Uhde ThyssenKrupp
2 Table of contents Page 1. Company profile 3 2. Two oil & gas hubs with global reach 4 3. Our oil & gas capabilities 5 4. Upstream oil & gas sector 6 4.1 Scope of services 6 4.2 Concept studies and field development 7 4.3 Facilities upgrades 8 4.4 Oil & gas production 9 4.5 Gas processing 10 5. Oil refining sector 12 5.1 Scope of services 12 5.2 Revamp experience 13 5.3 Challenges facing the refining sector 14 5.4 Technologies 16 5.5 Highlights in refining 18 6. Some of our references 23
1. Company profile 3 Uhde s head office in Dortmund, Germany With its highly specialised workforce of more than 4,500 employees, Uhde, a Dortmund-based engineering contractor, has successfully designed and built over 2,000 process plants throughout the world. Uhde offers a complete range of technology and project delivery services to the oil & gas industry, from upstream production and processing through to downstream oil refining from its global engineering hubs located near Frankfurt, Germany, and in Melbourne, Australia. These are supported by a global network of regional offices. Uhde provides a comprehensive range of services - from project definition, process consulting and licensing of technologies to complete project execution and plant commissioning. In 2002, Uhde acquired refinery specialist Edeleanu to enhance its refining technologies portfolio. Uhde now boasts more than 100 years' proven experience in process technologies and customer-oriented engineering. Uhde Shedden, with main offices in Melbourne, Australia, and Bangkok, Thailand, has been providing high quality front-end and project delivery services to the upstream oil & gas and oil refining industries since 1979. Uhde branch office, Bad Soden, (Frankfurt a. M.), Germany Uhde Shedden Melbourne, Australia
4 2. Two oil & gas hubs with global reach Calgary Bridgeville Houston Dortmund Frankfurt Cairo Moscow Dzerzhinsk Islamabad Al Khobar Abu Dhabi / Dubai Beijing Shanghai Hanoi Mexico City Mumbai/ Pune Bangkok / Map Ta Phut Major technology hubs oil & gas Frankfurt (Bad Soden), Germany and Melbourne, Australia Major engineering and project delivery centres Head office in Dortmund, Germany and other worldwide subsidiaries/offices Johannesburg Perth Melbourne Brisbane As an international plant contractor, Uhde can also boast two major technology hubs for upstream and downstream oil & gas. These can avail themselves of the regional services of our major engineering offices around the globe, allowing us to offer customers local engineering and project delivery capabilities wherever they are. To offer the very best quality our offices are equipped with process simulation, 3D CAD and other state-of-the-art engineering and project delivery systems. Cairo Bangkok Mumbai Johannesburg Mexico City Dzerzhinsk
3. Our oil & gas capabilities 5 Oil refining Upstream oil & gas sector Natural gas (power, industry, domestic) LNG, LPG Feedstock for fertilisers, synfuels, chemicals Transport fuels Oils Feedstock for petrochemicals Uhde s capabilities span the complete oil and gas chain, from upstream production and processing through gas pipelines and LNG / LPG extraction to downstream refining. As a major technology supplier and contractor in the chemical and petrochemical industries, Uhde can also assist customers with the supply of technologies and plants for the processing of natural gas and refinery products to a wide range of further products including hydrogen, ammonia, methanol, synthetic fuels, aromatics, olefins and polymers.
