SONATRACH Downstream Activities

Refining Division

Oil Refineries upgrading Program For the production of clean fuels In Algeria

OPAEP Symposium Bahrain Oct 25th to 27th - 2010

CONTENTS
1. Crude refining activity in Algeria Existing facilities for each refinery. Present scheme for production of gasoline and Diesel Present status of motor fuels in Algeria Rehabilitation and adaptation program Principles and objectives . History of actions . Program for each refinery. Future Lay outs.

2. 3.

4. 5.

Present status for each project Other projects to be implemented

2

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

1- Crude Refining Activity

In Algeria

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Skikda
Arzew
2,7 MMT 1964 15 MMT 1980

2,5 MMT 1973 et 1984

Hassi Messaoud
1,2 MMT 1979

In Amnas
0,3 MMT 1980

Motor fuels

Lub-oil

Bitumen

Aromatics

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Existing Refineries

Algiers Refinery
Location: 10 Km South of Algiers (on 200 Ha) Final Products: Motor Fuels and LPG (For Local Market) Naphtha et fuel oil (For Export)

Shipment:

trucks (LPG) pipelines

sea vessels

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

BLOCK FLOW DIAGRAM - ALGIERS REFINERY

FUEL-GAZ

STABILISATION

Gas - Plant

LPG

LPG LPG Light Naphtha

PROPANE

BUTANE

Crude. 2700.000

REFORMING

Heavy Naphtha

Topping Unit

REFORMATE

Gasoline Blending

RegularGasolin e Premium Gasoline

NAPHTHA KEROSENE JET LGO HGO

Gas - oil Blending

DIESEL

RESIDU OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010 Fuel - oil (LS)

view of Algiers Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Existing Refineries

Arzew Refinery
Location: Industrial Area in Arzew (150 Ha) Final Products: Motor Fuels + LPG + Bitumen (For Local Market) Lubricants (For Local Market and Export ) Naphtha and Fuel-oil (For Export)

Shipment:

by trucks
pipelines

sea vessels
rail way

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

BLOCK FLOW DIAGRAM - ARZEW REFINERY FUEL GAZ

LPG
STABILISATION ESSENCES Light Naphta REFORMING CATALYTIQUE Gas Plant PROPANE

LPG

BUTAN E NAPHTH A Regular Gasoline Gasoline Blending

TOPPING UNIT

KEROSENE LGO Heavy Naphtha

2,5 M

Premium gasoline JET

Crude

HGO Gas - oil Blending

Base Oils

DIESEL Fuel - oil (LS)

Lub 1 Lube Blending Imported Reduced Crude 278.800 T

EXPORT Lubes

Lub 2
Vacuum Distillation Blowins Unit

Grease
Wax Fuel - oil (HS) Oxydised Bitumen

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Road Bitumen

view of Arzew Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Existing Refineries Skikda Refinery

Location : Industrial Area in Skikda, Land Area 190 Ha Final Products : LPG + bitumen (For Local Market) Motor Fuels (For Local Market

and Export)
Fuel-oil (For Local Market

and Export) and

Naphtha (For Export) Aromatics(For Local market and Export)

Shipment:

by trucks (for Bitumen & Toluene)) pipelines (Motor Fuels, LPG) sea vessels
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

BLOCK FLOW DIAGRAM - SKIKDA REFINERY

FUEL-GAZ

GAS-PLANT (3units) Topping unts (2)

PROPANE
BUTANE

NAPHTHA

15.000.000

Crude

REFORMING CATALYTIQUE (2 units)

BENZENE BT Extraction TOLUENE Gasoline blending Regular Gasoline Premium Gasoline

Unleaded Gasoline
PX Cristallisatio n Kerosene Sweetening Imported Reduced Crude MELANGE-XYLENES PARA-XYLENE JET A1 Gas - oil Blending Blowing Unit DIESEL Fuel - oil (LS) Fuel - oil (HS)

277.100
Vacuuum Distillation

Oxydised Bitumen
Road Bitumen OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

view of Skikda Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Existing Refineries

Hassi-Messaoud Nr 1 & 2 Refineries

Location: South Industrial Center (SH-DP) Final Products: Motor fuels (For Local Market)

Shipment:

trucks

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

BLOCK FLOW DIAGRAM - HASSI-MESSAOUD REFINERIES

RHM2

1. HASSI-MESSAOUD 1

LPG

Crude

T O P P I N G

LPG Unit

FUEL.GAS. BUTANE

STABILIS.

