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Home > TAKREER
Refineries > Ruwais Refinery |
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| Ruwais Refinery |
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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. |
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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. |
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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. |
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| For
more details please go through the below links |
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| Processing
Units |
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. |
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| 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. |
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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. |
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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. |
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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. |
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| Refinery
Utilities |
| 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 |
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| 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. |
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| Marine Terminal |
| 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. |
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| 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. |
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| 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. |
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