adapting petroleum refinery technology for …
TRANSCRIPT
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ADAPTING PETROLEUM REFINERY TECHNOLOGY FOR NATIONAL DEVELOPMENT: THE AHMADU BELLO UNIVERSITY EFFORTS
1
BY
Prof. I. A. MOHAMMED-DABO MINIREFINERY DEVELOPMENT RESEARCH TEAM
DEPARTMENT OF CHEMICAL ENGINEERING
AHMADU BELLO UNIVERSITY, ZARIA, NIGERIA
0803 361 1734/ 07055671304 [email protected] [email protected]
Paper presentation at 25TH COREN ASSEMBLY
International Event Centre (The Dome), Akure
August , 2016
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PRESENTATION OUTLINE
•INTRODUCTION
•BRIEF ON REFINERY OPERATIONS
•NIGERIAN REFINERIES CAPACITY UTILIZATION
NIGERIAN vs. AFRICAN REFINERIES
•ILLEGAL REFINERY OPERATIONS
•ABU REFINERY DEVELOPMENT
•CHALLENGES
•CONCLUSION
•REFERENCES
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INTRODUCTION Any country that strives to develop technologically should try to
domesticate the technology of its manufacturing industry.
It should be noted that in reality “TECHNOLOGY IS NEVER TRANSFERRED” ONLY
ITS COMPONENT CAN BE TRANSFERRED.
TECHNOLOGY IS EITHER ACQUIRED OR “STOLEN”.
HOWEVER, AN EXISTING TECHNOLOGY CAN BE ADAPTED TO SUIT THE NEEDS OF A NATION OR REGION
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TECHNOLOGY DEVELOPMENT
HE WHO IS AFRAID AND ALWAYS THINKING OF FAILURE WILL NEVER SUCCEED
EXPERTS BUILT THE TITANIC BUT IT SANK
LOCAL CARPENTERS BUILT NOAH’S ARK
AND IT WITHSTOOD THE FLOAD
BECAUSE:
NEVER BE AFRAID OF DEVELOPING A TECHNOLOGY
Be with those who encourage you and not
those who discourage you
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NIGERIAN POTENTIALS NIGERIA IS BLESSED WITH BOTH MINERAL AND HUMAN RESOURCES
POPULATION: 173.6mln(2013)
CRUDE OIL RESERVE: 37 trillion barrels DAILY PRODUCTION CAPACITY: 2.3 MBPD
NATURAL GAS RESERVE: 187 Trillion Cubic Feet (TCF)
ANTICIPATED RESERVE: As high as 800TCF
REFINERIES INSTALLED CAPACITY: 445,000 BPD +1,000BPD
Daily consumption capacity: 250,000BPD @60% Production(267,000BPD) – No importation None of the refineries produce at near 50% capacity
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BRIEF ON REFINERY OPERATIONS Petroleum refinery A highly complex manufacturing sector for handling complex mixture
of HCs.
It uses crude oil and processes it into various end products, some
of which can be used as ready made products while others serve as
the starting raw materials for other chemical and petrochemicals
industries.