NAPHTHA JET DIESEL RESIDU

2. HASSI-MESSAOUD 2
GPL
NAPHTHA UNIT LPG/RHM1 SLOPS

Crude

100.000

T O P P I N G

R E F O R M I N G
REFORMATE

Regular gasoline

Gasoline Blending

Premium Gasoline

JET DIESEL RESIDU TO SLOPS

Existing Refineries

In-Amenas Refinery
Location: Industrial Area of In- Amenas (SH-DP))

Final Products: Motor Fuels (For Local market) Shipment: by Trucks

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

BLOCK FLOW DIAGRAM - IN AMENAS REFINERY

FuelGaz

Crude 300.00 0 MTA

T O P P I N G

Naphtha
Gasoline Blending

Vers Slop
Regular Gasoline Premium Gasoline JET

Kerosen e Diesel

sweetening

Diesel

Fuel-Oil
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Slops

2- Present status of Motor fuels in Algeria

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Present status of motor fuels in Algeria

Gasoline
At the present time the local market consumption is about 2,3 million Tons/Year of gasoline including 3 types:

Regular leaded gasoline RON 89 (20 % of the market),

Premium leaded gasoline RON 96 (70 % of the market), Unleaded gasoline RON 95/MON 85 (10 % of the market),

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Leaded Gasoline Specifications for the local market

Specification Specific gravity RON RVP up to 37.7 C (summer/winter) Max Bar 10 % vol 50 % vol Distillation ASTM D86 95 % vol PF Sulphur content Lead content ppm g/l 195C max 205C max 100 max 0.40 195C max 205C max 100 max 0.40 Unit Kg/m3 Regular Gasoline 710 765 89 0.65 / 0.80 70C max 140C max Premium Gasoline 730 770 96 0.65 / 0.80 70C max 140C max

Unleaded Gasoline Spcifications for the local market

Limits Premium 95 Specs RON MON Benz ene Specific gravity Sulphur Distillation ASTM 86 70C 100C 180C 210C Final Poi nt Reid Vapor Pressure Winter / Summer Units Min 95 85 % Vol Kg/m3 ppm 725 5 780 100 Max

% Vol

15 40 85 90

47 70

215

Kpa

80 / 65

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Gasoline Status in Algeria (cntd) Unleaded gasoline specifications (cntd)

Comments:
The specification of unleaded gasoline in Algeria doesnt

mention any limit for aromatics, olefins and oxygen ( the unleaded gasoline RON 95, is similar to leaded premium
gasoline RON 96, with a quite wide gravity gap). The benzene content is limited to 5 % vol. (means in the limit of the skikda refinery production quality)

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Gasoline Status in Algeria (cntd) Gasoline Average Qualities for the Local Market lead content was reduced by the Regulation from 0.65 to 0.40 g/l. max, from the year 2000 According to the regional demand of gasoline and the available basestocks in each refinery for gasoline

blending, lead content at the present time is as follows:

0.10 to 0.15 g/l at Skikda refinery, 0.20 to 0.30 g/l at Arzew,

0.40 g/l at both Algiers and Hassi-Messaoud

refineries.

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Gasoline status in Algeria (cntd.)

Gasoline Average Qualities / Local Market (cntd.) Sulphur average content : less than 30 ppm (due to good crude quality and good quality of basestocks), Aromatics content : 50 to 60 % vol. (due to use of

reformate or aromatic byproducts as basestocks),

Benzene content : 2 to 3 % vol.

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Typical scheme for gasoline blending in Algeria

Butane Isopentane Light Naphta Reformate Raw Toluene Heavy aromatics Leaded Regular RON 89

Gasoline blending

leaded Premium RON 96 Unleaded Gasoline RON 95

rafinate

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Basestocks for gasoline blending for local market

RA1K Butane Light Naphta Naphta ex-deIsoC5 RA1G RA1Z RHM2

X X X X

X X X

X X X X X

Reformate Iso-pentane Pentane exReformate Raffinate Raw Toluene

Heavy aromatics.