6 4. Upstream oil & gas sector 4.1 Scope of services Coal seam gas production Spring Gully, Australia FPSO (floating production, storage and offtake vessel) Retrofit Singapore Gas treatment plant Dinh Co, Vietnam Gas plant upgrade Temane, Mozambique Multi-discipline engineering International procurement Scheduling & cost control Construction management Strong process resource Latest design tools technology Proven management principles ISO 9001 quality certified company From wellhead to export of stabilised crude oil and processed gas, Uhde s experience includes: wellheads and test separation reservoir support and artificial lift flowlines and gathering systems onshore and offshore production and processing facilities for heavy, waxy and emulsified crudes product storage, export pumping and compression, product metering and loading systems liquid separation and processing gas conditioning, dehydration and dew-point control gas sweetening and acid gas processing natural gas liquids (NGL) recovery NGL fractionation removal of sulphur compounds In addition, we offer an extensive range of services from advisory and study assignments through to execution and delivery of complex large-scale projects. These include: business and opportunity consulting development planning conceptual and front-end studies detailed design global procurement, expediting and inspection project management construction and commissioning operations and maintenance support
4.2 Concept studies and field development 7 For a major stranded gas field in Australia's Browse Basin, Uhde was engaged by an international oil & gas operator to undertake a study to define a potential downstream gas utilisation project. This was followed by a prefeasibility study into the construction of a gas processing plant on a floated concrete pontoon structure. Uhde also works with its customers where innovation and problem-solving precede project execution, for example: debottlenecking studies brownfields modifications plant capacity expansion changing wellstream characteristics flow assurance due diligence operability and constructability studies. Services offered by Uhde include: Field development planning: Selection of development concept and confirmation of project feasibility. Conceptual and technical studies: Process selection, flow assurance, substructure type, soils, drilling plan, processing and export schemes, fabrication/installation, future facilities and lifecycle costing. Process design: Complete process design and bid packages. Front-end engineering design (FEED) packages Project management: Experienced project managers, established project execution procedures, computerised project planning, cost control and quality control procedures.
8 4.3 Facilities upgrades Sasol s Temane gas development, Mozambique BP Vietnam and Petrovietnam, Phase II treatment plant Esso Australia, platform upgrade Uhde was commissioned by Esso Australia to assist in the selection of a field development concept for a new gas field in Australia s Bass Strait. The concepts ranged from maximum use of existing infrastructure in multiple locations to installation of a new platform and pipeline. Uhde defined the process, flow assurance, construction, operations, capital and operating costs and schedule parameters associated with each option. The preferred platform upgrade option was then converted to a FEED package. For Sasol s Temane gas development in Mozambique, Uhde undertook the concept study, followed by basic engineering to increase the capacity of the onshore gas processing plant from 122 to 183 PJ/annum. The facility expansion included additional gas processing units with triethylene glycol (TEG) dehydration, dew point control, HP compression and fiscal metering as well as condensate stabilisation, storage facilities and a utilities upgrade. A dynamic model of the pipeline and a flow assurance study were also performed. Uhde later undertook a pre-feasibility study to define various options to further expand the capacity of the central production facility (CPF) unit to 240-300 PJ/annum. After having been involved in the detail design of the original plant, Uhde was awarded the FEED and detail design & procurement services for the Phase II development of the Dinh Co gas treatment plant for BP Vietnam and Petrovietnam. The Phase II treatment plant has a capacity of 355 mmscfd including a slug catcher, two low-temperature separation trains, gas-liquids stabilisation and condensate stabilisation.
4.4 Oil & gas production 9 Basker Manta oil project, Bass Strait, Australia Origin Energy, Spring Gully, Queensland Uhde established a joint engineering and project management team together with the owner, Origin Energy, to deliver the Spring Gully coal seam gas (CSG) plant in central Queensland. Stage 1 of the project included the drilling and completion of approximately 50 coal seam gas wells and the installation of associated surface infrastructure, including 150km of water and gas gathering lines, the construction of a 36 TJ/day gas processing plant and the supply of water storage facilities. Uhde was engaged on an EPCM basis to design and install topsides modifications to the floating production, storage and offtake vessel, Crystal Ocean for the extended production test and the full-field development phases of the Basker Manta oil project in Bass Strait, Australia. The modifications were undertaken in Singapore. At peak production the FPSO is capable of producing 30,000 to 35,000bpd.
10 4.5 Gas processing Nam Con Son gas project, Vietnam The Nam Con Son Gas Project, the largest energy project ever undertaken in Vietnam, was developed by a joint venture of BP, PetroVietnam and Statoil. It features offshore structures plus a two-phase sub-sea pipeline to deliver gas and condensate from the Eastern Sea, some 350km south-east of Vung Tau, to an onshore treatment plant at Dinh Co. From there, the separated gas is transferred to a metering station at Phu My for distribution to customers. Uhde undertook the detail design of the onshore gas treatment plant and gas metering station as well as assistance for vendor liaison, commissioning planning and on-site technical assistance during construction & commissioning. The treatment plant has a capacity of 356 mmscfd (approx 390 TJ/day) and consists of slug catchers, lowtemperature separation, a gas-liquids stabilisation unit and a condensate stabilisation unit.
