sulphur Recovery Unit 4 1,334 MTPD Merox Unit 1 20,000 BPSD CCR Naphtha Reformers 2 Gas Oil Desulphurization Unit 1 61,600 BPSD New Gas Oil Desulphurization Unit 1 70,000 BPSD Tail Gas Treatment Unit (TGT) MTPD Sour Water Treating Unit (SWT) GPM Refinery Scheme (post FUP) MAA refinery has three crude distillation units [03/04/05] (the feed for which is Kuwait Export Crude) plus one EOCENE unit [39] which is also a distillation unit (the feed for which is Eocene crude oil). The off gases from these units (except Eocene) are sent to the Flare Gas Recovery Unit [05] for compression to recover LPG as a product. The remaining low-pressure gases are used as fuel gas within the refinery. The off-gas from the Eocene unit is used directly as fuel. The straight-run (SR) naphtha from CDU-3 is sent to a debutanizer to separate the C4 and lighter components as LPG and stabilized naphtha products. The SR naphtha from CDU-4/5 and Eocene are sent to a stabilizer [4/5] for the same purpose. The kerosene from the crude units (except Eocene) is sent to kerosene desulfurization unit [43] for sulfur removal using catalyst at high T&P in H2 atmosphere. The resulting kerosene (ATK/DPK/JP8) is sold as a final product. Kerosene is not produced in Eocene unit. Why? ATK Merox removes mercaptans sulfur. The light gas oil (LGO) from the crude units and the GO from Eocene unit are all sent to the Gas Oil Desulfurization unit (GOD-44) for treatment. The same is for the heavy gas oil from CDU-4/5. The Treated gas oil is blended to make Export gas oil (EGO) or High speed diesel (HSD) 6-14

15 HGO from CDU-3 is blended without treatment. Atmospheric residue from the crude units [4/5] is sent to the ARDS [unit-41/42/81/82] for desulfurization and upgrading. The atmospheric residue from the Eocene [unit-39] is sent to the Bitumen [unit-12], which is a vacuum distillation unit, for further separation, or blended for light & heavy fuel oil (LFO/ HFO). The Atmospheric residue from CDU-3 is blended for HFO without treatment. The ARDS unit produces Naphtha, distillate, and LSFO. The raw Naphtha is sent to the ARDS Naphtha Stabilizer to remove the light gases in the form of LPG and the stabilized naphtha is sent (along with the same from CDU-3/4) to a pre-fractionator (Naphtha splitter). The light naphtha from the top of the fractionation column is treated for sulfur removal in the Merox and the heavy naphtha from the bottom is sent to the CCR (continuous catalytic reforming unit) for catalytic upgrading into high octane components for motor gasoline blending. The VGO from the Vacuum Rerun Unit and the Bitumen Unit is converted in the Hydrocracker [Unit-84] to lighter and more valuable products like LPG, Naphtha, ATK, and Gasoil. The heavy gas oils (from MAA and other refineries) are converted in the Fluid Catalytic Cracking (FCC) Unit-86 to lighter and more valuable products such as LPG, Gasoline, and Fuel oils. The FCC Light and Heavy naphtha are further treated for sulfur in the Merox unit. Additional Facilities (utilities) include - Hydrogen Production Unit - Sour water Treatment Unit (SWT) - Tail Gas Treating Unit (TGT) - Hydrogen Sulfide Removal (HSR) - Blending Facilities (for MOGAS, PCN, GO, MDO, LSFO, LFO, HFO) 6-15

16 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Figure Aerial view of refinery Figure Refinery Flare system 6-16

17 MAA Main Units Crude Oil Distillation Unit: The capacity of the three CDU units to around 466,000 bpd. The crude oil distillation units receive crude oil mix feed from Burgan, Ratawi and other oil fields. In these units, the raw material is separated in the distillation tower into gas, naphtha, kerosene, light and heavy gas oil (Diesel) and residue. The distillates are sent to other conversion units in order to improve their specifications to the required international standard. Fluid Catalytic Cracking Units (FCC) The unit was commissioned in 1986 as part of the Refinery Further Upgrading Project (FUP) with a capacity of 30,000 bpd. In 1997, the unit was revamped and its capacity was raised to 40,000 bpd as part of MAFP (MTBE Alkylation, and FCC revamp Project). The unit objective is to produce maximum LPG and Gasoline. (Conversion level 79 of LV% to gasoline). The Olefin rich LPG strea is further processed in downstream units (gas plant) to produce Propylene, MTBE, and Alkylate. The hydrocracker gives saturated products (no double or triple bonds). Whereas, FCC gives unsaturated & saturated products that require hydrotreating or reforming to saturate. CCR Naphtha Reformers (Continuous Catalyst Regeneration) After the June 2000 incident in Mina Al-Ahmadi Refinery, the company decided to build two identical reformate production units in place of the old destroyed catalytic reformer. The new (October 2003) Naphtha Complex includes two identical process trains. 6-17