X X X X
X

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Diesel fuel :
The Algerian market consumes currently up to 7 millions Tons / year of Diesel

Specification Specific density Cetane number Flash point Pour point /winter. Pour point /summer. Distillation ASTM D86

Unit Kg/m3 C C C 65 % vol 90 % vol PF ppm

Gasoil 810 860 48 min 55 min -12 max -7 max 250C min 350C max 390C max 1 500 max

Sulphur content

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Diesel status as fuel in Algeria .(cntd.)

Average quality of diesel / Local market

Real sulphur contents :
Less than 800 ppm at Skikda,

Between 900 to 1200 ppm at the other refineries.

Nota: Before Year 2005, Skikda refinery has produced Diesel for export (in the limit of 350 ppm max sulphur content ) from SR

Gas-oil mixed with kerosene.

This was achieved with an adequate selection of crude fields to feed the refinery (less than 500 ppm of sulphur).

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Typical scheme for Diesel blending in Algeria

SR Kerosene
SR Light Gas-oil

Gas-oil blending
SR Heavy Gas-oil

Diesel

Vacuum Gas-oil

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Basestocks for Diesel production for Local Market

RA1K SR Kerosene

RA1G

RA1Z

RHM2

SR Light Gas-oil
SR Heavy Gas-oil Vacuum Gas-oil

X X

X X X
X

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

3- Rehabilitation And Adaptation Program of the existing Facilities

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Main objectives of the Rehabilitation and Adaptation Program

Proceed with a large refurbishment program in order to sustain the production level of the refineries for the medium and long term,

Modernize the instrumentation for a better optimization of the various Units, Produce clean fuels for the local market and for export, for a better environment

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

History of the activities

This program deals with the achievement through the company own means and other specialized companies in the sector of tehnical diagnosis studies,

debottlenecking of process Units and definition of the master plan of the

instrumentation modernization.

From October 2001 to March 2003, we worked after an open tender for
each subject: For Skikda Refinery: with Foster Wheeler France (for the process and

technical study and instrumentation study)

For Arzew Refinery: with KBR (USA) and Honeywell-Belgium,

For Algiers Refinery: with Sofresid (France) and Foxboro-France

For Hassi-Messaoud Refinery: with the same two companies
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010 33

History of activities (ctnd)

1.

Evaluation of the various reports and options proposed by the consultancy companies

Selection of the options to be implemented in each refinery Identification of all the small projects which do not need deep engineering work, in order to implement them immediately Agglomerate all the other subjects in one, two, or three major EPC projects, including capacity increase Minimize the shutdown duration for construction and tie-ins

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

History of activities (ctnd)

2. Issuance of call for tenders for selection of consultancy companies (one

for each refinery) which will be involved in three stages :

Preparation of FEED package,

Technical support for the evaluation of the bids to be received for the EPC projects,

Follow up of projects by the consultancy companies

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation Program for each Refinery

The rehabilitation program will be implemented simultaneously in the three coastal refineries, Shutdowns of existing rehabilitation work, units will be minimized for the

The normal investment program for maintenance purposes will be continued in parallel at each refinery,

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Skikda Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Revamp and Expansion

Existing CDUs/ Gas Plants with 10% capacity increase Add / Modify existing utilities / offsite facilities.

RECONFIGURATION MODERNISATION Revamp of Reformer Nr 1

Of the Instrumentation with

DCS / APC/Optimisation type .New Blast Resistant Control Room. Electrical network with ECS .

