Abdulkader- Djellout Algeria

Oil Refineries upgrading Program

For the production of clean fuels

In Algeria

OPAEP Symposium – Bahrain – Oct 25th to 27th - 2010

SONATRACH – Downstream Activities

Refining Division

2

CONTENTS

1. Crude refining activity in Algeria

Existing facilities for each refinery.

Present scheme for production of gasoline and Diesel

2. Present status of motor fuels in Algeria

3. Rehabilitation and adaptation program

Principles and objectives .

History of actions .

Program for each refinery.

Future Lay outs.

4. Present status for each project

5. Other projects to be implemented

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

1- Crude Refining

Activity

In Algeria



Skikda

Hassi Messaoud

In Aménas

2,5 MMT1973 et 1984

2,7 MMT1964

15 MMT1980

1,2 MMT1979

0,3 MMT1980

Motor fuels

Lub-oil Bitumen Aromatics

Arzew

Existing Refineries

Algiers Refinery

Location: 10 Km South of Algiers (on 200 Ha)

Final Products: Motor Fuels and LPG (For Local Market)

Naphtha et fuel oil (For Export)

Shipment: trucks (LPG)

pipelines

sea vessels


BLOCK FLOW DIAGRAM - ALGIERS REFINERY

To

pp

ing

Un

it

STA

BIL

ISA

TIO

N

Ga

s-

Pla

nt

Gasoline

Blending

Gas - oil

Blending

RESIDU

LPG

LPG

LPG

REFORMATE

Light Naphtha

Heavy Naphtha

KEROSENE

LGO

HGO

Cru

de.

2700.0

00

FUEL-GAZ

PROPANE

BUTANE

RegularGasolin

e

Premium

Gasoline

NAPHTHA

JET

DIESEL

Fuel - oil

(LS)

RE

FO

RM

ING



view of Algiers Refinery

Arzew Refinery

Location: Industrial Area in Arzew (150 Ha)

Final Products: Motor Fuels + LPG + Bitumen

(For Local Market)

Lubricants (For Local Market

and Export )

Naphtha and Fuel-oil (For Export)

Shipment: by trucks

pipelines

sea vessels

rail way


Existing Refineries

BLOCK FLOW DIAGRAM - ARZEW REFINERY

TO

PP

ING

UN

IT

Cru

de 2,5

M

LPG

Light Naphta

LPG

Heavy Naphtha

KEROSENE

LGO

HGO

Gas - oil

Blending

Gasoline

Blending

FUEL

GAZ

PROPANE

BUTAN

E

NAPHTH

A

Regular Gasoline

Premium gasoline

JET

DIESEL

Fuel - oil (LS)

Oxydised Bitumen

Fuel - oil (HS)

Road Bitumen

RE

FO

RM

ING

CA

TA

LY

TIQ

UE

Gas P

lan

t

ST

AB

ILIS

AT

ION

ES

SE

NC

ES

Blo

win

s

Un

it

Vacu

um

Dis

till

ati

on

Imp

ort

ed

Red

uced

Cru

de

278.8

00 T

Lub 1

Lub 2

Lube

Blending

EXPORT

Lubes

Grease

Wax

Base Oils



view of Arzew Refinery

Skikda Refinery

Location : Industrial Area in Skikda, Land Area 190 Ha

Final Products : LPG + bitumen (For Local Market)

Motor Fuels (For Local Market

and Export)

Fuel-oil (For Local Market

and Export) and

Naphtha (For Export)

Aromatics(For Local market

and Export)

Shipment: by trucks (for Bitumen & Toluene))pipelines (Motor Fuels, LPG)sea vessels


Existing Refineries

To

pp

ing

un

ts (

2)

GAS-PLANT

(3units)

Kerosene

Sweetening

PX

Cri

sta

llis

ati

o

n

Gasoline

blending

Gas - oil

Blending

FUEL-GAZ

PROPANE

BUTANE

NAPHTHA

BENZENE

TOLUENE

Regular Gasoline

Premium Gasoline

Unleaded Gasoline

MELANGE-XYLENES

PARA-XYLENE

JET A1

DIESEL

Fuel - oil (LS)

Fuel - oil (HS)

Oxydised Bitumen

Road Bitumen

Cru

de

Imp

ort

ed

Red

uc

ed

Cru

de

BLOCK FLOW DIAGRAM - SKIKDA REFINERY

277.1

00

RE

FO

RM

ING

CA

TA

LY

TIQ

UE

(2 u

nit

s)