11 BassGas project, Bass Strait (Melbourne), Australia Uhde was involved in the BassGas project to develop the Yolla gas field with Clough Engineering as the head EPC contractor. The project comprised the extraction, transport, processing and delivery of sales gas and associated products. The Yolla gas field is located in the Bass Strait, approximately 150km off the Victorian Coast in 80m of water. The onshore gas processing plant is located near Lang Lang, approximately 70km south of Melbourne. The onshore facilities include a fluids receiver and slugcatcher, a gas sweetener and dehydrator, an LPG recovery unit, a fractionator, a condensate stabiliser and product storage and shipping facilities as well as all necessary utilities such as heating medium, power generation, instrument air, fire protection and flare systems. The BassGas field development facilities have been designed for the production of 67 TJ/day of sales gas and produce 3700 barrels/day of condensate, 166 tonnes /day of propane and 95 tonnes/day of butane.
12 5. Oil refining sector 5.1 Scope of services Uhde provides complete service packages for grassroots plants, plant conversions and revamps from the idea, conceptual design and engineering to the construction and commissioning of your plant on a lump-sum turnkey basis. Technology partners Axens / IFP UOP Albemarle BASF Criterion Catalysts ExxonMobil Haldor Topsoe Kellogg Brown & Root Lyondell Sasol Shell Global Solutions Project development After-sales services Studies and concepts Commissioning Laboratory/testing facilities, licensing Construction management Procurement Basic engineering Project management HAZOP studies Detail engineering
5.2 Revamp experience 13 Laser scanning image for refinery revamp project. Uhde has extensive project delivery experience in performing revamps and capacity upgrades to existing refineries to meet market drivers such as: Increased capacity requirements Tighter product quality specifications Increase in octane pool Poor quality or distressed cargo crude feedstock Energy conservation through the use of pinch analysis techniques and/or equipment enhancements Support for planned maintenance turnarounds Rejuvenation of aging facilities This type of work demands a different set of skills from greenfields projects, including: use of laser scanning and photogrammetric as-built data gathering, validation and updating of existing design data and documentation base line performance testing and optimisation knowledge of working within a live operating plant specialised construction techniques such as modularisation to minimise on-site work and personnel exposure to an operating plant environment, and to improve fabrication quality Plant model for a hydrodesulphurisation project showing separate preassembled modules. These projects often start with a comprehensive field test run, followed by optimisation studies to determine the existing capacity and actual performance of the unit before revamp design commences. This knowledge and experience has been gathered over many years and many successful brownfields projects.
14 5.3 Challenges facing the refining sector Fuels are the most important energy sources, particularly in the transport sector. Therefore, the global petroleum market is focussed on the production of state of-the-art environmentfriendly fuels which meet the high quality standards of modern times. To add to environmental protection, a growing interest is also being shown in the use of renewable energies. Changing market requirements and ever more stringent environmental standards necessitate high investments in additional conversion units to convert heavy gasoils and residues into light products, such as gasoline and diesel fuel. Technology providers, designers and catalyst vendors are challenged to deal with feedstocks becoming gradually more difficult to process in the future. Uhde offers refinery customers optimum processes and efficient plants to enable them to meet these challenges and produce high-quality fuels. Two examples are shown on the next page.