Rehabilitation Program

Reconfiguration of aromatics chain (revamp of the Benzene /Toluene recovery unit Addition of a cristallization unit and a mixed xylene isomerisation unit

CLEAN FUELS 02 New NHT/ light naphta isom Units 02 New DHDS Units
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation program of Skikda refinery

The rehabilitation and adaptation program includes three main EPC projects: Project 1: Electrical network for common facilities,
Project 2: Rehabilitation and increase capacitiy for fire fighting network,

Project 3: includes the following operations,

Rehabilitation of existing facilities (Toppings and gas-plants) for the treatment of the future crude (with upgrading and modernisation of obsolete equipments), Rehabilitation and upgrading of Magnaforming Unit, Upgrading of aromatics production units, with production maximisation (supply by the two reformings, and setting up of xylene isomrisation unit) with upholding a significant production of gasoline Rehabilitation of Utilities production and distribution, Rehabilitation and modernization of electrical equipments, upgrading
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation program of Skikda refinery (cntd)

Achievement of two Units for light naphta isomerisation, Rehabilitation of electrical equipments, upgrading of electrical network , Achievement of two Hot Oil systems,

Achievement of new unit for hydrogen purification,

Achievement of new unit for demineralizing Boiler Water, Achievement of a unit for condensat recovery and treatment,

Instrumentation modernization (implementation of DCS with a centralized control room), Upgrading of the Quality control laboratory,

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation program of Skikda refinery (cntd)

Achievement of a new unit for acid water treatment

Achievement of a new unit for effluent treatment

Achievement of new unit for nitrogen production, Laying out and extension of various reception, storage, shipping facilities of oil products,

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Arzew Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Revamping
Existing CDU/ Gas Plants for 50% higher crude oil processing capacity Add / Modify existing utilities / offsite facilities.

MODERNISATION

Of the Instrumentation with

DCS / APC/Optimisation type .Main oprating Central Room. Of the Electrical network with ECS type.

Rehabilitation Programme

ADAPTATION FUELS 01 New Unit for Isomerization Gasoline to improve the LSRN characteristics 01 New Unit for Diesel Hydrodesulphurized

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation program of Arzew refinery

The rehabilitation and adaptation program includes three projects major EPC

Project 1: Instrumentation modernisation (implementation of DCS + APC + optimisation with a centralized control room),
Project 2: Rehabilitation of electrical equipments, upgrading of electrical network Project 3: Main EPCC Capacity increase for Topping and Gas plant, Adaptation for utilities and storage units,

Adaptation and modernization of effluent treatment unit,

Setting up of Hot Oil unit,

Setting up of light naphta isomerisation unit,

Setting up of gas turbine for electricity production,
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Algiers Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Revamping
Existing CDU/ Gas Plants for 35% higher crude oil processing capacity Add / Modify existing utilities / offsite facilities.

MODERNISATION Of the Instrumentation with DCS / APC/Optimisation type .Main oprating Central Room. Of the Electrical network with ECS type.

Rehabilitation Programm

RECONFIGURATION
New Reforming Unit (CCR mode). New RFCC Unit for the gasoline
and Diesel production.

ADAPTATION FUELS 01 New Unit for Isomerization Gasoline to improve the LSRN characteristics 01 New Unit for clean Diesel
OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation program of Algiers refinery

The rehabilitation and adaptation program includes one large EPC project: Topping and gas plant capacity increase. New MS Block (NHT + Isom + CCR Reforming)
RFCC and Merox Units Rehabilitation of Utility production and distribution facilities MOderniztion of the Instrumentation (implementation of DCS with a centralized control room), Rehabilitation of electrical equipments , upgrading of electrical network, and setting up of a gas turbine, New Waste Water Treatment Unit (biological type)

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Rehabilitation program of Hassi Messaoud refinery

Oprations included in one large EPC project: Rehabilitation of existing facilities (Topping Unit and Reforming Unit with a new catalyst). Rehabilitation of the Utility production facilities and distribution network, Rehabilitation of electrical equipments, upgrade of electrical network.

