FAST TRACK PRODUCTION SOLUTIONS Early Production Facilities Field Diesel Units Crude Oil Topping Units Gasoline Refineries
Pyramid E&C is a multicultural company having the core competence of delivering comprehensive solutions for Oil and Gas Production, Storage, Transportation and Refining facilities. We endeavor to service Oil and Gas asset owners in all stages of development, commencing from Feasibility Studies through Engineering, Project Execution, Delivery and Operation of facilities. Pyramid E&C specializes in fast track deliveries by investing in pre-engineered and/or pre-fabricated equipment ready in stock. Most of the solutions offered by us are in modular construction and can be shipped in sizes to suit site logistics. Pyramid E&C has its own Modular Fabrication Yard measuring 20,000 m² with 8,000 m² of covered area. The yard is close to Mundra port in Gujarat, Western India. Due to its proximity to jetty, Pyramid E&C can ship large process equipment and modules weighing up to 800 tons in a single piece. About Pyramid E&C with option to purchase. We also carry out financial engineering and participation for qualified opportunities. Pyramid E&C has flexible business models to suit needs of asset owners including rentals of production systems with or without operation support or Build, Own and Operate services Ecomar Refinery, Fujairah, UAE Our Clients: 2
5,000 BOPD Early Production Facility, Sweet Crude Pyramid E&C has generic, pre-engineered modular units available for rental for 5,000 BOPD Crude Oil Production. These facilities fit into several containerised modules suitable for sea and road transport. The rental EPF is reasonably complex to provide saleable product for mid-range Crude Oil. The use of the unit on a rental basis allows the customer to start production and thus revenue generation as soon as possible. Our robust equipment design ensures hassle-free operation for customers. Design Basis The following lists the inlet parameters and product specifications for the 5,000 BOPD rental EPF. Inlet Parameters Capacity : 5,000 BOPD Nature of Crude : Sweet Crude Grade : API 22+ Product Specification BS&W (volume) : 0.5% Salt Content : 8 PTB RVP : <10psia Process Description: First Stage Separation: The well stream fluid from the Inlet Manifold is flashed in the First Stage Separator which operates at a pressure of 20 bar(g).this provides the initial separation between oil, gas and water. Crude Preheat Exchanger: The Oil from the First Stage Separator is heated in Stabilised Oil-Crude Interchanger by recovering heat from treated Crude exiting the Heater Treater. Second-Stage Separation: Heated Crude along with Condensate from the Flare Knockout Drum enters the Second Stage Separator which is a Three-Phase Separator. It operates at a pressure of 5 bar(g) for oil, gas and water separation. Gas from the Separator is flared. The produced water is cooled prior to disposal. Crude Stabilizer: Crude from Second Stage Separator is stabilized in a Heater Treater to remove light ends and achieve required RVP of the Crude. Associated gas is sent from Heater Treater to Flare. In case of desalting requirement, the Heater Treater will be provided with an electrode grid and Wash Water System to achieve the required Crude specifications. Crude Oil Storage: Stabilized Oil is pumped through the Stabilized Oil-Crude Interchanger, where it is cooled by the Crude feed. The stabilized oil is further cooled by an Air Cooler and then stored in Crude Oil Storage Tanks. Crude Oil Transfer: Stored Oil is pumped using Crude Oil Transfer Pumps to loading bays for truck loading. Utilities: Supporting utilities required for operation can be either be tapped off from the existing unit or provided along with the facility. 3
