The Middle East Downstream Week Abu Dhabi, United … 2 1130 Yabhouni... · The Middle East Downstream Week Abu Dhabi, United Arab ... o Look beyond current quality specifications

The Middle East Downstream Week Abu Dhabi, United Arab Emirates

12 – 15 May 2013

Carbon Black & Delayed Coker Project at Ruwais Refinery

Insight into how the Project Transforms Production of Heavy Oil and Enhances Integration with Local Industries

http://www.wraconferences.com/

1. Introduction 2. Vision 3. CBDC – Supporting Vision 4. Simplified Flow Scheme 5. Unique Aspects 6. Configuration Features 7. Other Aspects 8. Statistics/Status 9. Conclusion

Carbon Black & Delayed Coker Project

at Ruwais Refinery


at Ruwais Refinery

1. Introduction Established in 1999, Abu Dhabi Oil Refining CO [TAKREER] is

responsible for managing, operating and developing the downstream oil refining activities of Abu Dhabi National Oil Company [ADNOC]

The current capacities of the two refineries in Abu Dhabi Emirate total 485,000 bpsd, with a new 400,000 bpsd expansion project nearing completion at Ruwais

ADNOC entered into the refining business modestly with

o Abu Dhabi Refinery commissioning a 15,000 bpsd plant in 1976; to be replaced by a 60,000 bpsd refinery in 1983 and subsequently expanded to 85,000 in 1992.

15,000 [1976] 60,000 [1983] 85,000 [1992]

Meanwhile, at Ruwais a 120,000 bpsd Hydro-skimmer refinery was started in 1981, with various expansions implemented over the years along with infra-structure facilities.

120,000 bpsd

• Hydro skimmer

• 1981

27,000 bpsd

•Hydro-cracker units

• 1985

280,000 bpsd

• Condensate units

• 2000

2500 ktpa

• Gasoline facilities

• 2006

5,750 ktpa

• Green Diesel facilities

• 2011

417,000 bpsd

• Petrochem Refinery

• 2014

660 MW Power 14 million gpd Water 26 ktpa Waste Treatment


at Ruwais Refinery

2. Vision To be a leader in the Oil Refining Industry. Achieving this requires

addressing

Demand & Growth

o Meet demand growth in the domestic market

o Maintain presence in the International Refined Products’ Market

o Provide feed stock to the rapidly growing Petrochemicals and other industries

Environmental & Quality Regulations

o Look beyond current quality specifications and prepare to meet the more stringent ones evolving in the industry

o Implement facilities to meet the highest standards in Environmental Emissions

o Minimize Carbon Footprint to the lowest level feasible


at Ruwais Refinery

Vision (continued) Diversification/Integration/Feed Stocks

Improve refining margins

o Reduce/eliminate low value products such as Heavy Oils, Slurry etc

o Diversify product lines by introducing new products that not only move up the value chain but also support the local industries such as, Special Carbon Black grades and Calcined Coke

Capture synergies by tighter integration between related industries – supplement/utilize feed stock from one to produce for the other


at Ruwais Refinery

GASCO Propane PDH in

CBDC Propylene

BOROUGE/EXPORT

3. One more step to support TAKREER vision In pursuing its stated vision to be a leader in the Oil Refining Industry

o TAKREER turned its attention to converting the Heavy Oils that would still be available after the RRE was commissioned to move up the value chain

o At the same time it explored ways to enhance integration with the local industry to support the growing Petrochemicals and Aluminum Industries sectors

o The result was the Carbon Black & Delayed Coker (CBDC) Project


at Ruwais Refinery

4. One more step to support TAKREER vision Essentially, the CBDC Project transforms the Heavy Oils: Slurry from the

RRE Project and Vacuum Residue from the existing refinery to produce

40 ktpa of Semi-conductive and UV grades of Carbon Black destined for Borouge in bags

430 ktpa of Anode Grade Calcined Coke for the local Aluminum Smelters through a dedicated bulk carrier jetty

Enhances integration with local industry by converting RRE and CBDC Propane – supplemented by imports from GASCO – into 520 ktpa of chemical grade Propylene as feed stock for Borouge

For flexibility, facilities are being implemented to export any excess production of above

