Mini Refinery

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1 Executive Summary

1.1 Worldwide Projection, Demand, Supply & BAE Mini-Refinery Solution:

Fiducia Petroleum Co. Ltd. has developed a unique refining process in limited volumes as a
compact crude oil processing to produce diesel, high octane gasoline grades (of AI92 and/or
AI95), kerosene, LPG, etc. Fiducia Petroleum Co. Ltd. solution is a minimized regular
hydro-cracking method of crude oil refining via utilizing the method of isomerisation and
aromatization.

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The methodology is based on a refining of hydrocarbons obtained through the direct distillation of crude oil,
namely the straight-run gasoline (fraction at 85-180°C). In order to process straight-run gasoline, we use
the process of "Metaforming", which increases the octane number of the crude, followed by the
production of motor fuels of Euro 3 and
Euro 4 standards (trade marks of AI-92 &
AI-95).

The purpose of Fiducia Petroleum Co.


Ltd. oil refinery is to be a solution supplier
for major distilled oil products as gasline,
LPG, diesel and fuel-oil with a cost
effective investment, low costed
operating and limited timeline. So to be
able to come with local potential solution
provider.

This business plan calls for setting up a mini refining solution with the capacity to process 2.600 metric
tons (MT) (18.000 bpd) of crude to naphtha and AI92 and/or AI95 octane gasoline in addition to diesel,
LPG, kerosene, etc. through the same process. The complete facility of a mini-refinery can be set up and
operating within 5-7 months.

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Some worldwide facts can be listed as follows:

1.2 Our Projection for 18.000 BPD Crude Refining Units:

1. Crude Distillation Unit


2. Kerosene Treater
3. Naphtha Reformer
4. Diesel hydro Desulfurizer Unit (Optional)
5. Liquefied Petroleum Gas Unit
6. Power Plant (Optional)
7. Tank Farm

1.3 Our Project Overview:

PROJECT : Crude Oil Refining

CAPACITY : 18.000 barrels/day

EXECUTIVE SUMMARY : To setup a turnkey brand new state of the art crude oil refinery plant
with Equipment and Machinery of Fiducia Petroleum Co. Ltd. to
site. The refinery is to process 31-42 API crude oil to produce
hydrocarbon fuels such as:
(a) AI92 or AI95 Gasoline
(b) Euro-3, Euro-4 or Euro-5 Diesel
(c) LPG
(d) Naphtha based solvents,
(e) Motor Sprits,
(f) Kerosene
(g) SRFO / HFO
i. Sales of fuel-oil to the market
ii. Converting to electricity with a power plant

PURPOSE: Fiducia Petroleum Co. Ltd. obtains a unique mini refinery project in the
following pages via own know-how, manufacturing and EPC abilities to
handle this project with compact structure and financials. The plant
project road-map can easily be handled in a short period to start up and
supply the market demands.

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2 Technology

Fiducia Petroleum Co. Ltd. technology is based on refining the crude to achieve major products.
Obtained 2 major processing for oil refining of Mini Refinery Plant, as a complete solution from crude oil
to high-octane refined oil products. Optimum capacity 900.000 MT/year (±3%) (2.600 MT/day), which
is approximately 6.000.000 barrels/year (18.000 barrels/day) of:

1. Primary Refining Plant: Crude Oil Processing


2. Metaforming – Secondary, “Naphtha” Processing

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The plant will be located near a refinery to utilize easy access to naphtha. It will occupy in
a hydrocarbon processing facility, which will include a roofed area, a stock area, an
administrative building with a laboratory and a tank farm terminal. The land should have
ready-to-use infrastructure such as roads, rail, power, gas, water supply etc.

2.1 The Technology: Fiducia Petroleum Co. Ltd. Unique Crude & Reforming
Process
Mini-refineries for the production of motor fuels (oil) are fully equipped modular units,
suitable for immediate installation on the site and to be launched within three weeks after
the equipment is delivered to the to the prepared construction site.

Fractionation of stable gas condensate (low-octane gasoline) and release of fraction of 30-
80°С and 80- 200°С. Catalytic isomerisation and aromatization. of fractions 80-200°С and
release of unstable catalyst Stabilization of unstable catalyst and producing of LPG and
stable catalyst

Fractionation of stable catalyst and release of target gasoline product (with end boiling point
up to 215°С) and removal of heavy residue. Mixing (compounding) of gasoline fraction (with
end boiling point up to 215°С) with the fraction of stable gas condensate of 30-80°С and
producing high-octane gasoline in addition to diesel, fuel oil and LPG.

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In the process of aromatization., the catalyst loses its activity. To restore the activity of the
catalyst oxidative regeneration is used. Technical nitrogen is used as oxygen-containing
gas. To prevent significant coke-sedimentation, reactors are to be stopped for regeneration
after every 300 hours of operation.