BT

Ex

tra

cti

on

Va

cu

uu

m

Dis

till

ati

on

Blo

win

g

Un

it

15.0

00.0

00



view of Skikda Refinery

Hassi-Messaoud Nr 1 & 2 Refineries

Location: South Industrial Center (SH-DP)

Final Products: Motor fuels (For Local Market)

Shipment: trucks


Existing Refineries

BLOCK FLOW DIAGRAM - HASSI-MESSAOUD REFINERIES

1. HASSI-MESSAOUD 1

2. HASSI-MESSAOUD 2

STA

BIL

IS.

T

O

P

P

I

N

G

Crude

LPG

RHM2

LPG

Unit

FUEL.GAS.

BUTANE

NAPHTHA

JET

DIESEL

RESIDU

T

O

P

P

I

N

G

R

E

F

O

R

M

I

N

G

Gasoline

Blending

G P LUNIT LPG/RHM1

NAPHTHASLOPS

REFORMATE

Regular gasoline

Premium Gasoline

JET

DIESEL

RESIDU TO SLOPS

Crude

10

0.0

00

In-Amenas Refinery

Location: Industrial Area of In- Amenas (SH-DP))

Final Products: Motor Fuels (For Local market)

Shipment: by Trucks


Existing Refineries

Crude

300.00

0

MTA

Fuel-Oil

Naphtha

Kerosen

eDiesel

T

O

P

P

I

N

G

Gasoline Blending

sweetening

Fuel-

Gaz

JET

Diesel

Slops

Vers Slops

Regular

Gasoline

Premium

Gasoline

BLOCK FLOW DIAGRAM - IN AMENAS REFINERY


2- Present status

of Motor fuels

in Algeria


Present status of motor fuels in Algeria

Gasoline

At the present time the local market consumption is about 2,3

million Tons/Year of gasoline including 3 types:

Regular leaded gasoline RON 89 (20 % of the market),

Premium leaded gasoline RON 96 (70 % of the market),

Unleaded gasoline RON 95/MON 85 (10 % of the market),


Leaded Gasoline Specifications for the local market

Specification Unit Regular Gasoline

Premium Gasoline

Specific gravity Kg/m3 710 – 765 730 – 770

RON 89 96

RVP up to 37.7 °C (summer/winter)

Max Bar 0.65 / 0.80 0.65 / 0.80

10 % vol 70°C max 70°C max

50 % vol 140°C max 140°C max

95 % vol 195°C max 195°C max

Distillation ASTM D86

PF 205°C max 205°C max

Sulphur content ppm 100 max 100 max

Lead content g/l 0.40 0.40

Limits Premium 95 Specs Units

Min Max

RON

MON

95

85

Benzene % Vol 5

Specific gravity Kg/m3 725 780

Sulphur ppm 100

Distillation ASTM 86 70°C 100°C 180°C

210°C Final Poi nt

% Vol

15 40 85

90

47 70

215

Reid Vapor Pressure Winter / Summer

Kpa

80 / 65

Unleaded Gasoline Spécifications for the local market


Comments:

The specification of unleaded gasoline in Algeria doesn’t

mention any limit for aromatics, olefins and oxygen ( the

unleaded gasoline RON 95, is similar to leaded premium

gasoline RON 96, with a quite wide gravity gap).

The benzene content is limited to 5 % vol. (means in

the limit of the skikda refinery production quality)

Gasoline Status in Algeria (cntd)

Unleaded gasoline specifications (cntd)


Gasoline Status in Algeria (cntd) Gasoline Average Qualities for the Local Market

lead content was reduced by the Regulation from 0.65 to

0.40 g/l. max, from the year 2000

According to the regional demand of gasoline and the

available basestocks in each refinery for gasoline

blending, lead content at the present time is as follows:

0.10 to 0.15 g/l at Skikda refinery,

0.20 to 0.30 g/l at Arzew,

0.40 g/l at both Algiers and Hassi-Messaoud

refineries.


Sulphur average content : less than 30 ppm (due to

good crude quality and good quality of basestocks),

Aromatics content : 50 to 60 % vol. (due to use of

reformate or aromatic byproducts as basestocks),

Benzene content : 2 to 3 % vol.