Naphtha and Gas oil streams are blended into the RRE products for sales


at Ruwais Refinery

5. Technology Intensive The process units in the CBDC Project are not only diverse but highly

technology intensive

There are 8 major licensed process units spread across 6 licensors. Additionally, during EPC minor licensed processes are being finalized for Sulphur Recovery, Spent Caustic Treatment etc


at Ruwais Refinery

6. Simplified Flow Scheme


at Ruwais Refinery

7. Unique Aspects The CBDC Project was initiated from studies to reduce Fuel Oil Utilizing RRE Slurry for producing low-Sulphur feed stock for the Carbon

Black Unit [CBU] appeared a synergetic fit The CBU requires ~0.1% wt Sulphur in its feed stock to be able to produce

the two special grades of UV and Semi-conductive Carbon Black A prototype Slurry HDT was designed based on Residue de-sulphurization

technology and pilot tests to confirm feasibility of converting the high Sulphur RRE Slurry into CBU feed stock

As the project developed, units for Coke Calcination and Propane Dehydrogenation were added – units which are normally not part of a refinery complex

However, though challenging, the CBDC Project puts together the diverse technologies; some such as the CBU, Calcination and PDH units generally stand-alone in the industry, into one unique package for the first time that seamlessly integrates with the existing and upcoming refineries


at Ruwais Refinery

Unique Aspects (continued) Tight integration between the RRE and CBDC projects however,

requires over 200 piping tie-ins to be implemented before the RRE facilities are commissioned to avoid difficulties in implementing them later in an operating plant.

However, integration was carefully planned to avoid compromising operational flexibility

These tie-ins were identified and incorporated into an Early Works schedule of the CBDC that includes

o A 3m diameter, 4 km long sea water intake pipeline system

o Three 25m diameter Propane/Propylene Spheres

o Additional pumps in cryogenic propylene tanks

o A truck loading facility in the Sulphur Recovery Unit


at Ruwais Refinery

8. Special Configuration Features The Delayed Coker unit [DCU] is designed to blend the balance low-

Sulphur HDT Slurry with Vacuum Residue to maintain the Green Coke Sulphur levels low enough to ensure the Anode grade Calcined Coke meets requirements of Emirates Aluminum.

Accordingly the DCU design features capabilities to optimize anode grade coke production


at Ruwais Refinery

Special Configuration Features (continued) Additionally managing the olefin rich LPG from the Delayed Coker

provided an opportunity for utilizing the Propane from the RRE units – supplemented by Propane from GASCO – to incorporate a world class capacity Propane Dehydrogenation [PDH] unit


at Ruwais Refinery

9. Other Considerations Specialists are engaged to identify gaps and propose leading edge

technologies to protect the CBDC network facilities from Cyber Attacks. Any implementation strategy adopted would include the RRE and other shared systems

Special measures are being implemented for controlling dust emissions during production and handling of Carbon Black, Delayed Coker and Coke

HDPE is being used for the first time in TAKREER, instead of GRE/GRV, for various water pipelines as applicable

Coming on the heels of the RRE, the CBDC Project is incorporating the Lessons Learnt from it and other previous projects

Since the site activities of the CBDC will ramp up as that of the RRE tapers off, utilizing the experience of the legacy work force is expected to benefit the project, especially in adherence to HSE aspects


at Ruwais Refinery

10. Project Statistics The CBDC consists of certain world scale facilities such as the Propane

De-hydrogenation unit that require significant resources, equipment and materials

Estimated quantities of material for CBDC


at Ruwais Refinery

11. Current Status EPC Contractor : M/s Samsung Engineering Co. Ltd

Contract effective date : July 31, 2012 [Lump Sum]

Project duration : 42 months

Progress [month 9] : 4.9% overall actual


at Ruwais Refinery

12. Conclusion In line with its vision, TAKREER is proceeding to implement projects

even in a slow moving economy. This creates

Self reliance in obtaining feed stock for local industries; EMAL, Borouge

Learning opportunities for UAE Nationals to enter the mainstream industries and participate in the nation’s development

Employment opportunities in different technical and non-technical fields for upgrading skill levels

Growth prospects in the support service sectors: fabrication, civil works, transportation, Third Party Inspection, etc

Opportunities for supporting industries supplying materials; structural steel, cables, HDPE etc


at Ruwais Refinery

Documents

The Middle East Downstream Week Abu Dhabi, United … 2 1130 Yabhouni... · The Middle East Downstream Week Abu Dhabi, United Arab ... o Look beyond current quality specifications