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Table: World Liquid Fuel Production vs. Consumption

Shortly the methodology is based on a secondary refining of hydrocarbons obtained through


the direct distillation of crude oil, namely the straight-run gasoline (fraction at 85-180°C).
In order to process straight-run gasoline, we use the process of "Metaforming", the aim of
which is to increase the octane number of the crude, followed by the production of motor
fuels of Euro 3 and Euro 4 standards (trade marks of AI-92 & AI-95). The technology process
is described below:

 In the process of production of gasoline, the reaction of catalytic aromatization and


isomerisation of hydrocarbon fractions (80-200°С) takes place in the presence of
catalyzer.
 Hydrocarbon fractions of 80-200°С are heated from its initial temperature being
within 90°С – 110°С up to the temperature of catalytic aromatization reaction i.e.
340°С – 450°С in heat exchangers- recuperators and in furnace for feed stock
heating
 The reaction of catalytic aromatization and isomerisation occurs in tubular reactors
in the presence of a catalyst; the pressure of the reaction is within 0,7 – 1,0 МPа,
the space velocity of raw material in the reactor 2 hour-1, which is constant for the
entire cycle
 After cooling, separation, stabilization and rectification of products of the reaction,
stable catalyst is released, which is compounded with 30-80°С fraction of gas
condensate to produce high-octane motor gasoline.

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 In the process of aromatization the catalyst loses its activity. To restore the activity
of the catalyst oxidative regeneration is used. Technical nitrogen is used as oxygen-
containing gas.
 To prevent significant coke-sedimentation, reactors are to be stopped for
regeneration after every 300 hours of operation

2.2 Products of Oil Refinery

1. Naphtha (straight-run gasoline) – with final boiling point up to 185 °C. Naphtha is
then used as a basic component in the production of high-octane gasoline.

2. Diesel fractions (mini refinery distillate) - A typical temperature of the product is in


the range from about 185 ° C to 340 ° C. The product was further subjected to
distillation to separate kerosene and diesel fuel.

3. Straight-run fuel oil (residual fraction) - a fraction remained after the primary
distillation with an initial boiling point of about 320 °C. This product is commonly
used in the production of various grades of marine fuel and fuel oil.

Processing of crude oil in the refinery with a specific gravity of 0.865 will produce light
naphtha at the volume of 20% of crude, 30% middle distillate (gasoline and kerosene
fraction), and 50% straight-run fuel oil, as residual fraction.

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2.3 The Inlet / Outlets of Facility

2.3.1 The Inlet / Outlets of Mini-refinery Process

Inlet : Crude Oil (Light preferred)


Outlet : Diesel, kerosene,
AI92/AI95, LPG The Stock Balance Chart:

Qty (%) Qty (%) Qty (%)


Input Product Output
(mtons) (mtons) (mtons)

High-octane 16,34%
Gasoline (Al92) (144.000)

1,90%
19% LPG
Naphtha (Boiling point - 180o) (25.650)
(171.000)
0,76%
Other/Loss
(6.600)

9% 9%
Kerosene Component (180-240o) Kerosene
Crude 100% (81.000) (81.000)
Oil (900.000) 20% 20%
Diesel (240-360o) Diesel
(180.000) (180.000)

Straight-run Fuel Oil (360o - Final 48% 48%


SRFO
boiling point) (432.000) (432.000)

4% 4%
Losses Losses
(36.000) (36.000)

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2.3.2 The Inlet / Outlets of HFO
Power Plant Inlet :
Heavy Fuel-Oil
Outlet : Electricty

The Stock Balance Chart:

Qty (%) Consumprion Output


Input Product Output
(mtons) (grams/kW) (kW)

~ 2.500.000.000 yearly
Mixture of
or
100% - SRFO
HFO 200-220 g Power Output ~ 6.850.000 daily
(~500.000MT) - Kerosene
or
- Diesel
~285 MWh

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BAE Mini-Refinery Process Diagram with Capacity

Crude Oil
900.000 MT/year

Crude Oil
Primary
Refining

Naphtha Kerosene Diesel


Losses
171.000 MT/year 81.000 MT/year Euro-3 & Euro-4 Fuel Oil

Secondary De-Sulphurization SRFO / HFO


Refining Process Power Plant
Metaforming 500.000MT

AI-92 Gasoline LPG Dry Gas & Loss Diesel Electricity

Actual production capacity and boiling points of the products may vary depending on the
characteristics of crude oil to be supplied.

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2.4 Distinctive Features:

Designing of the installation is based on the following criteria:


 Optimization of technological process with an aim to minimize capital and
operational expenditures
 Modular design ensuring minimum costs during installation
 Simplicity in management and maintenance
 Autonomy of the work of installation
 Possibility for flexible correction of technological parameters
 Compliance with safety, fire safety, environmental protection requirements
 Maximized automation and process standardization

3 Facility

3.1 Location-Infrastructure

The best suitable place for installing a “Mini Refinery” is nearby port to receive/import crude.
A tank farm, energy, piping, ready-to-use infrastructure also helps for a quick start-up.

The infrastructure requirements for the metaforming plant installation include the following:

• Installation Location – near a port, terminal or crude supply chain as well as a land plot
with industrial infrastructure (automobile or rail roads, power, gas, water supply etc.).

• Power supply – The supply of AC electrical energy from the available power grid is
envisaged. Power supply for the installation is to be AC 380/220 V, 50 Hz. As part of the
equipment for the installation, an uninterruptible power supply unit is to be provided with
a purpose to manage the installation in the cases of emergency or termination of power
supply.

• Compressed air supply – To produce compressed air, two compressors with capacity of
500m³/h is to be considered. Each shall be with a fully automated drying nod. Compressed
air is stored in a tank for compressed air with volume of 70m³. The pressure of the air to
be supplied to the processing station is to be 5kg/cm²

• Natural gas supply – Natural gas is to be supplied from the available gas pipeline. In case
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