Located some 240 kilometers west of Abu Dhabi City, the Ruwais Industrial Complex was developed as a major contributor to the national economy and represents a series of multi-million dollar investments.
The Ruwais story began in the 1970s, when plans were laid to transform a remote desert site into a self-contained industrial town, geared to fulfilling the down stream requirements of Abu Dhabi's booming oil and gas industry.
Centered around Ruwais Refinery, the complex was officially inaugurated in 1982 by the late Sheikh Zayed bin Sultan Al Nahyan “May Almighty Allah rest his soul in eternal peace” , former President of the UAE and the visionary behind Abu Dhabi's remarkable development and prosperity.
Soon after commissioning the original 120,000 barrels per day (bpd) Hydro skimming refinery in June 1981, plans were drawn up to add a 27,000 bpd Hydro cracker complex that was started in 1985. To consolidate operations, the General Utilities Plant, set up in 1982 to provide electricity and water for the area, was merged with the Refinery in 1986.
In support of the company's HSE policy, a central Sulphur Handling and Granulation Plant was established in 1991 to handle all the liquid Sulphur recovered in the GASCO and ADGAS Natural Gas Liquefaction facilities. Its operations were also integrated with the Ruwais Refinery Division in 1992. After its expansion in early 2001, the granulation capacity, at 7,650 tons per day, has become one of the largest in the world.
Two 140,000 bpd condensate processing trains were commissioned in year 2000 - 2002 to process condensate produced in the on-shore gas fields of Abu Dhabi. Currently these are two of the largest such condensate splitters in the world. Meanwhile, support facilities such as berths, power generation and water production facilities continued to be expanded to meet the growing needs of the industrial area.
The original Hydro skimming complex was designed to process 120,000 bpd of crude oil, mainly for the export market. Growth in demand for Abu Dhabi's high quality refined products spurred the continuous expansions at Ruwais. Today the range of refined products includes Liquefied Petroleum Gas, Premium Unleaded Gasoline (98 Octane), Special Unleaded Gasoline (95 Octane), Naphtha grades, Jet-A1 and Kerosene grades, Gas Oil grades, Straight run Residue, Bunker grades 180 and 380 cst and Granulated Sulphur.
For more details please go through the below links
- Refinery Utilities.
-Tank farm & offsites.
- Sulphur Handling Terminal & Granulation plant.
-General Utilities Plant.
These are produced by the following primary and secondary processing units:
Crude oil Distillation (120,000 bpd): After desalting, crude oil is distilled to produce full-range naphtha, kerosene, light gas oil, heavy gas oil and straight run residue, which are further processed in downstream units.
Naphtha Hydrodesulphurization (34,350 bpd): The full-range naphtha from the crude oil unit and heavy naphtha from the Hydro cracker unit is hydro treated to remove the Sulphur compounds and then LPG is stripped from whole naphtha. After dehydration, the raw LPG is sent to the GASCO-NGL plant for further processing while the whole naphtha is split into light naphtha, used for gasoline blending, and heavy naphtha, used as feedstock for the Catalytic Reformer Unit.
Atalytic Reformer (19,150 bpd): The heavy naphtha is processed to improve its anti-knock properties by using a bimetallic platinum-based catalyst. The Reformate obtained is used as the main blend component for gasoline production. The hydrogen-rich gas is used in the reaction sections of the hydrotreaters and the remaining gas goes to Refinery Fuel Gas system.
Kerosene Hydrotreater (20,780 bpd): The unit improves the burning quality of kerosene by desulphurization and saturation of aromatics required to meet international specifications for jet fuel.
Gas Oil Hydrodesulphurization (21,850 bpsd): The unit removes Sulphur compounds in the heavy gas oil from the crude oil unit using a cobalt/molybdenum oxide-based catalyst. The hydrotreated heavy gas oil is used as a blending component to produce different grades of gas oil.
Vacuum Unit (46,000 bpd): The Vacuum Unit processes atmospheric residue from the crude oil unit to produce heavy vacuum gas oil as feedstock for the Unibon unit. Ruwais residue is supplemented by residue from Abu Dhabi Refinery.
Unibon Unit/Hydro cracker (27,000 bpd): The Unibon Unit converts the heavy vacuum gas oil feed into lighter products in the reactor section by passing the feed, plus hydrogen, over catalysts under high temperature and pressure. The products from this reaction are then separated in the fractionation section to yield high value finished products ranging from LPG to gas oil.
Hydrogen Plant (60,000 Nm3/hr): The Hydrogen Unit converts natural gas and steam into hydrogen with the aid of catalysts. Propane can also be used as an alternative feed.
Two Sulphur Recovery Plants (44/49 tons per day): These units recover sulphur from hydrogen sulphide-rich gas produced in the Hydrodesulphurization and Unibon units by converting it into elemental sulphur through a thermal and catalytic reaction. The liquid sulphur is then sent to the Sulphur Handling Terminal for granulation and export.
Two Condensate Splitters (2x140,000 bpd): Each splitter is designed to process condensate from the On-shore Gas Development and Asab Gas Development fields. The splitters fractionate the condensate into unstabilized light naphtha, medium naphtha, heavy naphtha, kerosene, light gas oil (LGO), heavy gas oil (HGO), and atmospheric residue, which are further processed in downstream units.
Two Naphtha Stabilizers (2x27,500 bpd): Each Stabilizer is designed to process 27,500 bpd of unstabilized light naphtha from the condensate splitters. LPG after treatment is sent to GASCO while stabilized light naphtha is routed to storage and blending.
Two Kerosene Sweetening Units (2x52,000 bpd): Kerosene produced in the Condensate Distillation Units contains mercaptans and naphthenic acids. The Merichem Sweetening units reduce the mercaptans by converting them into disulphide. The sweetened kerosene from each unit is routed to storage and blending.
The refinery generates all the utilities, which are required by the process units. Equipment and systems include steam boilers, seawater cooling systems, a closed-loop fresh water cooling system, instrument and plant air, fuel oil and fuel gas systems
Tank Farm & Offsites
The Refinery has 91 tanks with a total nominal storage capacity of over three million cubic meters. Of these 12 are feedstock tanks, 34 are for intermediate products and 45 for finished products. Off sites include ballast reception facilities, CPI separator system, four flares, blending and shipping facilities with LPG truck loading.
The Refinery's Marine Terminal provides for the loading and unloading of tankers ranging from 2,000 to 330,000 dwt. It has four cabotage berths to accommodate tankers from 2,000 to 7,000 dwt, and three large tanker berths for vessels from 7,000 to 330,000 dwt.
Sulphur Handling & Granulation Plant
The Sulphur Handling and Granulation Plant has nine granulators with a total capacity of 7,650 tons per day and covered storage for 145,000 tons of granulated product. Multiple bays for receiving liquid Sulphur trucks from the on-shore gas processing facilities and a jetty to handle liquid imports from ADGAS have been recently upgraded. The jetty is capable of handling vessels up to 45,000 dwt for granulated Sulphur exports.
General Utilities Plant
Ruwais Refinery Division operates the GUP to provide reliable power and water not only for its needs but the industrial area and community at large. Power is generated by seven gas turbines and two steam turbines with an installed capacity of over 650 MW. Water production capacity is over 60,000 m3/day from five desalinators. Interconnection of GUP with ADWEA grid and synchronization enabled TAKREER to acquire the capability and flexibility to import and export power, along with the stability of supply of electrical power to consumers.