BITUMEN PRODUCTION IN KNPC MAA REFINERY
PREPARED BY: ABDULLAH MANDANI - PROCESS ENGINEER PROCESS ENGINEERING DIVISION - TSD KNPC-MAA
PRODUCING BITUMEN IN KNPC MAA REFINERY PRESENTATION OVERVIEW • • • • • • • •
Introduction Different Feed Stocks Block Flow Diagram Process Flow Diagram Overall Process Description Bitumen Storage Tanks Loading Facilities Future Plans
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PRODUCING BITUMEN IN KNPC MAA REFINERY Introduction
• KNPC MAA is the only producer and supplier of Bitumen in the state of Kuwait. • MAA Bitumen unit was installed/ commissioned in 1978 to process 12,000 BPD of KEC residue from upstream CDUs. • The unit was designed to produce different grades (60/70, 90/15) of Bitumen with Air Blowing of Vacuum Residue. • Penetration of straight run Vacuum Residue of KEC crude is 220 pen. • Continuous Blowing Tower increase penetration to 60/70 and Batch Blowing Tower to 90/15. 3
PRODUCING BITUMEN IN KNPC MAA REFINERY Introduction Contd…
• In 1984 major revamp was carried out to enable the unit to process Eocene Residue for direct production of 60/70 grade Bitumen from Vacuum Residue. • The revamped unit was established to process a maximum capacity of 11,000 BPD of Eocene Residue. • Both Air Blowing units and associated facilities were demolished after revamping of the unit as Vacuum residue is directly meeting the specifications of Bitumen product.
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PRODUCING BITUMEN IN KNPC MAA REFINERY Different Feed Stock for Bitumen Unit PROPERTIES
EOCENE CRUDE KUWAIT EXPORT CRUDE
API GRAVITY
17.9
29.9
SULFUR WT%
4.53
2.65
CON CARBON WT%
9.92
6.11
ASPHALTENES WT%
6.2
2.5
TAN mgKOH/g
0.36
0.18
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PRODUCING BITUMEN IN KNPC MAA REFINERY Block flow diagram of Bitumen unit at MAA OFF GAS
EOCENE RESIDUE ( FEED )
BITUMEN UNIT
VACCUM RESIDUE ( BITUMEN )
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WAXY
PRODUCING BITUMEN IN KNPC MAA REFINERY Process Flow Diagram of Bitumen unit at MAA
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PRODUCING BITUMEN IN KNPC MAA REFINERY Overall Process Description
• Bitumen unit is currently operating at a feed throughput of 9000 BPD of Eocene Residue producing 900 TPD of Bitumen. • Eocene Residue is directly fed to Vacuum Heater in Bitumen unit. • Vacuum Column Residue from Bitumen unit is directly routed to Storage tanks after cooling to 150 C. • Penetration and Viscosity is adjusted with Column Vacuum and Heater coil outlet temperature.
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PRODUCING BITUMEN IN KNPC MAA REFINERY Overall Process Description
• No Air Blowing Facilities (CBT, BBT) required as Eocene crude Vacuum Residue directly meets the specification for Bitumen. • Only 60/70 pen Bitumen is produced .
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PRODUCING BITUMEN IN KNPC MAA REFINERY Bitumen Storage Tanks
• Hot Bitumen is stored in 3 tanks of operating capacity of 6750 Tons each. • Adequate storage capacity is provided so as to make possible product dispatch for a period up to one month during shutdown of Bitumen plant. • The storage temperature is maintained at 170-1800C by hot oil circulation coils installed inside each tanks. • Product in one tank is certified by Laboratory Services prior to dispatch. No simultaneous filling and lowering are done in Bitumen tanks . 10
PRODUCING BITUMEN IN KNPC MAA REFINERY Bitumen Storage Tanks
• MC -70 grade Bitumen is produced by blending 60/70 Bitumen with Kerosene in Cutback grade tanks. • Capacity of blending equipment is such as to produce 10,000 tons/year of cutback bitumen.
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PRODUCING BITUMEN IN KNPC MAA REFINERY Loading Facilities
• Bulk loading facilities are designed to enable a maximum loading and dispatching rate of 200 tons/Hr in order to account for anticipated fluctuation in demand. • Three loading arms have been provided to charge 60/70 Bitumen products. • Delivery days: 5 days/week
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PRODUCING BITUMEN IN KNPC MAA REFINERY Future Plan
• As per study conducted by consultants, Bitumen demand in Kuwait will increase to 1300TPD by 2030. • A new study is initiated to enhance Bitumen production, storage and loading facilities in MAA Refinery to meet the Bitumen demand till 2030.
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