MODULAR REFINING SOLUTIONS

Field Diesel UnitTopping UnitHydroskimming RefineryFull Conversion RefineryBitumen Refinery

www.pyramidenc.com

Pyramid E&C is an international technology and EPC company having core competence of supplying modular process plants for Automotive Fuels, Fertilizer and Petrochemicals production from Oil and Gas resources.We enable oil and gas asset owners enter downstream market at the lowest cost and produce a range of hydrocarbons to serve regional market, thus maintaining a tight operation insulated from commodity price fluctuation and international product suppliers.Our services cover all stages of development; from feasibility studies through financial engineering, manufacturing, equipment supply, project management, installation, commissioning and operation of facilities.Pyramid E&C engineering and project management centers in Houston, London, UAE and India have capability to deliver and operate projects worldwide. Pyramid E&C specializes in fast track deliveries by using standard plant configurations and modularization. Our fabrication facilities in US and India have capabilities of equipment manufacturing, process automation and deliver process modules up to 1,000 tons in a single piece thus ensuring quality and most efficient execution.

About Pyramid E&C

Modular Refining Solutions Field Diesel Unit www.pyramidenc.com

Field Diesel Unit A Field Diesel Unit (FDU) is effective in areas where there is a ready supply of crude oil but limited supply of fuel for power generation and drilling operation. This unit extracts the diesel component from the crude oil and blends rest of the products back to crude oil stream. The FDU is supplied in easily transportable skids, it is quick to install and is self-sufficient. The unit can be started when needed and stopped when the tanks are full. The diesel produced by these units largely depends on the type of crude oil, lighter varieties will provide greater diesel yield and higher cetane number.

Standard Sizes (Crude oil throughput) • 200 BPD • 500 BPD • 1000 BPD

Major Equipment • Desalter • Fired Heater / Hot Oil Heater • Distillation Column • Diesel Stripper Column • Heat Exchangers • Chemical Injection System

ProcessPreheating and Desalting Crude Oil from storage tank is pumped through preheat exchangers to an electrostatic desalter and washed after mixing with fresh water. The desalted crude is further heated in exchangers with hot product streams before it enters the heater.

Heating The preheated crude oil from desalter is then charged to a heater fired by off-gas or one of the product streams. Crude oil enters the heater convection section, passes through the radiant section and exits the heater at appropriate temperature for fractionation.

Distillation The heated crude oil is flashed into vapor and liquid fractions in the flash zone of the distillation column. The vapor fraction rises through the wash zone fractionating trays of the column, whereas liquid fraction flows down to the bottom through the stripping section. Diesel fraction in vapor is condensed and drawn as product from the chimney trays into a diesel stripper. The lighter fractions go up and condense in overhead condenser. Part of condensate is fed back as reflux and the balance is blended with the residue from the bottom and mixed with the Crude Oil. The uncondensed gases are vented to Flare system.

Flare

WaterReflux

Reflux Drum

Desalter

Auxiliary systems

Utility & Offsite systems

Heater

Flare

Inst. Air Nitrogen Power Storage

Drain

ToppingColumn

Diesel

Crude

Red. Crude

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Modular Refining SolutionsTopping Plantswww.pyramidenc.com

Topping Plants

A Topping plant is a simple refinery that allows for distillation of crude oil into naphtha, straight run kerosene, diesel and fuel oil. Pyramid E&C supplies these units complete with auxiliary and utility packages in modular construction to reduce site work and achieve faster execution.

Standard Sizes (Crude Oil throughput) • 2000 BPD • 5000 BPD • 10000 BPD • 25000 BPD

Major Equipment • Desalter • Fired Heater • Distillation Column • Stripper Columns

Process

Preheating and Desalting Crude Oil from storage tank is pumped through preheat exchangers to an electrostatic desalter and washed after mixing with fresh water. The desalted crude is further heated in exchangers with hot product streams before it enters the heater.

Heating The preheated crude oil from desalter is then charged to the heater which is fired by off-gas or one of the product streams. Crude Oil enters the heater convection section, passes through the radiant section and exits the heater at suitable temperature for fractionation.

Distillation The heated Crude oil is flashed into vapor and liquid fractions in the flash zone of the distillation column. The vapor fraction rises through wash zone fractionating trays of the column, whereas liquid fraction flows down to bottom. At certain operating temperature, diesel and kerosene fractions in the vapor condense, flow back into liquid phase and are drawn as products into the respective side strippers for specification control. The lighter fractions including naphtha go up and condense in overhead condenser. Part of the condensate is fed back as reflux and the balance is drawn as full range naphtha and LPG. The uncondensed gases are vented to the flare system.

