Presentation on theme: "REFINING There are (3) major Refineries in Iraq:"— Presentation transcript:
1 REFINING There are (3) major Refineries in Iraq: 1- Doura Refinery – built in the Fifties of the last Century with acapacity of (70) kb1/d which was increased to (110) k b1/d by adding4 (10) k b1/d units.2- Basrah Refinery - built in the seventies of the last Century with acapacity of (140) kb1/d which was increased to (180) k b1/d by adding4 (10) k b1/d units.3- Baiji Refinery- built in the seventies and eighties of the last Centurywith a capacity of (290) kb1/d which was increased to (310) k b1/d byadding 2 (10) k b1/d units.
2 REFINING All these refineries .were simple designed to produce white products not exceeding (50 -55%) of the feed crude. OnlyBaiji has a hydrocracker units of (30)kb1/d capacity.All three refineries have lube oil plants of various capacities.These refineries sustained severe damage during the 1991gulf war . They were all fixed and put int operation within2 -3 months from the end of the said war , but were notrestored to a healthy state . The long period of UN sanctioninflicted more damage due to disrepair&lack of maintenance .
3 REFINING Period April 2003 – Dec 2008 The operation of refineries was adversely affectedby the security situation.Insurgent & terrorist attacks targeted crude oil &product pipe lines.Refineries suffered frequent stoppage of operation,either due to lack of crude oil or inability to evacuateproducts. This applies to the period 2005 –In 2008 there is a definite improvement in theoperation thus the daily average for refining hasbeen gradually increasing coupled with decrease ofoil products imports.
4 Status End 2010 1- MIDLAND REFINERIES A- Doura Refinery Installed Capacity : 210kb 1/d.- 2 new CDUs,each of 70 kb1/d - both in operation.- A third Hydrotreater Reformer Unit 10 kb1/d – procurement phase.- Isomerisation Unit 10 kb1/d – Civil work & supply of equipment phase.- A power generation station 50 mw – under construction.- One New Boiler 150 ton/h with Demin Water Unit –completed & inoperation. Second New boiler 150 ton/h under construction.- An RFCC Unit 40 kb1/d – FEED Package awarded.- New Cooling Tower – Contract awarded.
5 Lube Oil Plants There are 3 Lube Oil plant : A- Doura RefineryThere are 3 Lube Oil plant :- No:1 – completed 1959 by Foster wheeler - capacity 25 kton/ypresent operation at 85% of capacity .- No:2 – completed 1969 by Snam Projetee – capacity 36 kton/y present operation at 77% of capacity- No:3 – completed 1978 by Nigata – capacity 60 kton/y- present operation at 94% of capacity
6 A- Doura RefineryFuture Plans- Replacement of 3 CDUs 70 kb1/d total capacity with one CDU unit 70 kb1/d.- Additional treatment of Industrial water including circulation of treated water.- Improvement of Flare system to reduce emmissions.- Complete renovation of lube oil plants.- Replacement of old reformer units with new ones.- New Gas Oil hydrotreater units
7 Status End 2010 MIDLAND REFINERIES B- Najaf Refinery: - 3 Distillation Units , (10)kb1/d each – in operation.- A Naphtha Hydrotreater & Reformer unit with all related utilities in the engineering phase.- Asphalt unit – planned.
8 Status End 2010 MIDLAND REFINERIES C- Samawa Refinery - 3 Distillation Units , (10)kb1/d each – in operation.- A Naphtha Hydrotreater & Reformer unit with all related utilities in the engineering phase.- Asphalt unit – planned
9 Status End 2010 1- MIDLAND REFINERIES D- Diwanya Refinery - One Distillation Unit , (10)kb1/d in operation.- 2rd Distillation Unit , (10)kb1/d under fabrication.
