the middle east downstream week abu dhabi, united arab emirates
TRANSCRIPT
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
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker 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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
at Ruwais Refinery
6. Simplified Flow Scheme
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
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
Carbon Black & Delayed Coker Project
at Ruwais Refinery