Power Steam GenerationStorageProduct Logistics

Inst. Air

Flare

Auxiliary systems

Utility & Offsite systems

Drain

Nitrogen DM Water Effluent Treatment

CrudeDesalter

Reflux Drum

Naphtha

Kerosene

Gas Oil

Fuel Oil

ToppingColumn

Heater

Fuel Gas

Reflux

Steam

Water

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Modular Refining Solutions Hydroskimming Refinery www.pyramidenc.com

Hydroskimming Refinery A Hydroskimming refinery comprises of atmospheric distillation unit, naphtha processing complex to produce gasoline from straight run naphtha and a distillate hydrotreater to produce low sulfur kerosene and diesel. Pyramid E&C designs the open art systems and integrates with third party licensed packages. The refinery is supplied complete with auxiliary and utility packages in modular construction to reduce site work and achieve faster execution.Standard Sizes • 10000 BPD • 25000 BPDMajor Units • Atmospheric Distillation • Naphtha Stabilizer • Naphtha Hydrotreater • Naphtha Reformer • Isomerization Unit • Distillate Hydrotreater • Sour Water Stripper • Sulfur Recovery • Hydrogen Purification / Generation

ProcessDistillation The topping unit is first unit in Hydroskimming refinery which produces straight run naphtha, kerosene, gas oil and residue. The straight run products are fed to downstream treatment units.Naphtha Hydrotreatment Stabilized full range naphtha will undergo further processing in the Naphtha Hydrotreater to remove sulfur, nitrogen, and other impurities, that would poison the catalyst used in the downstream catalytic reforming process. Sulfur removal is also required to meet gasoline product specifications.

Reforming Heavy naphtha is sent to the catalytic reformer where it gets converted into a stream comprising of aromatic components with high octane number in the range of 90 to 100. The reforming unit also generates streams rich in hydrogen and fuel gas.Isomerization Unit Light naphtha from the Naphtha Hydrotreater is fed to the isomerization unit with hydrogen rich gas from reformer unit. Here the naphtha is converted to high octane isomerate, stored in intermediate tanks and then blended into gasoline pool.LPG Recovery The naphtha fraction is stabilized by separating C3 and C4 components which form part of LPG pool. The LPG stream from stabilizer is mixed with that from the reformer and sent to the de-propanizer to achieve required blend. The overhead vapors are sent to the sweetening unit for use as fuel gas. Stabilized naphtha is sent to the hydrotreatment unit.Hydrogen Purification The hydrogen-rich gas from reformer is treated in a pressure swing adsorption (PSA) unit that purifies hydrogen for usage in hydrotreating process. The PSA will typically deliver hydrogen with a purity higher than 95 mol%. Off-gas from the PSA unit is used as sweep gas for the flare system.Distillate Hydrotreating The intermediate distillates from the topping unit are combined, mixed with recycled hydrogen and then brought to the reaction temperature by a heater prior to being fed to the Diesel Hydrotreater. By-products of the DHT reaction include un-stabilized naphtha, fuel gas and sour gases which are routed to a stripper for acid gas removal. Stripped liquids are heated and fed to a splitter column to be separated into kerosene and diesel and then routed to Jet Fuel and/ or low Sulfur diesel blending and storage.

Auxiliary systems

Utility systems

AGRU

LPG Recovery

NHT

PSA Unit

Distillate Hydrotreater

Isomerization

Reforming Unit

NaphthaStabilizer

Inst. Air

Effluent Treatment Logistics Steam Generation Power Fuel System

Nitrogen D M Water Cooling Water Storage

HGU Sour Water Stripper Flare

Crude Oil Hydrogen Rich Gas

Fuel Gas

Desalting/ CDU

LPG

Gasoline

Kerosene

Diesel

Fuel Oil

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Modular Refining SolutionsFull Conversion Refinerywww.pyramidenc.com

The hydrocracking process occurs over a catalyst in a hydrogen rich environment at elevated temperature and pressure. In this process, the high-boiling, high molecular weight hydrocarbons are cracked into lower-boiling, lower molecular weight hydrocarbons.

Fluid Catalytic Cracking If Gasoline production needs to be maximized, an FCC unit can be provided where a fluidized bed of catalyst particles is brought into contact with VGO along with steam injection to break down VGO into short chain molecules.

Alkylation Should there be a requirement of high octane gasoline, an alkylation unit can be provided to improve octane number by converting light olefins produced by the FCC or Coking unit into a gasoline blending component (alkylate), consisting of branched chain paraffinic hydrocarbons (iso-heptane and iso-octane).