Refinery Processes Separation; Cracking; Upgrading; Recombination; Treatment
Types of Petroleum refinery Simple -Topping
Complex
Fuels direction
Fuels & Lubes direction
Fuels, Lubes and Petrochemicals
Mini, Small & Mega
Cost of a Refinery: $500 mln – $20bln
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FUEL DIRECTION REFINERY PROCESS FLOW CHART FUEL DIRECTION OF REFINERY FLOW CHART (SOURCES OF REFINER GASES)
`
Stabilizer Saturates Gas Plant
Isomerizer
Alkylation
Unsaturates Gas Plant
MTBE Plant
Polymerizer
Visbreaker
Coker
Thermal Cracker
Dist. H-cracker
Cat Cracker
Reformer
G
A
S
O
L
I
N
E
B
L
E
N
D
I
N
G
GO Treater
Kero Treater
Splitter
ADU
VDU
75 -1800C
180 -2400C
240 -3500C
Crude Oil
<1800C
>3500C
Atm. Residue
C3/
C4
Butanes
SRG
Alkylate
Isomerate
Reformate
Kerosene
FCCG
MTBE
TCG
Coker Gasoline
Coke
Fuel Oil
VBG
GO/Diesel
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NIGERIAN REFINERIES CAPACITIES AND PRODUCTS SLATES
S/N Refinery Units Capacity (bpd)
KD Warri PH-1 PH-2 Ogbelle Eleme PC
1 Crude unit 1 (fuels) 60,000 125,000 60,000 150,000 1,000
2 Crude unit 2 (lubes) 50,000
3 Vacuum unit 1 (fuels) 15,200 34,200 54,000
4 Vacuum unit 2 (lubes) 23,000
5 FCC 21,000 40,000
6 Catalytic reformer 17,500 21,000 6,000 33,000
7 Naphtha hydrotreater 24,000
8 Kerosene hydrotreater 17,500 15,800
9 Distillate hydrotreater 33,000
10 Propane deasphalter 7,860
11 Furfural extraction 12,450
12 MEK dewaxer 5,300
13 Wax deoiler 1,050
14 Wax hydrofinisher 75 t/d
15 Sulphur recovery 10 t/d
16 Bitumen unit 6,000
17 LAB unit 30,000mta
18 Isomerization 3,600
19 Alkylation 2,850 7,020
20 LPG Unit 6,000
21 Carbon black 18,000mta
22 Olefin 483,000mta
23 Polypropylene 35,000mta 80,000mta
24 Polyethylene 250,000mta
25 Total capacity 110,000 125,000 210,000 1,000
26 Year Established 1980 1978 1965 1989 2013 1995
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Nigerian Refineries vs. other African Refineries COUNTRY/
CAPACITY
POPULATION
REFINERY NAME TYPE OWNER/OPERATOR Capacity (MB/D)
ALGERIA
450,000BPD
39.21mln
(2013)
Algiers Refinery Simple Sonatrach 60
Arzew Refinery Simple Sonatrach 60
Hassi Messaoud Refinery Simple Sonatrach 30
Skikda Refinery Simple Sonatrach 300
EGYPT
677,700BPD
82.06mln
(2013)
Amerya Refinery Simple Egyptian Gen. Pet. Corp. 47
Asyut Oil Refinery Simple EGPC 78
Cairo Ref. Co . Mostrod Simple EGPC 145
Cairo Refinery Co.Tanta Simple EGPC 35
El Mex Refinery Simple EGPC 100
El Suez Refinery Complex EGPC 99.3
Suez Petroleum Processing Co Simple EGPC 66.4
MIDOR Refinery Complex Mid-East Oil Ref.Co., Alexandria 100
Wadi Feran Refinery Simple EGPC 7
LIBYA
343,000BPD
6.202mln
(2013)
Azzawiya Simple Government of Libya 115
Ras Lanuf Simple Government of Libya 220
Sirte Oil Co. Simple Government of Libya 8
Sidi Kacem Refinery Simple Société Cherifienne des Petroles 30
NIGERIA
445,000BPD
173.6mln (2013)
Kaduna Refinery Complex NNPC 110
Port Harcourt I & II Complex NNPC 210
Warri Refinery Complex NNPC 125
SOUTH AFRICA
489,000BPD
52.98mln (2013)
Calref Complex Chevron - Texaco 110
Engen Refinery
Complex Petronas, Worldwide African
Investment Holdings (Pty) Ltd
105
Natref Complex Sasol Ltd, TOTAL- SA. (Pty) Ltd 109
Sapref
Complex Shell & BP S/A Petrol. Ref. Ltd 165
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CONSEQUENCES OF INSUFFICIENT
REFINED PETROLEUM PRODUCTS
(FUELS)
Importation/(Subsidy???)