18 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Each process train consists of a Naphtha Hydrotreater, Naphtha Splitter and CCR reformers for gasoline production. A dedicated Nitrogen Generation Unit provides N2 for both units. The objective of the complex is to produce reformat with RON or MON of 90 and Benzene content of 1.0 vol% max. Naphtha Hydrotreater: Naphtha is catalytically hydrotreated in a fixed bed reactor employing catalyst and hydrogen rich stream to decompose organic sulfur, oxygen and nitrogen compounds contained in hydrocarbon fractions. In addition to removing Sulfur and Nitrogen, naphtha hydrotreaters farther remove organometallic compounds and saturate olefin compounds. Sulfur Recovery Units: Within phases 1 and 2 of Mina Al-Ahmadi Refinery Modernization Project, four units were constructed to recover the sulfur from refinery processes sour gas. The total capacity of these units is 1,334 metric tons of sulfur per day. Sulfur Storage and Handling Facility: MAA Refinery houses the sulfur solidification and granulation facilities, which serves both MAA and MAB refineries. Originally, sulfur is liquid, then it turns into a solid cohesive mass when it cools. It is flaked into small pieces to facilitate handling. A special compound was built for the storage and breaking into flakes the Sulfur. Precautions are taken to prevent air pollution with sulfur dust when it is broken or carried. Elemental sulfur is transported by conveyer belts that reach the vessels (السفن) directly. The sulfur breaking and handling compound at MAA Refinery receives the sulfur produced at Mina Abdulla through pipelines that are heated continuously to ensure the smooth flow of the liquid sulfur. Figure 6-13 MAA CCR Central Control System: A state-of-the-art central control room was established in addition to several local control rooms. Each central control room houses several operation stations equipped with monitors linked to a microprocessor that monitors the refinery units. 6-18

19 The computer displays drawings and plans with different variable data and the operation status (temp., pressure, flow, etc) of every unit. The computer also gives alarm messages when any of these values exceed the limits for safe operation. The computer performs complicated mathematical operations required for the control and operation of the units, thus ensuring added security and safety. The control system further helps in the conservation of energy and accurately controls the specifications of the petroleum products. The New Oil Pier at Mina Al-Ahmadi Refinery The refinery has two oil piers to export crude oil, LPG and petroleum products. SOUTH LOADING PIER (connected with the Refinery) NORTH LOADING PIER (10 KM north of the Refinery) The New South Pier is the largest and the most advanced marine facility in the Middle East. The pier has six berths for the export of petroleum products. Petroleum products being exported are; Crude oil, LPG, Naphtha, Kerosene, Diesel, Light and Heavy Fuel Oil. Tankers advanced (satellite connected) berth monitoring system ensure safe and accurate anchorage. Sudden-Interruption suction system for petroleum products during loading operation. Figure 6-14 MAA old loading pier The Pier s Main Features Number of Mooring Points 5 Tankers deadweight 160,000 tons Estimated design life 30 years Total of mooring points 4300 m Total number of Platforms 5 Anchor s depth 17 m 6-19

