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Info Middle Alahmadi Refinery

Catalytic Reforming EquipmentMina Al-Ahmadi Refinery (MAA) was inbuilt 1949 as a simple refinery with a refining capacity not exceeding 25,000 bpd to supply the native market with its needs of gasoline, kerosene and diesel. The refinery is situated forty five km to the South of Kuwait City on the Arabian Gulf. It covers a total area of 10,534,000 m2.

Following the establishment of KPC and the restructuring of the oil sector, ownership of the refinery was handed from Kuwait Oil Firm (KOC) to Kuwait Nationwide Petroleum Company (KNPC) which became answerable for the oil refining and gasoline liquefaction operations in Kuwait. Within the early 1980’s as a part of an general plan
to improve the refining industry and broaden the refineries , work began on two bold projects to modernize Mina Al-Ahmadi Refinery, particularly the MAA-Refinery Modernization Undertaking (MAA-RMP) (which was accomplished in 1984) and the Additional Upgrading Challenge MAA-FUP (which was commissioned in 1986). Throughout the framework of these two initiatives, 29 new units were constructed at this refinery which has now grow to be one of the world’s trendy refineries when it comes to both refining capacity, which exceeds 460,000 bpd and the advanced technology it employs.
Mina Al-Ahmadi Refinery Modernization Undertaking (RMP) was mainly supposed to provide the local and world markets with low sulphur -content petroleum products, and to reduce dependence on gas as fuel, offering cheaper and more stable gas to the country’s power technology plants.
The Additional Upgrading Venture (FUP) was based mostly on extra comprehensive view of the future of petroleum product markets in order to maximise profits and ensure a stable marketplace for the three refineries output. The venture additional sought to increase the share of light and medium merchandise of the distillation course of and reduce the share of gas oil in the long run output, resulting in the next return from the crude oil refining processes. The refinery now accommodates 29 new models, in addition to the outdated units, together with the crude distillation models, the Fluid Catalytic Cracking Unit, the Atmospheric Residue Desulphurization Items, the Vacuum Rerun Unit and the Sulphur Restoration unit.

Mina Al-Ahmadi History
• 1949: 25,000-30,000 BPD Refinery commissioned below KOC.
• 1958/63: Refinery enlargement to 190,000 PBD & 250,000 BPD respectively.
• 1978: Fuel liquefaction plant was commissioned.
• 1981: Rhenformer Models commissioned.
• 1984: Transfer of MAA Refinery to KNPC.
• 1984: Refinery modernization challenge (RMP) untis commissioned progressively.
• 1985: Further upgrading challenge (FUP) models commissioning started.
• 1987: FCC was commissioned
• 1997: FCC unit capacity increased to 40,000 BPD (revamp), as part of MAFR. – PRU, MTBE, ALKAYLATION, and SAR units commissioning began.
• 2000: A mishap as a consequence of a leak in fuel condensate line, led to a destruction of a number of services. Quick rehabilitation happened to repair and substitute the broken facilities. New ATK MEROX unit was commissioned.
• 2002: New G.O.D is commissioned in April, 2002.

MAA Important Items
Crude Oil Distillation Unit:
The total capacity of the two new crude oil distillation units is 290,000 bpd. They obtain crude feed from the Burgan, Ratawi and other oil fields. In these models, the uncooked materials is separated within the distillation tower into a lot of products reminiscent of fuel, naphtha, kerosene, mild gasoline oil, heavy gasoline oil and residues. The distillates of those two models are sent to other conversion units so as to improve their specs to the required standard. These two models were constructed as part of the refinery modernization project (MAA-RMP). They supplement the production of the present crude distillation unit to boost the capability of those three CDU units to round 466,000 bpd.

Fluid Catalytic Cracking Models (FCC)
The unit was commissioned in 1986 as part of the “Refinery Additional Upgrading Venture (FUP)” with a capacity of 30,000 bpd.
In 1997, the unit was revamped and its capacity was raised to forty,000 bpd as a part of MAFP (which stands for MTBE Alkylation, and FCC revamp Project). Since that point the unit continues to play a serious function as a coronary heart conversion unit among the many three refineries , the place it processes varied feed to supply prime quality merchandise and feedstock for downstream models for further processing. The unit goal is to produce maximum Liquefied Petroleum Gases (LPG) and Gasoline (Conversation level seventy nine of LV% to gasoline ). The “Olefin” rich LPG stream (Double Bond Hydrocarbons) is further processed in downstream items to provide Propylene, MTBE and Alkylate.

FCC unit consists of the following sections
• Reactor/ Regenerator
• Predominant Fractionators
• Fuel Concentration Unit
• Power Restoration

FEED 40,000BPD (VGO.75vol%, CGO. 26vol%) FCC Products VIELDS
Important Units at Mina Al-Ahmadi Refinery

CCR Naphtha Reformers
After the June 2000 mishap in Mina Al-Ahmadi Refinery, quick action was taken to rehabilitate the damaged facilities. The company decided to construct two an identical reformate production units instead of the outdated destroyed items with state-of-artwork technology.
The new “Naphtha Complex” consists of two an identical course of trains. Every course of prepare consists of a Naphtha Hydrotreater, Naphtha Splitter and CCR (Steady Catalyst Regeneration) reformers for gasoline production. A devoted Nitrogen Generation Unit can also be being built to cater to N2 requirement for both items.
The target of the complex is to produce reformat with RON of MON of 90.06 and Benzene content of 1.Zero vol% max. The complex was commissioned in October 2003.