Queues for petroleum products at filling stations Granting Licenses to construct more refineries
Illegal refining
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2002 LICENSED PRIVATE REFINERIES IN NIGERIA
S/N REFINERY
NAME
TYPE OWNER/
OPEATOR
LOCATION/
STATE
CAPACI-
TY (BPD)
REMARKS
1 Amakpe
Refinery
Topping
(H/skimming)
Amakpe Int. Refinery
Inc.
Eket, AKWA IBOM 12,000 -
2 Ikot Abasi
Refinery
Complex Resource Petroleum &
Petrochem. Int. Inc.
Ikot Abasi, AKWA IBOM 100,000 Designed completed
awaiting DPR review
3 Iwopin
Refinery
Complex
(mini),
Antonio Oil Iwopin, OGUN 27,000 Civil works started on
site in 2010
4 Ipokia Complex Gasoline Assoc. Int. Ltd. Ipokia, OGUN 100,000
5 Ikang
Refinery
complex Amexum Corporation, Ikang, CROSS RIVERS 100,000
In 4 phases, each
with 25,000 BPD
6 Ologbo
Refinery
Topping (H/-
skimming)
Ologbo Refinery Comp.
Nig. Ltd.
Ologbo, EDO
12,000
Designed completed
awaiting DPR review.
(Future plan 18,000)
7 Immingiri
Refinery
Topping Rehoboth Natural
Resources Limited
Immingiri, BAYELSA 12,000 -
8 Sapele Ref. Complex Sapele Petroleum Ltd. Okpe-Sobo, Sapele, DELTA 100,000 -
9 Ogbelle
Refinery
Modular.
Topping
Niger Delta Petroleum
Resources
Ogbelle, RIVERS
($600mln)
1,000
Completed and
operational(Diesel)
TOTAL CAPACITY 464,000
Dangote Refinery/Petrochemicals/Fertilizer plants
10 Dangote
Refinery
Complex Dangote Group
($9Bln)
OK-LNG Free Trade Zone,
between Ogun and Ondo
states.
400,000 To be completed in
2017
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The Federal Government had granted LTC to 22 private investors in 2002 but later cancelled the licenses for non-performance. However, the affected investors had cited non-deregulation of the downstream sector as the reason for their non-performance. In reality, lack of proper financial backing was the cause of their non-performance
REVOCATION OF 2002 LICENSES
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COMPANIES GIVEN PRELIMINARY APPROVAL TO CONSTRUCT PRIVATE REFINERIES IN 2012
S/N Company
1 Akwa Ibom Refining and Petrochemicals Ltd
2 Badagry Petroleum Refinery Ltd.
3 Clean Waters Refinery
4 Ilaje Refinery and Petrochemicals
5 Niger – Delta Refinery and Petrochemicals
Company Ltd.
6 NSP Refineries and Oil Services Ltd.
7 Ode-Aye Refinery Ltd.
8 Orient Petroleum Resources Ltd.
9 Owena Oil and Gas Ltd.
S/N Company
10 Rivgas Petroleum and Energy Limited
11 Sapele Petroleum Ltd.
12 Southland Associates Ltd.
13 Southwest Refineries and
Petrochemicals Company
14 Starex Petroleum Refinery Ltd.
15 The Chasewood Consortium
16 Tonwei Refinery
17 Total Support Refineries
18 Union Atlantic Petroleum Ltd.
13
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FIRST NIGERIAN PRIVATE REFINERY
Plate 1.View of the 1000BPD Ogbelle Refinery. Plate 2. Products Line of the Ogbelle Refinery
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SECOND NIGERIAN PRIVATE REFINERY UNDER CONSTRUCTION
Plate 2.View of the Second 1000BPD Modular Refinery.
