From 10k bbl-day packaged refinery to 250k bbl-day, at Techsol Services Inc. we provide engineering and design support work starting from modular units (skidded) to large complex upgraders.
The term upgrader refers to a refinery operating on diluted bitumen feed instead of typical crude oil, where the ATM crude unit is called a Diluent Recovery Unit (DRU); the function of the unit is to separate the diluent (naphtha, diesel or others) from the viscous bitumen and to return the diluent back to the mining site via a dedicated pipeline.
In today’s oil–sand operation/bitumen upgrading and due to low API density of produced bitumen, new refineries are built with extra, non-conventional, processing units to enhance the conversion of crude residue into synthetic oil using hydrogenation, partial cracking, continuous cracking as well as other processing methods.
We at Techsol Services Inc. understand the need for new methods and technologies in the areas of synthetic crude/bitumen extraction and production and upgrading, which is why we offer on-hand dedicated staff specialized in conventional (proven) as well as unconventional refinery design to assist oil producers worldwide.
We provide design support in the following areas:
- -Crude & Vacuum Units
- -Delayed Coking Unit
- -Fluid Catalytic Cracking Unit
- -Catalytic Reforming Units
- -Alkylation Units
- -Sulfur Recovery Unit
- -Unsaturated Olefins Reduction
- -Oil Residue Hydrogenation
- -Bitumen Soft Cracking
- -ATM & Vacuum Units fractionate crude oil into propane, naphtha, kerosene, diesel, gas oils and residuum.
- -Delayed Coking Unit (DCU) converts heavy vacuum residuum and asphalt from the Crude Unit into fuel gas, gasoline, diesel, gas oil and petroleum coke.
- -Fluid Catalytic Cracking Unit (FCCU or "Cat") upgrades gas oils from the Crude Unit into gasoline and other products such as propane, gasoline, and diesel fuel. A silica-alumina catalyst is used in Cat reactor to break down large oil molecules into lighter ones, making for a more valuable product.
- -In Hydrotreaters, the kerosene, diesel or low octane naphtha are combined with a catalyst in a high pressure, hydrogen-rich atmosphere. The results are mixed of hydrogen sulfide, ammonia and desulfurized hydrocarbon. Hydrocarbons are then distilled to produce low octane naphtha and jet fuel.
- -Catalytic reforming provides a high-octane blending component needed to produce gasoline. First low-octane, desulfurized naphtha from the HTU is fed to the unit. Heat will be supplied and a platinum catalyst help rearrange the hydrocarbon molecules. The result: a high-octane hydrocarbon material called reformate, or re-formed gasoline. Hydrogen gas is produced as by-product from the chemical reactions.
- -In Polymerisation, the by-product of the cracking reactions in the FCCU and DCU is passed through beds of phosphoric acid-impregnated catalyst pellets. Polymerization happens. The end result is "polymer gasoline," used to help blend gasoline. The poly unit can also produce nonene used for making petrochemicals.
- -In the Alkylation (Alky) Units, olefins (propylene and butylene) from the FCCU are combined with isobutane and a sulfuric acid catalyst. They are mixed vigorously before removing the sulfuric acid. The mixture is pumped to distillation towers, where it is separated into liquefied petroleum gas (LPG), mixed butanes and alkylate. Alkylate is a high-octane blending component used in lead-free premium gasolines.
- -The sulfur plant converts "sour" gases to pure liquid sulfur. Hydrogen sulfide is converted through controlled combustion. The reaction produces sulfur and water vapour. More hydrogen sulfide is converted to sulfur by passing the gaseous mixture over a catalyst.