Gasoline status in Algeria (cntd.)

Gasoline Average Qualities / Local Market (cntd.)


Gasoline blending

Butane

Light Naphta

Reformate

Raw Toluene

Heavy aromatics

rafinate

Leaded Regular

RON 89

leaded Premium

RON 96

Typical scheme for gasoline blending in Algeria

Unleaded

Gasoline

RON 95

Isopentane


Basestocks for gasoline blending for local market

RA1K RA1G RA1Z RHM2

Butane X X X

Light Naphta X X X X

Naphta ex-deIsoC5 X

Reformate X X X X

Iso-pentane X

Pentane ex-Reformate

X

Raffinate X

Raw Toluene X

Heavy aromatics. X


The Algerian market consumes currently up to 7 millions Tons / year of Diesel

Specification Unit Gasoil

Specific density Kg/m3 810 – 860

Cetane number 48 min

Flash point °C 55 min

Pour point /winter. °C -12 max

Pour point /summer. °C -7 max

65 % vol 250°C min

90 % vol 350°C max Distillation ASTM D86

PF 390°C max

Sulphur content ppm 1 500 max

Diesel fuel :


Diesel status as fuel in Algeria .(cntd.)

Average quality of diesel / Local market

Real sulphur contents :

Less than 800 ppm at Skikda,

Between 900 to 1200 ppm at the other refineries.

Nota:

Before Year 2005, Skikda refinery has produced Diesel for

export (in the limit of 350 ppm max sulphur content ) from SR

Gas-oil mixed with kerosene.

This was achieved with an adequate selection of crude fields to

feed the refinery (less than 500 ppm of sulphur).


Gas-oil blending

SR Light Gas-oil

SR Heavy Gas-oil

Vacuum Gas-oil

Diesel

SR Kerosene

Typical scheme for Diesel blending in Algeria


Basestocks for Diesel production for Local Market

RA1K RA1G RA1Z RHM2

SR Kerosene X X X X

SR Light Gas-oil X X X

X

SR Heavy Gas-oil X X

Vacuum Gas-oil X


3- Rehabilitation

And Adaptation Program

of the existing Facilities


Main objectives of the Rehabilitation

and Adaptation Program

Proceed with a large refurbishment program in order to sustain the production level of the refineries for the medium and long term,

Modernize the instrumentation for a better

optimization of the various Units,

Produce clean fuels for the local market and for export, for a better environment


33

This program deals with the achievement through the company own means

and other specialized companies in the sector of tehnical diagnosis studies,

debottlenecking of process Units and definition of the master plan of the

instrumentation modernization.

From October 2001 to March 2003, we worked after an open tender for

each subject:

For Skikda Refinery: with Foster Wheeler France (for the process and

technical study and instrumentation study)

For Arzew Refinery: with KBR (USA) and Honeywell-Belgium,

For Algiers Refinery: with Sofresid (France) and Foxboro-France

For Hassi-Messaoud Refinery: with the same two companies

History of the activities


1. Evaluation of the various reports and options proposed by the

consultancy companies

Selection of the options to be implemented in each refinery

Identification of all the small projects which do not need deep

engineering work, in order to implement them immediately

Agglomerate all the other subjects in one, two, or three major

EPC projects, including capacity increase

Minimize the shutdown duration for construction and tie-ins

History of activities (ctnd)


2. Issuance of call for tenders for selection of consultancy companies (one

for each refinery) which will be involved in three stages :

Preparation of FEED package,

Technical support for the evaluation of the bids to be received for

the EPC projects,

Follow up of projects by the consultancy companies

History of activities (ctnd)


The rehabilitation program will be implemented simultaneously

in the three coastal refineries,

Shutdowns of existing units will be minimized for the

rehabilitation work,

The normal investment program for maintenance purposes will

be continued in parallel at each refinery,

Rehabilitation Program for each Refinery



Skikda Refinery


Revamp and Expansion• Existing CDUs/ Gas Plants with 10% capacity increase

•Add / Modify existing utilities / offsite facilities.

MODERNISATION

• Of the Instrumentation with

DCS / APC/Optimisation type

.New Blast Resistant

Control Room.

• Electrical network with

ECS .