Process Description
Naphtha Hydrotreater:
Hydrotreating of Naphtha is essential to remove catalyst poisons corresponding to Sulphur, Nitrogen which is catalytically hydrotreated in a hard and fast mattress reactor eia oil consumption employing a choose catalyst and hydrogen rich stream to decompose natural sulphur, oxygen and nitrogen compounds contained in hydrocarbon fractions. As well as, hydrotreating remove organometallic compounds and saturates olefin compounds.
The Naphtha hydrotreating process makes a major contribution in the operations and economic system of platforming.

Sulphur Recovery Units:
Inside phases 1 and a couple of of Mina Al-Ahmadi Refinery Modernization Venture, 4 units were constructed to get well the sulphur obtained as a byproduct of sure refinery processes. The total capability of those items is 1,334 metric tons, of sulphur per day.

Central Control System:
In every of the 2 phases of the MAA Refinery Modernization Challenge, a state- of- the – artwork central control room was established along with several local management systems, or sub-control rooms. At Mina Al-Ahmadi, the central control system relies on state-of- the art microprocessor technologies. Each central management room houses a number of operation stations geared up with monitors linked to a microprocessor that displays the refinery models. The pc performs an in depth sequence of operations such because the quite a few variable information within the manufacturing processes (heat, strain, and so forth). The pc displays drawings and plans of the production items with totally different variable data and the operation status of each unit. The pc also offers alarm messages
when any of those values exceed the boundaries for safe operation. Moreover, the computer performs sophisticated mathematical operations required for the management and operation of the models, thus ensuring added security and security.
The CCR additionally helps within the conservation of energy and precisely controls the specifications of the petroleum merchandise.

The new Oil Pier at Mina Al-Ahmadi Refinery
The brand new south pier in MAA was inaugurated in February 2004 as part of the (Development and Restoration of MAA Two oil piers) the refinery has two oil piers to export crude oil, LPG and eia oil consumption petroleum products.
SOUTH LOADING PIER (related with the Refinery)
NORTH LOADING PIER (10KM north of the Refinery)
The project mainly envisaged building of a new pier to exchange the South Pier and restoration of the North Pier in order that its life will probably be extended for 15 12 months.
The new South Pier is the most important and essentially the most superior marine facility within the Center East with the state of art expertise. The construction of the pier took seven years, 4 for research and three for building. it has six berths for the export of Crude oil, LPG and petroleum merchandise.

The new Pier’s Superior System and Technology – Primary Options
Variety of Mooring Factors 5
Tankers deadweight 160,000 tons
Estimated design life 30 years
Whole of mooring points 4300 m
Complete variety of Platforms 5
Anchor’s depth 17m

Petroleum products being exported:
• Light and Heavy Fuel Oil
• Diesel, Kerosene and Naphtha
• LPG
• Crude Oil
• Tankers superior and satellite connected berth monitoring system that ensures secure and accurate anchorage
• Sudden-Interruption suction system for petroleum merchandise during loading operation.

LPG Plant at Mina Al-Ahmadi Refinery
Gasoline Liquefaction Plant (LPG) at Mina Al-Ahmadi went on stream in 1978. It consists of three trains the capacity of every is 560,MMSCF designed for the extraction of propane, butane and pure gasoline. The plant additionally consists of storage tanks divided into two tank farms. Anticorrosion Strong Cavitation Device The greater portion of the LPG plant production is now being exported to the world market from the south pier of Mina Al-Ahmadi which is related to the plant by a pipeline network. The average each day charge of feedstock to the plant stands at round 1680 MMSCF per day.
The LPG plant receives natural fuel from Kuwait Oil Firm (KOC) gathering centres (26) in located at the various oil fields in Kuwait and liquid fuel from KNPC refineries. Propane and butane are exported via the refinery south pier.
The mixture of gases is separated in the plant’s units into the following merchandise:

In addition to lean gas and residues.
The Gas plant was built to course of all related fuel/ condensates collected from Kuwait Oil Firm (KOC), another KPC firm which is accountable for oil / gas exploration & manufacturing. It consists of three an identical trains with a complete processing capability of 1.Sixty eight billion SCF/ day (together with 80,000 BPD of hydrocarbon condensate). While the LPG plant essentially produces liquefied propane, liquefied butane that are saved in refrigerated tanks and Kuwait Pure Gasoline (KNG) It also produces high-stress (HP) and low pressure (LP) lean gases.
It must be noted that the LPG plant plays a major position as the first power provider to power stations, KNPC refineries & PIC. It is usually the one petrochemical feed stock supplier of ethane gasoline to Equate for the manufacture of poly- ethylene.
So as to satisfy the new unleaded gasoline specification in addition to to upgrade cracked LPG from the FCC unit, new facilities were added downstream of the FCC unit. These units together referred to as the MAFP block and commissioned in 1997, together with services to provide propylene product to PIC for the manufacture of polypropylene and to provide Alkylate and MTBE, that are both mogas components.
Acid Gas Removel mission (AGRP) the AGRP was applied within the yr 2000 so as to deal with related bitter fuel from the oil fields.
In order to fulfill newest diesel qualities, a brand new Gasoline Oil Desulphurization Unit was added to the refinery configuration in the yr 2002.
Further, two new Naphtha Continuous Catalytic Reforming (CCR) units are built and commissioned within the yr 2003. MAA Refinery additionally houses the management of sulfur solidification and granulation services, which serves the three KNPC refineries. MAA & LPG plant employees about 1550 Staff.

Gas Plant: (Abstract eia oil consumption of Most important Features)
• Situated at Mina Al-Ahmadi Refinery.
• Consists of three Trains of an identical capability each.
• Complete capacity is 1680 MMSCF per Day (560 x 3 Trains). Processes sweet related gasoline & condensate from the crude manufacturing.