Shell, Saudi Aramco JV complete 5-year Texas refinery expansion; 600,000 barrels per day, US’ largest
Motiva, the joint venture between Shell and Saudi Aramco, marked the completion of a five-year construction project that more than doubled the daily processing capacity of the Motiva Refinery in Port Arthur, Texas to 600,000 barrels of crude. (Earlier post.) Motiva Port Arthur now ranks as the US’ largest refinery and one of the largest in the world.
The Crude Expansion Project (CEP) added an additional 325,000 bpd capacity. The expanded refinery can process a wide variety of crude oils, ranging from relatively light to heavy. It also has the flexibility to switch between primarily producing gasoline and diesel to adapt to varying market conditions.
Additional production from CEP includes:
- > 6.0 million gallons/day gasoline
- > 3.4 million gallons/day of ultra low sulfur diesel
- 1.3 million gallons/day jet fuel
- 8,000 tons/day petroleum coke
- 1,050 tons/day sulfur
- LPG (8,000 bpd), propylene (5,000 bpd), butane (3,000 bpd), iso butane (1,500 bpd)
Major units of the CEP include:
VPS5/SGP. The unit is designed to process 325,000 bpd (325 MBPD) of crude. The unit consists of an Atmospheric and Vacuum Section. Light ends-Naphtha is processed in the Saturates Gas Plant which is integrated on the VPS plot. Products include avjet distillate, diesel distillate, heavy atmospheric gas oil, medium vacuum gas oil, heavy vacuum gas oil, and vacuum residuum.
DCU2. The purpose of the Delayed Coker is to process the vacuum residue from VPS 5 to make higher valued distillate products. The six-drum unit is based on ConocoPhillips ThruPlus Coking Process. In addition to vacuum residue, the unit will serve to reprocess several refinery streams: recovered oil, refinery wastes, and FCCU heavy cycle oil. The DCU is rated at 95 MBPD of feed. The Delayed Coker products are treated gas for refinery fuel, treated propane/propylene for petrochemical feedstock, treated mixed butylenes for alkylation feed, full-range coker naphtha, light gas oil, heavy gas oil, and petroleum coke.
HCU/DHT. HCU2 is an integrated 75 MBPD hydrocracking unit with a 60 MBPD distillate hydrotreating section. The HCU section consists of two first stage reactors operating in parallel ultimately feeding into a recovery section that serves to produce product and recycle feed to the second stage, which also returns to the same fractionator for product recovery. Feeds to the HCU include heavy coker gas oil from both DCUs, extracts from the lube operations and medium vacuum gas oil from VPS5. Products are a hydrogen-rich stream, a treated fuel gas, a mixed propane-butane stream, light and heavy naphtha, light and heavy ULSD, and unconverted oil for FCCU feed.
The DHT section is designed to produce ULSD as the primary product but does generate lighter than diesel material from side reactions at higher reactor temperatures. Feedstocks include diesel from the VPS5, light Coker gas oil, and light cycle gas oil. It shares some equipment with the hydrocracking section.
NPC. The Naphtha Processing Complex consists of four units: NHTU2—a Hydrotreating section rated at 113 MBPD, Naphtha Splitter, Penex—50 MBPD C5/C6 Isomerization, and CRU5 —85 MBPD UOP continuous regeneration catalytic reforming unit. The NPC is designed to hydrotreat, fractionate, improve octane and limit the benzene content of a blend of naphthas received from the CEP and base plant. The main product streams from the NPC include: C5/C6 isomerate, C4 and lighter, high octane reformate and hydrogen for internal PAR consumption.
CFH. The “Cat Feed Hydrotreater” is licensed by SGS. The design rate is 50 MBPD of vacuum gas oil streams from VPS5. Its primary product is low sulfur FCCU feed. Fuel gas, naphtha and diesel are co-products. A PSA for upgrading CRU produced hydrogen will be located at the CFH.
Sulfur Recovery Complex. The sulfur recovery complex consists of: three sulfur recovery units, three tail gas treating units, two amine regeneration units, and two sour water strippers. The sulfur recovery units (SRU) will process amine acid gas and sour water acid gas. The three units combined are capable of producing 1050 LTPD of sulfur on air. With oxygen enrichment, two units will be able to carry the load without curtailing the CEP units. Each sulfur recovery unit configuration includes a three-stage Claus unit, equipped with ammonia destruction systems, followed by a SCOT Tail Gas Treating Unit and sulfur collecting pit and a licensed Shell sulfur degasification system. The sulfur recovery unit is required to achieve a sulfur recovery efficiency of 99.3% for total feed to the sulfur recovery unit.
PS4. PS4 consists of four GE Frame 6B Gas Turbogenerators (GTG) with independent heat recovery steam generators (HRSG). Each GTG will produce 36.5 MW at 13.8 kV and its respective HRSG will generate 400 MPPH of steam at 1500 psig utilizing supplemental firing. Voltage will be increased to 69 kV for distribution. A stand-alone power boiler rated at 400 MPPH will provide steam at 1500 psig.
Motiva’s marketing operations support a network of approximately 8,300 Shell-branded gasoline stations in the eastern and southern United States. Company assets include three refineries located in Norco and Convent, LA., as well as Port Arthur, Texas, which are currently capable of refining more than 1 million barrels of crude oil per day. Motiva also has ownership or partial interests in 38 product terminals.