RECONFIGURATION

• Revamp of Reformer Nr 1

• Reconfiguration of aromatics

chain (revamp of the Benzene

/Toluene recovery unit

• Addition of a cristallization

unit and a mixed xylene

isomerisation unit

CLEAN FUELS

• 02 New NHT/ light naphta isom Units

• 02 New DHDS Units

Rehabilitation

Program

The rehabilitation and adaptation program includes three main EPC

projects:

Project 1: Electrical network for common facilities,

Project 2: Rehabilitation and increase capacitiy for fire fighting network,

Project 3: includes the following operations,

Rehabilitation of existing facilities (Toppings and gas-plants) for the

treatment of the future crude (with upgrading and modernisation of

obsolete equipments),

Rehabilitation and upgrading of Magnaforming Unit,

Upgrading of aromatics production units, with production

maximisation (supply by the two reformings, and setting up of xylene

isomérisation unit) with upholding a significant production of gasoline

Rehabilitation of Utilities production and distribution,

Rehabilitation and modernization of electrical equipments, upgrading

Rehabilitation program of Skikda refinery


Achievement of two Units for light naphta isomerisation,

Rehabilitation of electrical equipments, upgrading of electrical

network ,

Achievement of two Hot Oil systems,

Achievement of new unit for hydrogen purification,

Achievement of new unit for demineralizing Boiler Water,

Achievement of a unit for condensat recovery and treatment,

Instrumentation modernization (implementation of DCS with a

centralized control room),

Upgrading of the Quality control laboratory,

Rehabilitation program of Skikda refinery (cntd)


Achievement of a new unit for acid water treatment

Achievement of a new unit for effluent treatment

Achievement of new unit for nitrogen production,

Laying out and extension of various reception, storage,

shipping facilities of oil products,

Rehabilitation program of Skikda refinery (cntd)



Arzew Refinery


Revamping• Existing CDU/ Gas Plants for 50% higher crude oil processing capacity


MODERNISATION



.Main opérating

Central Room.

• Of the Electrical network with

ECS type.

ADAPTATION FUELS

•01 New Unit for Isomerization

Gasoline to improve the

LSRN characteristics

•01 New Unit for Diesel

Hydrodesulphurized

Rehabilitation

Programme

The rehabilitation and adaptation program includes three major EPCprojects

Project 1: Instrumentation modernisation (implementation of DCS + APC

+ optimisation with a centralized control room),

Project 2: Rehabilitation of electrical equipments, upgrading of electrical

network

Project 3: Main EPCC

Capacity increase for Topping and Gas plant,

Adaptation for utilities and storage units,

Adaptation and modernization of effluent treatment unit,

Setting up of Hot Oil unit,

Setting up of light naphta isomerisation unit,

Setting up of gas turbine for electricity production,

Rehabilitation program of Arzew refinery



Algiers Refinery


Revamping• Existing CDU/ Gas Plants for 35% higher crude oil processing capacity


MODERNISATION



.Main opérating Central Room.

• Of the Electrical network with

ECS type.

RECONFIGURATION

• New Reforming Unit (CCR mode).

• New RFCC Unit for the gasoline

and Diesel production.

ADAPTATION FUELS

•01 New Unit for Isomerization Gasoline to improve the

LSRN characteristics

•01 New Unit for clean Diesel

Rehabilitation

Programm

The rehabilitation and adaptation program includes one large EPCproject:

Topping and gas plant capacity increase.

New MS Block (NHT + Isom + CCR Reforming)

RFCC and Merox Units

Rehabilitation of Utility production and distribution facilities

MOderniztion of the Instrumentation (implementation of DCS with a

centralized control room),

Rehabilitation of electrical equipments , upgrading of electrical network, and

setting up of a gas turbine,

New Waste Water Treatment Unit (biological type)

Rehabilitation program of Algiers refinery


Opérations included in one large EPC project:

Rehabilitation of existing facilities (Topping Unit and Reforming Unit with a

new catalyst).

Rehabilitation of the Utility production facilities and distribution network,

Rehabilitation of electrical equipments, upgrade of electrical network.

Instrumentation modernization ( DCS with a blast resistant control room),

Rehabilitation of underground piping

Rehabilitation program of Hassi Messaoud refinery


future configuration

of the refineries


GP – I

BBU

KTU-I

CD

U -

I

LNHT-I/

LNISOM-I

LNHT-II/

LNISOM-II

DHDS-I

DHDS-II

GP – II

NHDS/

REFORM-I/

PLAT SPL

NHDS/

REFORM-II

ARU

PX

REC.