20 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Figure 6-15 MAA new Pier Figure 6-16 MAA Sulfur Storage مصنع اسالة الغاز LPG gas liquefaction plant (Gas Plant) at Mina Al-Ahmadi Refinery Gas Liquefaction Plant (LPG) at Mina Al-Ahmadi consists of three identical trains the capacity of each is 560 MMSCF (total processing capacity of 1.68 billion SCF/day) including 80,000 BPD of hydrocarbon condensate. Building a 4 th gas train was underway and a 5 th train was planned. The LPG plant consists of storage tanks divided into two tank farms. The greater portion of the LPG plant production is for export from the south pier of Mina Al- Ahmadi which is connected to the plant by a pipeline network. The Gas plant processes sweet 1 associated gas املصاحب) condensates /(الغاز collected from the crude production from Kuwait Oil Company (KOC) 2 gathering centers (26) and liquid gas from KNPC refineries. In addition to lean gas and residues, the mixture of gases is separated in the plant s units into liquid products as follows: Product Capacity (Bbls/day) Percentage Liquid Propane (LPG) 100, % Liquid Butane (LPG) 55, % Natural Gasoline (KNG) 40, % While the LPG plant essentially produces liquefied propane, liquefied butane (stored in refrigerated tanks) and Kuwait Natural Gasoline (KNG), it also produces high-pressure (HP) and low pressure (LP) lean gases. LPG plant supply lean gas to power plants, KNPC refineries and PIC. LPG plant provides ethane gas to Petrochemicals (Equate) for the manufacture of polyethylene. MAFP block was added downstream of the FCC unit to meet the specifications for unleaded gasoline as well as to upgrade cracked LPG from the FCC unit. It including facilities to supply propylene product to PIC for the manufacture of polypropylene and to produce Alkylate and MTBE, which are both mogas (motor gasoline) components. 1 Sweetening is done in MAA refinery Acid Gas Removal Unit 2 Another KPC company which is responsible for oil / gas exploration, drilling & production. 6-20

21 Saturates (n-c 4 Blended into gasoline or LPG Wet Gas Crude Coker Cracker Gas Plant Saturates (i-c 4 ) Unsaturates LPG Fuel Gas propene butene pentene burned as fuel in refinery furnaces sent to alkylation unit for processing. Figure 6-17 Gas Plant Vapor Recovery Section Acid Gas Removal project (AGRP) AGRP was implemented in 2000 to treat associated sour gas from the oil fields. Gas Oil Desulfurization Unit In order to meet latest diesel specs a new Gas Oil Desulfurization Unit was added to the refinery configuration in Figure Gas plant at mina Al-Ahmadi refinery 6-21

22 FCC Unit Bitumen EOCENE Unit Vaccum Rerun Unit (VRU 13) Atmospheric Residue Desulfurization Unit (ARDS) Hydrocracker (HCR) Crude Distillation Unit (CDU-3/4/5) LSRN Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Storage Tanks Crude oil from Storage (KOC) Eocene Gases SR Naphtha Kerosene LGO HGO Atmospheric Residue Debutanizer or Stabilizer ATK Merox Kerosene Desulfurization Gasoil Desulfurization Gases to FGRU EO Naphtha EO GO EO Residue (LFO) ATK Kerosene GO Flare Gas Recovery Unit lt Prefractionator hvy Gases LPG Naphtha Light Ends Distillate Fractionator Bottoms Gases Naphtha Merox Overflash Wax Distillate Bitumen TLSRN Gas LPG Catalytic Reformer Reformate Gases Slops LVGO HVGO Vaccum Gasoil Vaccum Rsidue Rich Amine Lean Amine Amine Regeneration Unit H 2 S LPG lt Naphtha Gases lt Naphtha Hvy Naphtha ATK GO Gases Hvy Naphtha Sulfur Unit TGT Unit LPG Merox Naphtha Merox Distillate Sulfur Natural Gas From Oilfields (KOC) Hydrogen Unit Fuel Gas to Units H 2 H 2 Hydrogen Recovery Unit H 2 to Catalytic Units H 2 Rich Off Gases From Catalytic Units Light cycle oil Heavy cycle oil Bottoms Figure A Simplified Process Flow Diagram for Mina Al-Ahmadi Refinery 6-22

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24 6-24 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering

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26 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering KNPC CFP (Clean Fuel Project) and NRP (new refinery project) There is increasing global interest in the production of environmentally-friendly products. KNPC crude oil refining capacity will increase to 1,415,000 BPD after the implementation of both new refinery project (NRP) and clean fuel project (CFP). CFP project upgrades/expands KNPC s existing MAA and MAB refineries into integrated refining complex that produce products which meet clean-fuel regulations. The project replaces some old units and add new process units to increase the refining capacity and produce high quality petroleum products compliant with the new standards and most stringent environmental terms. The refining capacity of both MAA and MAB will be 800,000 BPD after completion of the CFP units can process Kuwait export crude (KEC) while continuing processing 24,000 BPD of Eocene crude oil in MAA to produce Bitumen for local market. NRP can also accommodate heavy crude oils when needed. The project will use SHU refinery storage and marine export facilities after SHU is retired. Project Budget is 4.68 billion KD. Table 6-3. KNPC future refining capacity CURRENT Capacity (BPD) FUTURE Capacity (BPD) MAA 466, ,000 MAB 270, ,000 ZOR - 615,000 TOTAL 1,415,000 Figure MAA & MAB CFP plots. 6-26

