Modular Oil Refineries

 

We can offer low capacity refineries – these are containerised modular crude oil atmospheric distillation units(ADU) which vary in size from 1000 BPD – 35,000 BPD capacity. These are built to international standards for either for hot tropical conditions or arctic conditions. They are simply controlled via a laptop and have many automatic safety features built-in. These are suitable for localised production of automotive diesel, naptha, jet kerosene, HFO etc. in an oil producing area.  Two or more plants can be installed on a single site allowing the simultaneous processing of more than one type of crude oil. One unit can still be in operation in the event another unit is down for maintenance. These can be set up and in operation within 6 to 8 month after arrival at a site where the foundations and storage tanks are already in place. The operator interface and safety features of the refining unit are specifically designed for easy operation. They can be maintained by personnel with a sound technical competency but who do not need to be skilled refining engineers. The manufacturers can also provide installation, an operational spares package and full operator training after installation.

Advantages of Mobile Refining

•No duplication of most existing infrastructure, meaning no duplication of corresponding operating costs

•No duplication of existing facilities, means no duplication of corresponding environment harmful problems

•Gas from oil well separator may be associated to heat balance of new skid units

•No over-sizing necessary to anticipate oil products market demand over a long term period

•Optimization of yields and units severity, as full capacity operation is possible over the pay out period

•Operating costs reduced to a minimum, as full capacity operation is possible

•Best processes, most recent equipment and last available catalysts chosen for the short term pay out period

•Best thermal efficiency chosen for pipe-still, topping heaters and other furnaces

•Easy revamp of particular skids to follow new crude oil analysis changes over the pay out period

•Easy geographical move of skid units after some years, if economical approach has changed

•Easy addition of extra skid units to follow new market demand

•Gas-plant for LPG supply from de-ethanizer, de-propanizer, de-butanizer, stabilizer, and stripper

•Vacuum distillation for heavy products : heavy fuel, asphalt, bituminous cuts

•Much more environmentally friendly than traditional refineries, with reduced risk of accidents leading to costly environmental remediation

•Paris Climate Accords Compliant

As an Augment traditional refineries for specialized production

•Production of specialty fuels from local crude oil on crude oil production region generates significant profit.

•No more dependence on imported crude oil with associated transportation, storage costs, and shortage possibilities. Heavy fuel oil available to drive the main power generation unit.

•Diesel-oil, natural gas, or electricity can be used for the remote external power generators and industrial engines. This is possible with small skid mounted crude oil refining units. The associated small skid mounted modular distillation plants can be run with

The Modular Refining unit consists of an Atmospheric Distillation Unit (ADU) (Topping Plant) and includes the following:

  • Air cooled fin-fans  required for cooling.
  • Instrument air compressor, if required after final design.
  • Furnace with a single or multi-burner management system with a high pressure burner feed pump to atomize the fuel for the burner system. All fuel for running the furnace will be produced by the refining process, except during black start.
  • SCADA/ DCS computer based control system for the balance of plant.
  • Multipurpose column to fractionate a wide range of crude oil and crude oil blends.   
  • Final equipment design and calculations for the refined product yields require a complete assay for the crude oil that will be used as feedstock.

The following are the prevailing codes and standards in the USA for engineering and design. These codes are adhered to in the processing, layout and selection of the various component parts used in the fabrication and assembly of this plant:

  • ASME Code Section VIII, Division 1, Pressure Vessels and Heat Exchangers
  • ANSI B31.3 Petroleum Equipment Piping
  • FM Requirements for Burner Control
  • API-RP520, Parts I and II, Design and Installation of Pressure Relieving Systems in Refineries
  • API-500A Classification of Areas for Electrical Equipment in Petroleum Refineries (Class 1, Group D, Division 2) on the process end of the skid.

All process vessels are designed and fabricated in accordance with the ASME Code, Section VIII, 

  • Coil: ASME Section I
  • Tubes: ASTM A-106 Grade B
  • Fittings: ANSI B16.9
  • Flanges: ANSI B16.5
  • Burner: FM Requirements

All piping and valves required within the process battery limits are provided, fabricated and installed to the maximum practical extent. Piping design is according to ANSI B31.3. All process piping is A-106, Grade B seamless unless otherwise specified.

Codes and Standards above will be determined by the manufacturer and are subject to revision based on final destination and overall product safety.