Visbreaking/ Coking The vacuum column residue can be treated in couple of ways to obtain either heavy liquid products or the solid coke. The visbreaker unit may be supplied to crack large hydrocarbon molecules into naphtha, gasoline and residue by heating in a furnace. The cracked products are quenched and flashed into a fractionator to separate light and heavy liquid streams. Depending on the oil properties and market conditions, a Coking unit can be considered to process the VDU residue to produce gas oil and petroleum coke (Petcoke).

Full Conversion Refinery Pyramid E&C offers full conversion refineries along with auxiliary, utility and offsite units in standard sizes and modular construction. The full conversion refinery adds bottom upgrade section to Hydroskimming refinery for conversion of heavy oil fractions into high value automotive fuels.

Standard Sizes • 25000 BPD • 50000 BPD

Major Units • Atmospheric Distillation • Vacuum Distillation • Reformer / Isomerizer • Distillate Hydrotreater • Hydrocracker and/or • Fluid Catalytic Cracker • Alkylation • Visbreaking/ Coking

ProcessVacuum Distillation (VDU) The bottom stream from atmospheric distillation column is drawn into a vacuum column to separate the gasoil from residue. From the VDU overhead, vent gases are routed to fired heater, steam condensate is sent to the Sour Water Stripper and the vacuum gasoil stream (VGO) is sent to hydrocracking unit, distillate hydrotreater unit or storage.

Hydrocracking The gasoil(VGO) from the VDU is fed to hydrocracking unit for conversion into lighter products LPG, reformer grade naphtha, Ultra Low Sulfur Kerosene (ULSK) and Ultra Low Sulfur Diesel (ULSD).

Desalting/ CDU

Saturated GasRecovery

UnsaturatedGas Recovery

Reformer

Isomerization

Hydrocracker

Fluid CatalyticCracking

VDU

SRU

Inst. Air

Storage Logistics Steam Generation DM Water Cooling Water

Nitrogen Fuel System Power Effluent Treatment Drain

AGRU Sour Water Stripper Flare PSAH2 Generation

Coking orVisbreaking

DistillateHydrotreater

LPG

Gasoline

Kerosene

Diesel

Fuel Oil

NaphthaHydrotreater

Gas Oil

Gas Oil

Gas Oil

Kerosene

Naptha

Naptha

Coke

Fuel Gas

Light Gases

Iso paraffins

Gas Oil

Auxiliary systems

Utility systems

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Modular Refining Solutions Bitumen Refinery www.pyramidenc.com

Bitumen Refinery Pyramid E&C offers Bitumen production refineries complete with auxiliary and utility units to monetize heavy crude oil and also get straight run diesel product. The flexible design allows production of different bitumen grades.

Standard Sizes • 5000 BPD • 10000 BPD

Major Equipment • Atmospheric Distillation • Vacuum Distillation • Bitumen Blowing Unit • Distillate Hydrotreater • Sour Water Stripper • Sulfur Recovery • Hydrogen Purification

ProcessVacuum Distillation The atmospheric residue from atmospheric distillation unit isprocessed in a vacuum column to separate the gasoil and residue. The residue drawn should be suitable for desired commercial grade of bitumen. Preheating sections of atmospheric and vacuum distillation are integrated to maximize heat recovery and thus minimize fuel consumption. Steam is used to strip vacuum residue at the vacuum column bottom to ensure that the bitumen properties meet desired commercial grades.

Bitumen Blowing Unit This unit blows air into hot vacuum residue stream to produce desired grade and properties of

bitumen. The vacuum residue is sent to the unit using gearpumps through charge heaters. The feed residue is contacted withair steam mixture using a set of spargers. A suitable temperature is maintained by controlling steam and air injection rates. The off gases from top are either flared or incinerated and converted bitumen is poured into the drums and left for cooling and solidification.Auxiliary and Utility Systems The auxiliary units required for operation include sour water stripper, flare, effluent treatment unit, fire detection and protection systems. Major utility systems required are instrument and plant air, steam, power and process water.

Modular Bitumen Refinery

H2

OFF GAS

TO SRU

ACID GASTO FUEL GAS

AGO

NAPHTHA

NAPHTHAKERO

KeroseneKERO

VGO

VGO

Bitumen

VGO

AGO

ATMRESID

VACRESID.

CRUDE

AGO

NAPHTHADesalter

Vacuum Heater

PSA Unit

IA/PA Nitrogen DM Water Steam ETP

H2 Gen. Unit SWS SRU Incineration Flare

Naphtha Stabilizer

HydrotreaterGasTreatment

VDU

BitumenBlowing Unit

HeaterADU

Auxiliary systems

Utility & Offsite systems

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Web ContactURL : www.pyramidenc.comEnquiry : sales@pyramidenc.com

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