27 Table 6-4. New refining units MAB refinery 6-27

28 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Table 6-5. New refining units MAA refinery 6-28

29 Table 6-6. Refining Units to be Revamped. Table 6-7. Refining units to be retired. Revamp cost for these units is too high. Better build modern units instead. 6-29

30 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Table 6-8. Key specifications of the petroleum products after the project implementation. 6-30

31 Figure Job opportunities after project implementation Refinery Sour Gas Amine Treating 125 Treated Gas H 2 S rich gas Gas Concentration 129 Sulfur Recovery 123 Gas LPG Sulfur Naphtha NHTU-117 CCR 127 Gasoline Crude CDU 111 KHTU-116/216 Kerosene Oil DHTU-115 Diesel AR KOC Gas H H 2 to HTU, ARDS, HCR ARDS H 2 H 2 Recovery 119 VRU 213 LSAR VGO HCR 114/214 Refinery H 2 -rich off-gases from HTU, ARDS, HCR, CCR LSVR Refinery Sour Water Acid Water Treating 126 Treated Water Figure MAB new refining units. 6-31

32 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering AL-ZOUR (ZOR) REFINERY KUWAIT INTEGRATED PETROLEUM INDUSTRIES COMPANY (KIPIC) Figure ZOR refinery (construction of ARDS reactors). Figure Transportation of a high-pressure reactor. 6-32

33 Summary of History & key features Kuwait Integrated Petroleum Industries Company (KIPIC) was established by the State of Kuwait in 2016 as a new subsidiary of Kuwait Petroleum Corporation (KPC). The government of Kuwait is now the sole share-holder. The construction of the refinery started in 2017 To be commissioned in September 2019 with a design capacity of 615 MBPD. KIPIC is one of the largest grass root integrated refining, petrochemical operations, and LNG import complex in the world. Located at Al-Zour industrial area, 990 Km south of Kuwait City. Total area is 16 million square meters. Number of employees contractors (for phase 1 only) In first phase, most of the refinery s production (225 MBPD) of LSFO (0.5-1%S) is to meet local demand (for electricity & water production), plus high quality ultra-low-sulfur distillate fuels (10 ppm wt). Second phase is a deep conversion refinery that includes RFCC of LSFO to produce naphtha for the petrochemical complex and a gasoline block that includes delayed coker, two HCRs, and Vacuum units. It also includes propane dehydration unit and aromatics block. Third phase includes import facilities for LNGI. Total reuse of water within the refinery (no water disposed to the sea) The refinery conforms to the highest safety and environmental standards مصفاة الزور تحقق أعلى معايير السالمة والنظم البيئية The consortium comprises Chevron, Shell, Fluor, Honeywell UOP, and Heilder Thompson. KIPIC was launched on May 1st, 2017 and is responsible for operating and managing refining, liquefied natural gas, and petrochemicals activities of ZOR complex. This consists of the following three facilities, currently under construction and anticipated to be operational progressively from 2019 to ZOR Refinery ZOR refinery facility Processes 615,000 bpd of Kuwait Crudes to produce high value products and fuel oil. This refinery is in the engineering, procurement and construction phase, with target date of completion by June 2019, and commencement of operations in phases thereafter. 2. LNGI Liquefied Natural Gas Import facility will be responsible for importing, vaporizing and distributing high quality gas up to 3,000 Billion BTU of LNG per day. Currently in the engineering, procurement and construction phase, this terminal is expected to be completed in December 2020, with an operations start date of February Petrochemicals Petrochemical facility is where base petrochemical products are manufactured, with an annual capacity of 2,761 ktpa of aromatics and Polypropylene. The facility is in the front-end engineering design phase with an expected completion date of January The engineering, procurement and construction phase is planned to be completed in July 2023, with an operations start date in February The objective is to maximize profit to Kuwait hydrocarbon resources. RFCC Block includes GHDT, MTBE, Alkylation, and C