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LABORATORY SCALE DISTILLER (KRPC/UNIPORT)
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Causes of illegal refining:
1. High demand for petroleum
products (esp. fuels)
2. Insufficiency of the products
3. Unemployment among the
Niger Delta youth
ILLEGAL refinery
OPERATIONS
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SOME PICTURES OF ILLEGAL
REFINERY OPERATIONS
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Plate 3. Part of the Illegal Refinery Plate 4. Improvised Condensers
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CRUDE OIL BUNKERING
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Plate 6. Heating fuel supply
Plate 7. Heating fuel supply
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DEATH OF AN OPERATOR
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Plate 9. Products Collection
Plate 10. Products Collection
ILLEGAL DISTILLATION
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Plate 11. Residue Disposal Plate 12. Residue Disposal
Uncondensed HC vapour
RESIDUE DISPOSAL
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Plate 13. Polluted abandoned site Plate 14. Polluted abandoned site
SITE POLLUTION
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Plate 17. Burnt site by JTF
JTF ACTIVITIES
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AHMADU BELLO UNIVERSITY EFFORTS IN
MINI-REFINERY TECHNOLOGY DEVELOPMENT & ADAPTATION
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LOCATION OF ABU MINIREFINERY
Boundaries: East --CERT ; North--Area A ; West-- Koraye Road ; SouthEast -- Waste dumping site
Located within the ABU Samaru Main campus
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AERIAL VIEW OF ABU MINIREFINERY
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ABU REFINERY DEVELOPMENT
WHY COUNTRIES DEVELOP TECHNOLOGIES
Most of the Developed countries were faced with the challenges of developing a technology for the product(s) they need. This could be due to many reasons, such as:
1. Need for self reliance. 2. No where to run to for such technologies. 3. Generate employment for their citizens. 4. Generate revenue by selling/supplying the
technology to other countries that may need it.
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Refineries are deliberately calibrated to
be sophisticated to make it difficult to
copy (Igwe,2012)
It is ONLY DIFFICULT but NOT IMPOSSIBLE TO COPY/ADAPT
INGREDIENTS FOR COPYING: Practical Experience Theoretical Background
OIL REFINERY- COMPLICATED PLANT
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HISTORICAL BACKGROUND OF THE PROJECT
YEAR EFFORTS
2001/2002 UG STUDENTS PRELIMINARY DESIGN TOPIC
2002 PROPOSAL TO UNIVERSITY FOR FUNDING. ==NO FUND.
2011 Prof. I. A. Mohammed-Dabo, the then Head of Department gave an MSc Research Topic titled “DESIGN, CONSTRUCTION AND OPERATION OF A 1000BPD (1BPD) CRUDE DISTILLATION UNIT (ADU & VDU)”.
2011 PROPOSAL TO UNIVERSITY MANAGEMENT/TETFUND
2012 FORMATION OF RESEARCH TEAM (FAC. OF ENGINEERING)
2013 DESIGN COMPLETION & FABRICATION
2013 INSTALLATION/TEST RUN
2015 DEVELOPMENT OF NHU & FCCU (RMRDC SPONSORED)
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STAGES OF
A.B.U. MINI-REFINERY TECHNOLOGY DEVELOPMENT
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SOME TEAM MEMBERS
I.A. Mohammed-Dabo S.M. Waziri A. Hamza P.C. Okonkwo
Muhammad Dauda S.A. Yaro N.S. Maina M. J. Abubakar
S. Bilal U. Abubakar A. Bukar O. Omorogbe
M. Abubakar A. Lawal I. Abdulkadir V.O. Samson
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1. BRIEF ENVIRONMENTAL IMPACT ASSESSMENT OF THE PROJECT
Members of the Research Team are quite mindful of the necessity to take into consideration effect of this projects on the environment. The Nigerian Government has enacted various acts regarding consideration of the environmental impact of any project or activity to be conducted, be it on land, in water or air. The Nigerian Environmental Act of 1992 specifically specified that for a chemical project to be undertaken, EAI must be carried out PROVIDED “capacity of such plant is up to 100tones/day (Environmental Impact Assessment Decree, 1992). Capacity of the project is 1barrel/day (0.14tones/day), which is not up to 1% of the required capacity for detailed EIA. However, since this is a chemical process plant, a brief EIA was carried out prior to commencement of the project.
