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REFINING There are (3) major Refineries in Iraq:

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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 a capacity of (70) kb1/d which was increased to (110) k b1/d by adding 4 (10) k b1/d units. 2- Basrah Refinery - built in the seventies of the last Century with a capacity of (140) kb1/d which was increased to (180) k b1/d by adding 4 (10) k b1/d units. 3- Baiji Refinery- built in the seventies and eighties of the last Century with a capacity of (290) kb1/d which was increased to (310) k b1/d by adding 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. Only Baiji 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 1991 gulf war . They were all fixed and put int operation within 2 -3 months from the end of the said war , but were not restored to a healthy state . The long period of UN sanction inflicted more damage due to disrepair&lack of maintenance .

3 REFINING Period April 2003 – Dec 2008
The operation of refineries was adversely affected by 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 evacuate products. This applies to the period 2005 – In 2008 there is a definite improvement in the operation thus the daily average for refining has been gradually increasing coupled with decrease of oil 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 & in operation. 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 Refinery There are 3 Lube Oil plant : - No:1 – completed 1959 by Foster wheeler - capacity 25 kton/y present 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 Refinery Future 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

17 Refining Levels - year : 2004 404 k b1/d - = : 2005 377 =
- = : = - = : = - = : = - = : = - = : = - = : = (Jan- Oct)

18 Import of Oil Products Year ton/d Total Value
million $ = = = = = = = = = = = = End of Aug * Import for Ministry of Electricity is not included

19 Consumption of white Products
Cubic Meters Legend Gasoline Gas Oil Kerosene

20 NEW REFINERIES 1- Karbala Refinery Capacity BPSD

21 SITE INFORMATION: Kerbala Refinery is located about (110) KM South west Of Baghdad. Area : 4 X 3 Km2 Coordinate U.T.M. : N : E :

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23 Products Specification will be according to EURO-4 as minimum required.
Gasoline , Kerosene &Gas oil with (10 ppm ) Sulphur content .

24 Expected Product Quantities :
Th.M3/SD PRODUCTS 160 T/SD LPG 8.750 GASOLINE 3.000 ATK/KEROSENE 3.85 DIESEL HEAVY DIESEL 3.7 FUEL OIL 1000 T/SD ASPHALT 175 T/SD SULPHUR 100 MW ELECTRICITY

25 2-Maissan Refinery Capacity BPSD

26 SITE INFORMATION: Maissan Refinery is located about (400) KM South Of Baghdad. Area :( 2 X 3) Km2 Coordinate U.T.M. : N : E :

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28 Products Specification will be according to EURO-4 as minimum required.
Gasoline , Kerosene &Gas oil with (10 ppm ) Sulphur content .

29 Expected Product Quantities :
Th.M3/SD PRODUCTS 250 T/SD LPG 9.000 GASOLINE 2.650 KEROSENE / ATK 7.650 DIESEL 0.8 HEAVY DIESEL 0.432 FUEL OIL 490 T/SD ASPHALT 490 T/SD SULPHUR 500 MW ELECTRICITY

30 3- Al-Nassiriya Refinery
Capacity BPSD

31 SITE INFORMATION: Al-Nassiriya Refinery is located about (400) KM South Of Baghdad. Refinery Area  5.6 Km2 Coordinates U.T.M. : N : E :

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38 Products Specification will be according to EURO-4 as minimum required.
Gasoline , Kerosene &Gas oil with (10 ppm ) Sulphur content .

39 Expected Product Quantities :
Th.M3 /D PRODUCTS 1200 T/D LPG 14.000 GASOLINE 7.000 KEROSENE /ATK 12.000 DIESEL 4.000 HEAVY DIESEL 6.500 REFINERY FUEL OIL T/D ASPHALT SULPHUR MW ELECTRICITY

40 4-Kirkuk Refinery Capacity BPSD

41 SITE INFORMATION: Kirkuk Refinery is located about (300) KM North Of Baghdad. Area :( 2 X 3) Km2 Coordinate U.T.M. : N : E :

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43 Products Specification will be according to EURO-4 as minimum required.
Gasoline , Kerosene &Gas oil with (10 ppm ) Sulphur content .