10,000 BOPD Early Production Facility, Sour Crude Pyramid E&C has generic, pre-engineered modular units available for rental for 10,000 BOPD Crude Oil Production. These facilities fit into several containerized modules suitable for sea and road transport. The rental EPF is reasonably complex to provide saleable product for mid-range Crude Oil. The use of the unit on a rental basis allows the Customer to start production and thus revenue generation as soon as possible. Our robust equipment design ensures hassle-free operation for customers. Design Basis The following lists the inlet parameters and product specifications for the 10,000 BOPD rental EPF. Inlet Parameters Capacity : 10,000 BOPD Nature of Crude : Sour Crude Grade : API 15+ Product Specification BS & W (volume) : 0.5% Salt Content : 8 PTB RVP : <10psia H2S Content : 20 ppm wt. Process Description: First Stage Separation: The well stream fluid from the Inlet Manifold is flashed in the First Stage Separator, which is a three-phase separator and operates at a pressure of 20 bar(g). This provides the initial separation between oil, gas and water. Crude Preheat Exchanger: The Oil from the First Stage Separator is heated in Stabilized Oil-Crude Interchanger by recovering heat from treated Crude exiting from Stabilizer bottom. Second Stage Separation: Heated Crude along with Condensate from the Flare Knockout Drum enters the Second Stage Separator, which operates at a pressure of 5 bar (g) for oil, gas and water separation. Gas from the Separator is flared. The produced water is cooled prior to disposal. Desalter (optional): The Oil from the Second Stage Separator is pumped to the Desalter using Desalter Feed Pumps. Wash Water is pumped through a Wash Water Pre-Heater and then mixed with the Crude Oil using a mixing valve or static mixer. The brine is mixed with the produced water for disposal. Crude Stabilizer: Desalted Crude is stabilized in a Stabilizer Column provided with reboiler (Nitrogen Stripping optional). This process removes H2S and also reduces the Reid vapour pressure of the Crude. The gas from the Stabilizer is flared. Crude Oil Storage: Stabilized Oil is pumped through the Stabilized Oil-Crude Interchanger, where it is cooled by the feed. The Stabilized Oil is further cooled by an Air Cooler and then stored in Crude Oil Storage Tanks. Crude Oil Transfer: Stored Oil is pumped using Crude Oil Transfer Pumps to loading bays for truck loading. Utilities: Supporting utilities required for operation can be either be tapped off from the existing unit or provided along with the facility. 4
Field Diesel Units Field Diesel Units are effective in areas where there is a ready supply of Crude Oil but limited supply of Diesel fuel, such as unpopulated areas, remote oil fields or drilling locations. A Field Diesel Unit can fulfill local fuel requirements for power generation and Drilling operation. This unit extracts the Diesel component from the Crude Oil and then blends rest of the products back to Crude Oil. The Field Diesel Unit is split into easily transportable skids; it is quick to install and self-sufficient. The unit can be started when needed and stopped when the tanks are full. The Diesel produced by these units largely depends on the type of Crude Oil, the lighter varieties will provide greater diesel yield and higher cetane number. Process Description: The Crude Oil is pumped from Storage Tanks and pre-heated in Crude Interchanger before further heating in a Hot Oil Heater. The temperature of Crude Oil at outlet of Heater is carefully controlled for optimal operation. The heated Crude Oil is flashed into vapour and liquid fractions in the flash zone of Distillation Column. At certain temperature, the Diesel fraction is drawn into Diesel Stripper for flash point control and sent to storage after cooling. The light fraction (condensate) is condensed in Overhead Condenser and collected into Reflux Drum. Part of condensate is fed as reflux and the balance is blended with the residue from the Column bottom and mixed with the Crude Oil. The uncondensed gases are vented to Flare system. Supporting utilities required for operationcan be tapped off from the existing system unit (Power, IA/PA, CBD, Flare etc.) or provided along with the unit as per the requirement. 5