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2. DESIGN METHODOLOGY DETAILED LITERATURE DIGEST
PROCESS SELECTION
WORKING DRAWINGS (Mechanical Design)
DESIGN BASIS+RAW MATERIALS SELECTION
DESIGN CALCULATIONS (Material & Energy balances; Equipment design)
FABRICATION
INSTALLATION/PIPING/INSTRUMENTATION
TEST RUN
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Method Major Activities
Literature Digest Various related works globally
Process Selection 2-Stage Distillation
Design Basis Selection 1,000BPD (1BPD); Escravous crude
Design Calculations (Manual & Software)
Mat. &Energy balances; Temperatures (Flash Zone, Products Draw-off, Tower Top, Side Stripper, Products); Condenser Duty, Reflux Ratio; etc
Equipment Design Column Diameters, No. of Trays & Holes; Furnaces; Steam ejector; HEs; Reflux Drum; etc
Working Drawings Various views of the equipment with appropriate Dimensions
Materials Selection Various Grades of Stainless & Mild Steels
Fabrication Competent/Certified Fabricators engaged
Installation/ Instrumentation
Following the Plant Layout and Control Loops Diagrams
Test Run Testing for leakages/Plant workability
DESIGN METHODOLOGY (Contd.)
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PLANT LAYOUT
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INSTALLATION,
PIPING,
INSTRUMENTATION
& TEST RUN
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Plate 18. ADU Colum Installation Plate 19. ADU and VDU Columns Erection
INSTALLATION
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Plate 20. Installation Plate 21. Piping
INSTALLATION/PIPING
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Plate 22. Cooling Tower Installation Plate 23. Furnace and Hot Air Generator
COOLING TOWER/FURNACE
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INSULATION
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Plate 24. Overhead Water Tower Plate 25. Products Line
OVERHEAD WATER/PRODUCTS LINE
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Plate 26. ADU Instrumentation Plate 27. VDU Instrumentation
INSTRUMENTATION
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Plate 28. Control Panel in Control Room
CONTROL ROOM
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Plate 29. System Steam Flushing
SYSTEM STEAM FLUSHING
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Plate 30. Atmospheric Distillation Unit Plate 31. Vacuum Distillation Unit
ADU & VDU
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PICTORIAL VIEW OF THE DEVELOPED PLANT UNIT
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PLANT VIEW AT NIGHT
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IMMEDIATE FUTURE PLANS
S/N
UNIT STATUS
1 NAPHTA HYDROTREATER (NHU)
Installation Stage
2 FLUID CATALYTIC CRACKER (FCC)
Installation Stage
3 KERO HYDROTREATER (KHU)
Design Stage Completed (No Funding)
4 CATALYTIC REFORMING Design Stage Completed (No Funding)
5 DIESEL/DISTILLATE HYDROTREATER (DHU)
Design Stage Completed (No Funding)
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Plate 35. View of the FCC Heat exchangers and Tanks
Plate 37. View of the proposed FCC units
PROPOSED FCC UNIT
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V-01 P-01 E-01 H-01 E-02 R-01 V-02
Surge
Drum
Pump Exchanger Fired
Heater
Cooler Reactor Separator
Figure 2. Process Flow Diagram of the proposed Naphtha Hydrotreating Unit
PFD OF PROPOSED NHU
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ENGINEERS AT WORK (ABU REFINERY)
NH Unit FCC Unit
FCC & NH Units installation in progress
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INSTALLATION STAGE OF NAPHTHA HYDROTREATING UNIT
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FCCU CONVERTER COUPLING STAGE
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UTILIZATION OF
MINIREFINERY FOR
TEACHING &
RESEARCH
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STUDENTS TAKING LECTURES AT THE MINIREFINERY SITE
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IMPact of THE PROJECT
1. Demonstration of the Nigerian local
capacity to design, fabricate and
operate mini-petroleum refinery units
2. Creation of Hands-on training facility
for both undergraduate and
postgraduate students.
3. Such plants can serve as a bridge
for Industry-Academia Collaboration.