34 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Aromatic Block includes CCR (continuous catalytic reforming), NHT (naphtha hydrotreating), AR (aromatics), ISO (Isomerization). Major feedstocks are LSFO, FRN, and LPG from ZOR refinery plus propane and FRN makeup. Products are 2,000 kta Mogas (motor Gasoline), 1,400 kta Paraxylene, and 940 kta Polypropylene. General Refinery Process Description ZOR Refinery consists of the following main units: Crude Distillation Unit, Naphtha, kerosene and diesel Hydrotreaters ARDS (3 units x two trains each) RFCC (later) Supporting units (e.g. Steam Boilers) Utilities & tank farm (88 Tanks with a total capacity of 15 million tons) Marina & Sea island The crude oil from oilfields are received in large storage tanks. The tanks are alternated so that while one tank is receiving crude oil from oil fields storage, the other tank is supplying crude oil to the refinery. This ensures enough crude oil supply to the refinery to operate for two days just in case of supply cut-off. It also ensures settling of free water and sediments in the bottom of the tank before sending the crude oil to the CDU. The feed to the refinery is Kuwait Export crude (KEC) at a design throughput of 615 MBPD. The refinery is also capable of processing heavy crudes such as Kuwait heavy crude (Eocene crude) however at a lower throughput. ZOR refinery is designed for total fuel gas (FG) firing in the heaters. There is no fuel oil (FO) firing. Hydrotreaters The diesel hydrotreating unit DHTU converts Sulfur from 1.25 wt% to 10 ppm wt..(من هنا جاءت تسمية الوقود البيئي. الن الوقود المنتج يتماشى مع اعلى المعايير البيئية ( The reactor in DHTU comprises four beds of catalyst operating at high pressure via a 1300 psia compressor. In the naphtha hydrotreater (NHTU) no compressor is required as the gas is already supplied at high pressure from the ARDS unit. Supporting units Include heavy oil cooling (HOC), H2 production (20 MM SCFD) & H2 recovery (using PSA technology), sour water stripping (SWS) unit to remove H2S from refinery water for reuse, and a sulfur block. The sulfur block includes a sulfur recovery unit. Acid gas flare unit. The refinery is provided with flare gas recovery system to minimize gas firing and the wasting of valuable gas. The refinery is also provided with smokeless ground flares. (الميناء والجزيرة الصناعية) Marina & Sea island The sea island is 17 km offshore with 8 interconnecting submerged pipelines capable of loading 4 ships at a time with 120,000 tons of products per ship. The marina has a loading capacity of 60,000 tons of products. 6-34

35 KIPIC will use a range of process technologies from Honeywell UOP. Honeywell UOP will supply technology licenses, design services, key equipment, and state-of-the-art catalysts and adsorbents to produce clean-burning fuels, p-xylene, propylene and other petrochemicals. "In addition to aromatics and propylene, the Euro-V fuels will be produced. The project includes a 50,000 barrels per day (bpd) RFCC complex with ethylene and propylene recovery, and a 24,000 bpd Honeywell UOP Selectfining unit to produce low-sulfur gasoline. Two Honeywell UOP Merox units will be used to treat propane for propylene production, and isobutane to make clean-fuels blending components, including MTBE produced by a UOP Ethermax unit. Also included is a Butamer unit to convert normal butane to isobutane. The contract also includes a 66,000 barrel-per-day (bpd) CCR Platforming unit with a 74,000 bpd naphtha hydrotreater to make gasoline blend stock, and an LD Parex aromatics complex (including the Honeywell UOP Sulfolane, Isomar and Tatoray processes) to make 1.4 million metric tons per year of paraxylene, a primary ingredient in plastics. In addition, an Oleflex propane dehydrogenation unit will produce 660,000 metric tons per year of polymer-grade propylene another basic component in the production of plastics, synthetic rubber and gasoline additives. Source KIPIC ( 6-35

36 Prof. Tareq Albahri 2018 Kuwait University Chemical Engineering Refinery Gases Crude Oil Sour Gas Crude Oil Distillation (U1) Gas Handling (U10) SR Naphtha SR Kerosene Sour Gas LPG to MAA LPG Naphtha HTU (U2) Kerosene HTU (U3) Amin Regen. (U11) H 2 S HT Naphtha HT Kerosene Sulfur Unit (U12) TGT (U 13 ) Sulfur (to Catalytic Units) H 2 Treated Water SWS (U 9 ) Hydrogen Production (U7) Sour Water From all Refinery Natural Gas From KOC Oil fields SR Atm Resid SR Diesel ARDS (U5) Diesel HTU (U4) Gas LPG Naphtha Distillates HT Diesel Fuel Gas to refinery heaters Gas Handling & PSA (U 8 ) Refinery H 2 -rich off-gases HT Atm Resid RFCC (U6) Gas Naphtha Distillate Resid Figure Simplified ZOR Refinery Layout (One of three identical trains). 6-36

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