15 (Photo left) OMV, Schwechat, Austria Stripper (W3) (Photo right) PETROM S.A., Brazi, Romania New FCC Gasoline Hydrotreating Unit 5.3.1 Clean fuels In September 2006 and May 2007 respectively, PETROM S.A., a subsidiary of OMV Austria, awarded Uhde with contracts for both FEED and EPC LSTK works for an FCC Gasoline Posttreater Project. The aim of the project was to provide facilities for the production of low-sulphur fuel in full compliance with the European Fuels Directive, which came into effect in Romania once it entered the European Union. The new plant consists of a new hydrodesulphurisation unit, a TAME unit, which was widely revamped under the contract, and the corresponding tieins and interconnections with the existing refinery s energy and piping networks. The plant was ready for commissioning at the beginning of March 2009, one week earlier than the contractual target date, and the project was completed with zero lost-time incidents. In 2003 Uhde was engaged by Caltex Australia to undertake the delivery, on an EPCM basis, of major clean-fuels projects at the company's refineries at Lytton, near Brisbane, and Kurnell, on the outskirts of Sydney. At Lytton, the scope included a light-cycle oil (LCO) hydrotreater revamp, and a grass-roots light reformate benzene hydrogenation unit. The work at Kurnell included a diesel hydrotreater revamp, a grassroots light-reformate benzene hydrogenation unit, and a sour water system debottleneck. Following completion of this work, Caltex awarded Uhde a contract for a second diesel hydro-treater at the Lytton site. 5.3.2 Residue upgrading OMV commissioned Uhde to build a deep thermal gasoil unit (TGU) at its refinery site in Schwechat, Austria. It was successfully started up in spring 2009. The new plant processes 2.000 t/day vacuum residue and is based on a process licensed by SHELL Global Solution International. It allows better utilisation of low-value products. This thermal conversion process uses high-quality products like gasoil and naphtha. In order to exploit available resources to the best extent, the TGU plant uses the exhaust heat stream from a gas turbine in a Heat Recovery Unit. This combines the generation of process heat with the generation of electrical energy at the refinery site in Schwechat. The objective of the TGU project is to maximise the yield of high-value products from the residue of the vacuum distillation, thereby replacing the old Visbreaker unit. In addition to naphtha and gasoil, the TGU plant produces a cracked-gas stream, TGU Gas, which is pre-treated inside the TGU plant and sent to the refinery gas network. The bottom-of-the-barrel product VFCR (Vacuum Flashed Cracked Residue) is incinerated to generate heat & power in the refinery s combined power plant. Uhde s scope of services included basic and detail engineering, as well as procurement services, construction management, and supervision of the commissioning activities.
16 5.4 Technologies (Photo left) Aromatics plant BASF/ Fina, Port Arthur, TX, USA (Photo right) Vacuum distillation, ConocoPhilips, Wilhelmshaven, Germany Uhde has extensive experience in undertaking projects based on third-party licences and has worked with a wide range of licensors including Albermarle, Axens/IFP, BASF, CDTech, Criterion Catalysts, ExxonMobil, Haldor Topsoe, KBR, Neste, Sasol, Shell Global Solutions International and UOP for delivery of refinery technologies. In addition, Uhde offers in-house process technology for specialised applications. 5.4.1 Aromatics Uhde's Morphylane process for aromatics extraction is one of the world's leading technologies for the production of high-purity aromatics. It is characterised by maximum product purity, high yields and extremely low energy consumption. More than 70 Morphylane plants with a total annual capacity of over 15 million tonnes of pure aromatics have now been built. Uhde also offers almost the entire range of other technologies for aromatics production such as: reformate hydrogenation pyrolysis gasoline hydrogenation coke oven light oil hydrorefining catalytic reforming xylene isomerisation disproportionation toluene dealkylation. 5.4.2 Crude oil processing & refining Owing to our wealth of experience in the field of refining, we are familiar with most refinery processes, including catalytic processes such as naphtha and middle distillate processing, catalytic reforming, hydrocracking, fluid catalytic cracking (FCC), isomerisation and alkylation, as well as visbreaking, oil and residue gasification, gas processing / treatment and offsites such as utilities and tank farms.