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FUNDING
CRUDE SUPPLY
BELIEVING IN OURSELVES COLLECTIVE ENCOURAGEMENT
CHALLENGES
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A mini crude oil distillation (atmospheric and vacuum) unit with a designed throughput of 1,000BPD (but scaled down to 1.0BPD) was successfully designed, constructed, installed and operated .
The ADU consists of column, side strippers, condenser, reflux drum, valves and
piping system while the VDU consists of column, TPA, BPA heat exchangers, steam ejector and piping system.
The plant is controlled by both manual and automatic modes. A utility and
safety systems were provided. Preliminary test runs indicated that the plant produces products such as Light
and heavy naphtha, kerosene and diesel fractions, and light and heavy vacuum gasoils.
The plant is currently used as teaching aid to students of Faculty of Engineering, Ahmadu Bello University Zaria.
CONCLUSION
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Engineers should pay more attention to practical aspects in addition to theory.
Federal Government should vigorously encourage practical researches with a view to domesticating various manufacturing technologies.
Institutions of Higher Learning should identify a specific technology and challenge their Engineers and Scientists to develop it.
RECOMMENDATION
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MY FELLOW ENGINEERS, WE CAN ALL DO IT
BUT NEVER BE AFRAID OF STARTING AND STOP THINKING OF FAILURE
EXPERTS BUILT THE TITANIC BUT IT SANK
LOCAL CARPENTERS BUILT NOAH’S ARK
AND IT WITHSTOOD THE FLOAD
BECAUSE:
NEVER BE AFRAID OF DEVELOPING A TECHNOLOGY
Engage those who will encourage you
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Bagajewicz, M. & Ji, S. (2001), Rigorous Procedure for the Design of Conventional Atmospheric Crude
Fractionation Units. Part I: Targeting: Ind. Eng. Chem. Res. 40.
Environmental Impact Assessment Decree 1992. http://www.nigeria-law.org/EnvironmentalImpact
Assessment DecreeNo.086 201992.htm
Igwe, G. (2014). Modular Refineries: Nigeria Should Try the Idea. Elombah.com A Nigerian Perspective
on World Affairs. Available at : www.elombah.com/index.php/special-reports/20816-modular-refineries-
nigeria-should-try-the-idea
Kalu, I.K. (2012). Presidential Committee Report on Petroleum Refining in Nigeria
Mohammed-Dabo, I.A. Safieva, R.Z. and Syunyayev, R.Z. (2008). Recycling of Used Industrial
Lubricating Oil through its Joint Refining with Crude Oil. Petroleum Training Journal (PTJ) Vol.3 No.2,
July, 2008
Mohammed-Dabo, I.A. Bugaje, I.A. Zakari, B.Y. and Yakubu, S. (2008). Upgrading the product
potentials of Antan Crude Oil through its Joint Refining with Oso Gas Condensate. Journal of Research
in Engineering, Vol 5, No. 4, pp.94-99
NNPC (2009). Nigerian National Petroleum Corporation
NPC (2001). Nigerian Population Commission Report
Adoyi Oche, Ibrahim Ali Mohammed-Dabo and Abdulhamid Hamza (2015). Comparative Analysis of
Manual and Aspen Plus Design for Crude Distillation Unit (CDU). International Journal of Scientific and
Research Publications, Volume 5, Issue 6, June 2015 1 ISSN 2250-3153 www.ijsrp.org
Oniwon, A.O. (2011). The Nigerian Oil and Gas Industry and the Global Economy. Paper presented at
the Ahmadu Bello University 35TH Pre-Convocation Lecture Series. November 23, 2011
Rao, B. (1990), Modern Petroleum Refining Processes, 1st ed. New Delhi, India.
Sinnott, R. N. (2006), Coulson and Richardson’s Chemical Engineering Series, Vol. 6, 4th Ed.: Elsevier
New Delhi.
Uppaluri, R. (2010), Refinery Process Design (Lecture Notes): Department of Chemical Engineering,
Indian Institute of Technology, Guwahati – India.
REFERENCES
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THANK YOU
FOR YOUR
ATTENTION