44 Expected Product Quantities :
Th.M3 /SD PRODUCTS 225 T/SD LPG 10.250 GASOLINE 3.450 KEROSENE /ATK 6.150 DIESEL 0.8 HEAVY DIESEL 0.265 FUEL OIL 490 T/SD ASPHALT 292 T/SD SULPHUR 400 MW ELECTRICITY

45 Gas Processing - Rehabilitation of the second train in Khor al Zubair – South gas – under way. - Rehabilitation of Sour gas treatment units at NGL North 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/d 2- Doura Refinery – Baghdad – 210 mb1/d 3- Basrah Refinery – Basrah -140 mb1/d + 70mb1/d under construction small refineries , 30mb1/d – 180 mb1/d Kirkuk,Syniah-Baiji , Najaf,Samawa,Nasiriyah,Maisan - 1 small refinery at Diwaniyah – 20 mb1/d = = = Kasak –Neinewah – 10 mb1/d = = = Haditha – Anbar – 16 mb1/d Total- 886 mb1/d mba under construction

48 Operating Capacity The 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 operational problems - 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 name UOP Saturated LPG Treater Units Naphtha Complex Naphtha Hydrotreating Units Light Naphtha Isomerisation Units Continuous Catalytic Reforming Units Total for Naphtha Complex FCC Complex Vacuum Gas oil Hydrotreating Fluidised Catalytice Cracking Unit Unsaturated Gas Plant FCC Unsaturated LPG Treating Unit

51 Nassiryah Refinery Process Units Design Capacity & Licensors
Unit name UOP FCC Complex Full Range Catalytic Naphtha Treating Unit Heavy Catalytic Naphtha Hydrodesulphurisation Unit Total for FCC Complex Axens C4 Isomerisation Unit DuPont(Stratco) H2so4 Alkylation Unit Sulphuric Acid Regeneration Unit Total CLG Hydrocracker Unit

52 Nassiryah Refinery Process Units Design Capacity & Licensors
Unit name Tecnimont KT Hydrogen Production Units Sulphur Recovery & Tail Gas Treating Units Poerner Bitumen Blowing Unit Axens Kerosene Hydrotreater Units Gaoil Hydrotreater Units Total Residue Hydrocracker Units SGS Flue Gas Desulphurisation Unit

53 Karbala Refinery Process Units Design Capacity & Licensors
Unit name Basic Design by Technip Crude and Vacuum Distillation UOP Naphtha Hydrotreating Isomerization Catalytic Reforming Axens Kerosene Hydrodesulfurization Diesel Hydrodesulfurization VGO Hydrotreating Fluid Catalytic Cracking Poly Naphtha Poerner Asphalt Blowing LPG Production Haldor Topsoe Hydrogen Production Unit – Train 1 & 2 Gas Sweetening and Amine Regeneration Sour Water Stripper KTI Sulphur Recovery – Train 1 & 2 Tail Gas Treatment

54 Missan Refinery Process Units Design Capacity & Licensors
Unit name KBR USA LLC Fluid Catalytic Cracking –Unit 190 Vacuum Residue Solvent De- asphalting ((ROSE)) –Unit 190 POERNER NGENIEUEGESLLSCHAFT MBH Blown Asphalt –Unit 250 AXENS Naphtha Hydrodesulphurization –Unit 120 Continuous Catalytic Reformer –Unit 130 Vacuum Gas Oil Hydro cracker–Unit 180 De-Asphalted Oil Hydrdesulphurisation –Unit 240 UOP Limited C5 & C6 Isomerisation Process –Unit 140 C4 Isomerisation Process –Unit 270 Saturated LPG Treatment ((SULFREX)) –Unit 155 Unsaturated LPG Treatment ((SULFREX)) –Unit 210 HALDOR TOPSOE A/S Kerosene Hydrodesulphurisation –Unit 160 Light Gas Oil Hydrodesulphurisation –Unit 170

55 Missan Refinery Process Units Design Capacity & Licensors
Unit name HALDOR TOPSOE A/S Hydrogen Production –Unit 280 E.I du Pont Nemours and Company C 3/ C4 Alkylation –Unit 260


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