Instrumentation modernization ( DCS with a blast resistant control room), Rehabilitation of underground piping

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

future configuration of the refineries

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Future configuration of Skikda Refinery

LPG

GP I
GP II

PROPANE BUTANE FG
H2 RICH GAS

PSA

ISO PENTANE

H2 TO CONSUMERS TO GASOLINE POOL TO NAPHTHA POOL

C6 CUT

CDU - I

NAP A NAP B HY. AROM. NAP C LPG

LNHT-I/ LNISOM-I
TOLU. CUT
C5 CUT

KERO

LGO+HGO

NHDS/ REFORM-I/ PLAT SPL

KTU-I
C8+ CUT

C6 CUT

LNHT-II/ LNISOM-II

RCO

BENZENE ARU
EXCESS KERO

CRUDE

TOLUENE TO ATF POOL

LPG

H2 RICH GAS TO PSA

TO NAPHTHA POOL

DHDS-I
C6 CUT NAP A

TO DIESEL POOL NHDS/ REFORM-II KTU-II PX REC. HY. AROM. UNIT DHDS-II PARAXYLENE HY ARO. TO GASOLINE CR KERO TO DIESEL POOL EXCESS C8+ TO GASOLINE

CDU - II

NAP B NAP C KERO LGO

PROPANE

GP III
RCO

BUTANE

CR LGO TO DHDS CR HGO TO DHDS

XYL-ISOM UNIT LOW SULPHUR FO GAS OIL OXIDISED BITUMEN ROAD BITUMEN

IMPORTED VAC. RESIDUE

BBU

LEGENDE DES COULEURS

EXISTING

C6 CUT

HGO

REVAMP

NEW

PAGE 50

Arzew Refinery
REHABILITATION FUTUR ET ADAPTATION
STAB.1
18 982 BPSD
LSRN 1 HSRN 1 LSRN 2

Gas Plant
6 289 BPSD

Propane Butane Naphta

Isomerisation
7500 BPSD Ess.Super Ess.Normale

STAB.2
14 346 BPSD
KERO HSRN 2

Unibon Platformer
8500 BPSD

CDU

Krosne

DIESEL
BHM

90 000 BPSD

LGO HGO

VGO LUB

HDS
36500 BPSD

Gasoil

Fuel BTS

Brut Rsidu Atmosphrique

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Future configuration of Algiers Refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

4- Present status of the rehabilitation

Program at each refinery

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Present status of the rehabilitation program at Skikda refinery .

For RA1K:
Project 1: Modernization of electricity Contractor: AREVA (France) started on March 30th 2008 Physical progress : 85%

Project 2: Rehabilitation and capacity increase of fire fighting network. Contractor: ETTERKIB (Algeria) started on February 23rd 2008 Physical progress: 77%
Project3: Rehabilitation and adaptation of production facilities. Contractor: SAMSUNG Engineering (South Korea) started on August 13th 2009 Physical progress: 28%

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Present status of the rehabilitation program at Arzew refinery

For RA1Z:
Project 1: Instrumentation modernization, Contractor: Honeywell (Belgium), started on February 9th,2004 Physical progress : 98%. Project 2:Electricity modernization. Contractor: CEGELEC SAS (France), started on March 1st 2008 Physical progress: 92% .

Project 3: Rehabilitation and adaptation of production facilities. Contractor: Groupement HYUNDAI Eng & Co Ltd / HANWHA / DAEWOO started on February 23rd, 2009. Physical progress: 39%.

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Present status of the rehabilitation program at both Algiers & Hassi-Messaoud refineries .
For RA1G: Contractor : TECHNIP France. Physical Progress: to be launched soon.
For RHM2: The adaptation and rehabilitation program will be conducted according to the following planning: Consultation for PMC: 6 months: April 2011. FEED studies: 15 months : June 2012. Consultation for EPC: 12 months : July 2013. Realisation EPC: 48 months :August 2017.

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Present status of the rehabilitation program at each refinery .

Work completion: End of 2011 for Arzew

End of 2012 for Skikda

End of 2013 for Algiers August 2017 for Hassi-Messaoud

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

5- Other projets to be implemented

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010

Other projects to be implemented :

new Refining at Hassi-Messaoud Area and rehabilitation of RHM 2 (Call for tender for FEED package)
Hydrocracking Unit at Skikda Area (Call for tender for FEED package) Naphta Aromizer for Aromatics production at Skikda Area (Feasibility stage)

OAPEC Symposium - Bahrain - Oct 25 TH to 27 th - 2010