Crude Oil Topping Units Pyramid E&C builds topping refineries which are suitable for light, low Sulphur Crudes to produce automotive fuels, i.e., Diesel and Gasoline from Crude Oil and Condensate. The building blocks of these refineries include Desalting, Atmospheric Distillation, and Side Stream Stripping. The yields and the treatment required depend on the API gravity, Sulphur and other properties of the Crude. Utilities include a Fuel Gas System, IA/PA System, CBD System, Water Treatment System, Steam System, etc. and Tanks for feed and product storage. Equipment Crude Charge Pump Fired Heater Distillation Column Flare System Stripper Column Pumps Chemical Injection System Desalter System Diesel Generator Set Steam Boiler Fuel Oil System Storage Tanks Truck Loading Terminal CBD System Water Treatment System Flare Systems Product Transfer Pumps Process Description Crude Oil is heated in pre-heat train and then treated in a Desalter Unit where salt in water, or brine, is removed. The Crude Oil leaving the Desalter Unit is heated in a Fired Heater from which it enters the flash zone of an Atmospheric Column. Natural Gas condensate can also be included in the feed or introduced directly into the Column. The Crude Oil mixture is separated into different cuts by boiling range. The Crude Column produces Naphtha, Kerosene, and Diesel as the side streams. The Crude Column bottom product, also called Reduced Crude is used as Fuel Oil. In large Atmospheric Columns, pump arounds are used for intermediate heat recovery in addition to product feed exchangers to the crude feed which reduces furnace firing. For small refineries of the order of 10,000 BOPD, allowing all heat removal to occur in the Overhead Condenser often minimizes CAPEX. Products are withdrawn from the tower under temperature control; by simulation modeling the tower, it is possible to predict the temperature, pressure, and number of trays required to produce the desired product specifications. The tower products are stripped of light ends using steam or Reboilers. This controls the inlet specification such as flash point of the product. Depending on the viscosity, Reduced Crude can be used as Fuel Oil directly. Alternatively, Kerosene or Diesel can be blended with the Reduced Crude to produce Fuel Oil. 6
Gasoline Refineries Pyramid E&C builds plants for processing Naphtha to produce Gasoline for automotive usage. These plants, also termed as Hydro-Skimming Units, can be added downstream of the Topping Unit to consume Naphtha stream for production of Gasoline. Equipment Crude Charge Pumps Fired Heater Desalter System Naphtha Hydrotreater Light Ends Processing Isomerization Unit Hydrogen Purification Unit Diesel Generator Set Chemical Injection System Truck Loading Terminal Product Transfer Pumps Crude Pre-Heater Distillation Column Debutanizer Flare System / SRU Naphtha Splitter Reformer Pumps Fuel Oil System Steam Boiler Storage Tanks The building blocks of the Naphtha Treatment line include Hydrotreaters, Naphtha Splitter, Reformer and Isomerization Units. The yields and the treatment required depend on the properties of the Crude Oil and Product Specification. The Reformer also produces Hydrogen as by-product, which is utilized in Hydrotreater. The Hydrotreater treats Naphtha and removes sulfur compound thereby preventing catalyst poisoning in downstream processign units. The plants can be supplied complete with utilities including Hydrogen Purification and Sulphur Recovery Units. Crude Oil is treated in a Topping unit, which yields Naphtha, Kerosene, Diesel and Fuel Oil as products. Amongst these, the Naptha stream is utilized for production of Gasoline. The wide Naphtha cut is fed into Debutanizer to separate LPG from Naphtha. Naphtha is then Hydrotreated using a catalytic process to remove Sulphur and fed into Naphtha Splitter to separate Light and Heavy Naphtha. The Light Naphtha is processed in an Isomerization Unit to increase its octane number prior to blending into the Gasoline pool. The Heavy Naphtha is processed in a Reformer, which creates aromatic rings to increase octane number and liberates Hydrogen. The Reformer is a fixed-bed, semi-regen type catalyst system. The Hydrogen is purified in a Pressure Swing Absorption Unit and used for Hydrotreating Naphtha. The Gasoline produced is stored in Gasoline Storage Tank. The Light Ends Processing System fractionates Butane for use in Gasoline Blending, or Propane and Butane for product LPG (Liquefied Petroleum Gas) which is stored in Mounded Bullets. The Kerosene side stream goes to Kerosene Storage Tank, while Diesel product goes to Diesel Storage. Depending on the viscosity, Reduced Crude can be used as Fuel Oil directly. Alternatively, Kerosene or Diesel can be blended with the Reduced Crude to produce Fuel Oil. 7
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