10 Status End 2010 2- NORTH REFINERIES A- Baiji Refinery Complex – Capacity 310 kb1/d.- New Isomeration Unit – 19.6 kb1/d – Final stages of construction.- 6 New boilers – 400 ton/hr total capacity -under construction.- New power generation plants (85)mw – contracted.- New LPG unit for North Refinery , 400 tons/d – Award of contract under processing.- Upgrading of Waste Water Treatment System – under implementation.- Re-construction of (51) storage tanks – 9 Nos complete, 80% completion of remaining tanks.- Rehabilitation & De- bottle necking of Hydro- Cracker Unit – under evaluation with Designer & Supplier .- New FCC unit 50 kb1/d – Feasibility Completed
11 Status End 2010 2- NORTH REFINERIES A-Baiji Refinery Complex - Lube Oil Plant , 250 kton/y – at present one train 125 kton/y is in operation. Second train is under rehabilitation.B- Kirkuk Refinery- 3 CDU 10kb1/d each – in operation.C- Kasak Refinery- one 10 kb1/d unit – in operation.- Second 10 kb1/d unit - civil work construction.- Waste Water Treatment Unit – under construction.- New Storage Tanks – under construction.
12 Status End 2010 2- NORTH REFINERIES D- Qayarah Refinery - 4 Old Asphalt Units, one 180 cum /d & three 360 cum/d each only one unit 360 cum/d is in operation at 50% capacity other units are under rehabilitation .- A new Asphalt Unit is planned .- One 10kb1/d CDU operating on Kirkuk Crude - installed.- 2rd 10kb1/d CDU operating on Kirkuk Crude - under installation.- 8 storage tanks –under construction.E- Seeniyah Refinery- Three 10 kb1/d units – in operation- 10 storage tanks – under construction.- Waste Water Treatment unit – under construction.
13 Status End 2010 2- NORTH REFINERIES Future Plans F- Haditha Refinery - 2 units , 16 kb1/d total capacity – in operation.- 12 storage tanks – under construction.- Waste Water Treatment Unit – planned .Future Plans- Rehabilitation of Gas Oil Hydrotreating Units.- Rehabilitation & upgrading of lube plant.- Replacement of old reformer units.
14 Status End 2010 3- SOUTH REFINERIES A- Basrah Refinery - New (70) kb1/d Distillation Units with an LPG unit (300) ton/d under construction.- Third Hydrotreater Platformer Unit 10kb1/d -under construction.- New LPG unit (200) ton for Train(1) – procurement phase- New Isomeriation Unit (11) kb1/d - Delivery of equipment & Site preparation.- 3 New Boilers , 100 ton/h each – under installation.- New Waste Water Treatment Plant – Awarded.- New cooling Tower – under construction .- New FCC Unit 30 kb1/d – FEED package preparation phase.- Replacement of old reformer units.
15 Future Plans - New Utility Package . - New Gas oil Hydrotreatment Unit- Design completed.- New Naphtha hyrotreater unit 15 kb1/d.- Upgrading of Instrumentation & Control.- Improvement of Flare System to reduce emmissions.- Up grading of waste water system & recirculation of treated water.
16 Status End 2010 3- SOUTH REFINERIES B – Nasiriyah Refinery - 3 Distillation Units , (10)Kb1/d each in operation.- A Hydrotreater Reformer unit with all related utilities Engineering phase.- A Waste Water Treatment unit – Evaluation of offers.- An Ro unit 50m3/h completed & in operation.- Expansion of utilities & tankage – planned.C- Missan Refinery- 3 CDUs , 10 kb1/d each – installed & in operation
45 Gas Processing- Rehabilitation of the second train in Khor al Zubair –South gas – under way.- Rehabilitation of Sour gas treatment units at NGLNorth Rumailah – under way .-Studies for New slug catchers at khor al Zubair & NGL &Sulphur recovery unit at North Rumailah –under way.
46 Future Plans - Third Train in North Gas – Studies & Evaluation. - Expansion of existing compressor stations for Rumailah,Zubair&West Qurna Fields to match future production levels from these fields.- Expansion of NGL capacity of South Gas from present mmscf/d to 2500 mmscf/d.- Implementing Sour Gas treatment & Sulphur recovery Units at Khor al Zubair.- Building Power generation at Khor al Zubair.- Rehabilitation of LPG & Ng Export Terminal at Khor al Zubair.