UNIT

KTU-II

XYL-ISOM

UNIT

CD

U -

II

IMPORTED

VAC. RESIDUE

GAS OIL

OXIDISED BITUMEN

ROAD BITUMEN

GP – III

CRUDE

RC

O

LOW SULPHUR FO

KERO

KERO

PROPANE

BUTANE

LG

O+

HG

O

PARAXYLENE

RC

OLPG

TO GASOLINE POOL

TO ATF POOL

BENZENE

TOLUENE

LGO

HGO

NAP B

NAP A

C6 CUT

C8+ CUT

TOLU. CUT

CR KERO TO DIESEL POOL

HY. AROM.

HY

. A

RO

M.

C5

CUT

NAP B

NAP A

C6 CUT

PROPANE

BUTANE

C6 CUT

LPG

C6 C

UT

TO DIESEL POOL

EXCESS

KERO

TO NAPHTHA POOL

ISO PENTANE

PSA

FG

H2 TO CONSUMERSH2 RICH GAS

H2 RICH

GAS TO PSA

HY ARO. TO GASOLINE

TO NAPHTHA POOL

CR LGO TO DHDS

CR HGO TO DHDS

EXCESS C8+ TO GASOLINE

NAP C

NAP C

LP

G

Future configuration of Skikda Refinery

EXISTING REVAMP NEWLEGENDE DES COULEURS PAGE 50

CDU

STAB.2

14 346

BPSD

LSRN 2

HSRN 2

HSRN 1

LSRN 1 STAB.1

18 982 BPSD

FUTURGas Plant

6 289 BPSD

KERO

LGO

HGO

VGO LUB

REHABILITATION ET ADAPTATION

DIESEL

HDS

36500 BPSD

Isomerisation

7500 BPSD

BHM 90 000BPSD

Propane

Butane

Naphta

Ess.Super

Ess.NormaleUnibon Platformer

8500 BPSD

Brut Résidu Atmosphérique

Kérosène

Gasoil

Fuel BTS

Arzew Refinery


Future configuration of Algiers Refinery


4- Present status

of the rehabilitation

Program

at each refinery


For RA1K:

Project 1: Modernization of electricity

Contractor: AREVA (France) started on March 30th 2008

Physical progress : 85%

Project 2: Rehabilitation and capacity increase of fire fighting network.

Contractor: ETTERKIB (Algeria) started on February 23rd 2008

Physical progress: 77%

Project3: Rehabilitation and adaptation of production facilities.

Contractor: SAMSUNG Engineering (South Korea) started on

August 13th 2009

Physical progress: 28%

Present status of the rehabilitation program at Skikda refinery

.


For RA1Z:

Project 1: Instrumentation modernization,

Contractor: Honeywell (Belgium), started on February 9th,2004

Physical progress : 98%.

Project 2:Electricity modernization.

Contractor: CEGELEC SAS (France), started on March 1st 2008

Physical progress: 92% .

Project 3: Rehabilitation and adaptation of production facilities.

Contractor: Groupement HYUNDAI Eng & Co Ltd / HANWHA /

DAEWOO started on February 23rd, 2009.

Physical progress: 39%.

Present status of the rehabilitation program at Arzew refinery


For RA1G:

Contractor : TECHNIP France.

Physical Progress: to be launched soon.

For RHM2:

The adaptation and rehabilitation program will be conducted

according to the following planning:

Consultation for PMC: 6 months: April 2011.

FEED studies: 15 months : June 2012.

Consultation for EPC: 12 months : July 2013.

Realisation EPC: 48 months :August 2017.

Present status of the rehabilitation program at both Algiers

& Hassi-Messaoud refineries .


Work completion:

End of 2011 for Arzew

End of 2012 for Skikda

End of 2013 for Algiers

August 2017 for Hassi-Messaoud

Present status of the rehabilitation program at each refinery

.


5- Other projets

to be implemented


Other projects to be implemented :

new Refining at Hassi-Messaoud Area and

rehabilitation of RHM 2 (Call for tender for FEED

package)

Hydrocracking Unit at Skikda Area (Call for

tender for FEED package)

Naphta Aromizer for Aromatics production at

Skikda Area (Feasibility stage)


Documents

Abdulkader- Djellout Algeria