The optimum process will be derived using a proven linear programming (LP) Model. The Refinery will be based on a multi-stream modularised Process using well proven technology. The process will be two staged: namely Stage 1 – hydro-skimming complexity upstream and Stage 2 – VGO hydro cracking complexity downstream including CCR Platforming, hydrogen, delayed petroleum coking for processing residuals and de-Sulphurisation units. The respective Refinery will be built in two overlapping phases of 100,000 barrels per day (bpd) each Phase such that the completion Refinery name plate capacity is 200,000 bpd as follows (a barrel is equivalent to 42 United States gallons):
1. First Phase – 100,000 bpd
This Phase is based on 5 identical hydro-skimming process complexities, 20,000 bpd process streams operating in parallel, each stream comprising of:
Crude Oil Atmospheric Distillate Tower, Vacuum Distillation Tower
Jet Fuel/ Kerosene Hydro-treater
Gas Oil Hydro-treater, Reformer.
These 5 process streams are further supplemented by downstream, single process, high complexity units:
VGO Hydro Cracker, CCR Platforming unit
Sulphur Recovery Unit
Delayed Coking Unit.
2. Second Phase -100,000 bpd
This comprises a “copy cat” repeat of the First Phase (100,000 bpd) in the way of a further five 20,000 bpd process streams plus an additional VGO Hydro Cracker Unit, CCR Platforming unit, Hydrogen Plant, Sulphur Recovery Unit and a Delayed Coking Unit thus resulting in a final Phase 1 plus Phase 2 total Refinery production of 200,000 bpd.
3. Total Refinery Complex – 200,000 bpd
The complete complex would comprise the following units:
Crude Oil Atmospheric Distillation Towers
Vacuum Distillation Towers
Jet Fuel/Kerosene Hydro-treaters, Diesel Hydro-treaters
Gas Oil Hydro-treaters
VGO Hydro Crackers, CCR Platforming Units, Hydrogen Units
Delayed Coking Units
Sulphur Recovery Units