47 Present Installed Refining Capacity 1- Salah al Din Complex – Baiji – 310 mb1/d2- Doura Refinery – Baghdad – 210 mb1/d3- Basrah Refinery – Basrah -140 mb1/d +70mb1/d under constructionsmall refineries , 30mb1/d – 180 mb1/dKirkuk,Syniah-Baiji , Najaf,Samawa,Nasiriyah,Maisan- 1 small refinery at Diwaniyah – 20 mb1/d= = = Kasak –Neinewah – 10 mb1/d= = = Haditha – Anbar – 16 mb1/dTotal- 886 mb1/d mba under construction
48 Operating CapacityThe average operating capacity is in the 580 – 620 mb1/d.The short fall in refining capacity is due to- Shortage in delivery of crude oil- Frequent stoppages due to operationalproblems- Accumulation of fuel oil or Naphtha in small refineries.
49 Main Projects in Existing Refineries - 3 Ismerisation Units at Baiji , Doura &Basrah – under construction.-2 Gasoline Reformers at Doura & Basrah- Procurement & Construction Phases.- Fcc unit at Basrah –FEED phase.- Fcc unit at Doura–FEED phase.- Fcc unit at Baiji – Feasibility Completed.-2Gas Oil Desulphurisation Units at Basrah & Doura Bidding Stage .-3 small Gasoline Reformer units at Najaf ,Samawa& Nasiriyah- Engineering phase.- Power Generation Units at Doura & Baiji – under construction
50 Nassiryah Refinery Process Units Design Capacity & Licensors Unit nameUOPSaturated LPG Treater UnitsNaphtha ComplexNaphtha Hydrotreating UnitsLight Naphtha Isomerisation UnitsContinuous Catalytic Reforming UnitsTotal for Naphtha ComplexFCC ComplexVacuum Gas oil HydrotreatingFluidised Catalytice Cracking UnitUnsaturated Gas PlantFCC Unsaturated LPG Treating Unit
51 Nassiryah Refinery Process Units Design Capacity & Licensors Unit nameUOPFCC ComplexFull Range Catalytic Naphtha Treating UnitHeavy Catalytic Naphtha Hydrodesulphurisation UnitTotal for FCC ComplexAxensC4 Isomerisation UnitDuPont(Stratco)H2so4 Alkylation UnitSulphuric Acid Regeneration UnitTotalCLGHydrocracker Unit
52 Nassiryah Refinery Process Units Design Capacity & Licensors Unit nameTecnimont KTHydrogen Production UnitsSulphur Recovery & Tail Gas Treating UnitsPoernerBitumen Blowing UnitAxensKerosene Hydrotreater UnitsGaoil Hydrotreater UnitsTotalResidue Hydrocracker UnitsSGSFlue Gas Desulphurisation Unit
53 Karbala Refinery Process Units Design Capacity & Licensors Unit nameBasic Design by TechnipCrude and Vacuum DistillationUOPNaphtha HydrotreatingIsomerizationCatalytic ReformingAxensKerosene HydrodesulfurizationDiesel HydrodesulfurizationVGO HydrotreatingFluid Catalytic CrackingPoly NaphthaPoernerAsphalt BlowingLPG ProductionHaldor TopsoeHydrogen Production Unit – Train 1 & 2Gas Sweetening and Amine RegenerationSour Water StripperKTISulphur Recovery – Train 1 & 2Tail Gas Treatment
54 Missan Refinery Process Units Design Capacity & Licensors Unit nameKBR USA LLCFluid Catalytic Cracking –Unit 190Vacuum Residue Solvent De- asphalting ((ROSE)) –Unit 190POERNER NGENIEUEGESLLSCHAFT MBHBlown Asphalt –Unit 250AXENSNaphtha Hydrodesulphurization –Unit 120Continuous Catalytic Reformer –Unit 130Vacuum Gas Oil Hydro cracker–Unit 180De-Asphalted Oil Hydrdesulphurisation –Unit 240UOP LimitedC5 & C6 Isomerisation Process –Unit 140C4 Isomerisation Process –Unit 270Saturated LPG Treatment ((SULFREX)) –Unit 155Unsaturated LPG Treatment ((SULFREX)) –Unit 210HALDOR TOPSOE A/SKerosene Hydrodesulphurisation –Unit 160Light Gas Oil Hydrodesulphurisation –Unit 170
55 Missan Refinery Process Units Design Capacity & Licensors Unit nameHALDOR TOPSOE A/SHydrogen Production –Unit 280E.I du Pont Nemours and CompanyC 3/ C4 Alkylation –Unit 260