17 5.4.3 Lube oil and waxes Today, Uhde is synonymous with over 95 years of experience and competence in lube oil and waxes technology. Our proprietary production technologies are: solvent extraction deasphalting solvent dewaxing white oil hydrogenation wax deoiling wax hydrogenation lube blending. 5.4.4 Ethers Uhde licenses processes for the production of ethers such as methyl tertiary butyl ether (MTBE), ethyl tertiary butyl ether (ETBE) (including the conversion of existing MTBE plans to produce ETBE), tertiary amyl methyl ether (TAME), tertiary amyl ethyl ether (TAEE), dimethyl ether (DME) and recently the etherification of light naphtha. We have completed a long list of projects with a wide variety of different requirements using proprietary know-how or technologies licensed from third parties or customers - Proof enough of our long experience. 5.4.5 Olefins and solvents Uhde licenses processes for the production of olefins and solvents by processing propene, C 4 olefins and methanol. The processes were developed in collaboration with the research organisation of RWE-DEA AG, now owned by SASOL, South Africa. Uhde is responsible for licensing the above processes exclusively on a worldwide basis. These processes are: Direct hydration of propylene to isopropanol (IPA) Dehydrogenation of IPA to dimethyl ketone (DMK, acetone) Hydrogenation of DMK to methyl isobutyl ketone Direct hydration of n-butenes to secundary butanol (SBA) Dehydrogenation of SBA to methyl ethyl ketone (MEK) Dehydration and condensation of methanol to high-purity dimethyl ether (DME). (Photo left) PCK Schwedt: MTBE complex (Photo right) Recovery of C 4 olefins, Fushun Petrochemical Co., PR China
18 5.5 Highlights in refining Wilhelmshavener Raffineriegesellschaft mbh, Wilhelmshaven, Germany (Photo right) A 9m diameter vacuum distillation column Integration of a vacuum distillation scheme at Wilhelmshaven, Germany Within the framework of the Wilhelmshaven Clean Fuels Project to comply with the requirements of the European Clean Fuels Program, the customer commissioned Uhde to provide a new 87,000 BPSD vacuum distillation unit. The LSTK scope was carried out within budget and on time, despite erection during the winter with exposure to North Sea coastal winds and the need for more than 300 tie-ins, the majority taking place during operation. The vacuum tower produces light vacuum gas oil (LVGO), medium vacuum gas oil (MVGO) and heavy vacuum gas oil (HVGO) that are combined to provide saleable vacuum gas oil (VGO) of tight specification as feed for hydrocracking. Slop wax and vacuum residue are blended with cutter stock to saleable heavy fuel oil (HFO). To enable handling of the new products, we modified the storage and logistical facilities without adding extra tanks, berths or loading arms. This meant extensive work on the several product export pipelines, designing and installing a new and innovative in-line pigging system. In addition, existing tanks were re-assigned and jetty facilities modified.
19 Victorian Engineering Excellence Award ExxonMobil, Altona, Australia Refinery project delivery recognised with engineering award. The clean fuels project at ExxonMobil s Altona (Australia) refinery, for which Uhde provided the basic and detailed engineering, procurement and project management services, was awarded the 2007 Victorian Engineering Excellence Award for Industrial Development and Manufacturing. The judges said they were impressed by the strong and capable management of all aspects of the project". The project, to produce low diesel sulphur and to reduce the benzene content of gasoline, involved substantially reconfiguring the refinery, installing new plant and equipment, changing the service of existing equipment and also refurbishing and reusing previously decommissioned equipment. The scope also included modifications to facilities outside battery limits, various upgrades of other refinery units, utilities design, tie-ins and interface work. The achievement of schedule was paramount to meeting government legislation and Uhde introduced a number of innovative solutions for maintaining schedule despite the difficulties of working within an operating refinery.
20 (Photo left) PCK Schwedt, Germany: FCC main fractionator (Photo right) PCK, Schwedt: Light naphtha etherification An array of projects in PCK* refinery, Schwedt Over a period of 12 years Uhde improved the PCK refinery in Schwedt in a number of stages by adding a diesel hydrotreater, a methyl tertiary butyl ether (MTBE) complex and a C5/C6 isomerisation unit. The crude and vacuum distillation units were revamped and later the MTBE unit was converted to produce ethyl tertiary butyl ether (ETBE). Further selective hydrogenation of MTBE raffinate and oxygenate removal were introduced. On top a propane-propylene splitter was built. Uhde s most recent project there was to build a turnkey plant for the etherification of naphtha with bioethanol. Besides the engineering, supply of all material and equipment, construction management and commissioning supervision, Uhde also trained the operating personnel. The plant, which has an annual capacity of almost one million tonnes of high-quality light naphtha and is based on a process licensed by the Finnish company Neste Jacobs Oy, started production on schedule. The light naphtha produced is used at the refinery as a blending component for the production of modern, environmentfriendly gasolines. The new plant raises the octane number of this fuel component by almost two points and considerably increases the percentage of replenishable feedstocks or renewable energy sources contained in the fuel. * PCK Raffinerie GmbH is a company of the mineral oil companies Ruhr Oel GmbH, Shell Deutschland Oil GmbH and AET-Raffineriebeteiligungsgesellschaft mbh (a company jointly owned by Total Deutschland GmbH and AGIP Deutschland GmbH).
21 Shell Refining Australia, Geelong, Vic., Australia Shell refinery projects demonstrate full range of skills Uhde s capability from conceptual design and refinery-wide optimisation studies through to complete EPCM project delivery is demonstrated through Uhde s recent project experience with Shell Australia, with whom the company has a 20+ year association. Shell operates refineries at Geelong (Victoria) and Clyde (NSW). In 2003, Uhde was awarded the contract for EP services for the hydrodesulphurisation unit (HDS2) at Shell s Geelong refinery. The project involved a 6000 tpd hydrodesulphurisation unit based on Shell global solutions international (SGSI) technology and designed to meet a 50ppm sulphur limit. Since startup the unit has been operating well and is capable of achieving the 2009 sulphur limit of 10ppm without modification. In 2006 Shell awarded Uhde the FEED and EP contracts for the fluid catalytic cracking unit (FCCU) particulates reduction project at the Geelong refinery and in 2007 the FEED and EPCM contracts for the revamp of the diesel 3500 tpd HDS unit at its Clyde refinery to meet the 2009 sulphur limit of 10ppm. The progression from project delivery into frontend assignments has continued with Shell, in 2007, engaging Uhde to develop their margin improvement projects for the Geelong refinery. This assignment initially involved a team of engineers scoping projects to improve refinery margins. Uhde performed the process design and assisted Shell in preparing documentation for its scouting and concept selection phase. As well as equipment and hydraulic checks, the work included full process simulations (including the crude unit), calibration against test runs, thermal pinch analysis of preheat trains in the crude and fractionation units and some new heat integration between units. At the completion of the concept phase, Uhde s role progressed through to the FEED and EP phases of the work.
22 (Photo left) MOL Hungarian Oil & Gas Plc. Szazhalombatta / Budapest, Hungary 6,696 t/day straight run (SR) gas oil hydrodesulphurisation unit Completion 2005 Scope: lump-sum turnkey (Photo left) Polski Koncern Naftowy ORLEN S.A. Plock, Poland 3,420 t/day FCC naphtha hydrodesulphurisation unit Completion 2006 Scope: EP (Photo right) Turkmenbashi, Turkmenistan Vacuum distillation Lube oil in Turkmenistan Lube oil was the starting point for our German refining engineering center (Edeleanu) some 100 years ago, and we have kept improving our proprietary process know-how ever since. Turkmenbashi Refinery commissioned Uhde to license and design a lube oil complex consisting of vacuum distillation, furfural extraction, methyl ether ketone (MEK) dewaxing, lube oil hydrofinishing, and blending units. Two desulphurisation projects in parallel, LUKOIL, Bourgas, Bulgaria Bulgarian company LUKOIL Neftochim Bourgas AD, part of the Russian petroleum group LUKOIL, commissioned Uhde and one competitor, in parallel, to each perform a FEED plus detailed cost estimate on diesel hydrodesulphurisation based on a process package from HALDOR TOPSOE AS. This work formed the foundation on which Uhde won the subsequent contract to build the plant at Bourgas on the Black Sea. On top and simultaneously Uhde executes a gasoline desulphurisation unit taking a process from Axens S.A.. The refining plants for the production of low-sulphur fuels have respective annual capacities of 1.6 million tons of diesel and 1.1 million tons of gasoline. Uhde s scope of supplies and services comprises the detail engineering, supply of equipment, construction support, commissioning supervision, and training of the operating personnel. With a sulphur content of less than 10ppm (parts per million) future production will comply with the EU fuel directive in force since 2005. This marks the Bulgarian refinery s conversion to low-sulphur fuels.
6. Some of our references 23 Crude oil and vacuum distillation Olefins & solvents Aromatics and derivates 50 units 40 units 120 units Lube oil, waxes & white oil Hydrotreating Tank storage facilities and offsites 50 units 60 units 30 units Alcohols, ketones, ethers Conversion and reforming Others 60 units 90 units 40 units Upstream oil & gas Offshore projects 50 units Onshore projects 60 units Uhde s expertise in oil refining has been acquired through the execution of more than 600 projects worldwide.
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