First Lube Refinery
The construction work of first Lube Refinery was started in May 1964. The Refinery came into production in June 1966,
with crude oil refining capacity of 539,700 tons per annum and production of 76,000 tons of various grades of Lube Base Oils
and 100,000 tons of Asphalt per annum. This Refinery also supplemented fuel products requirement of the country particularly
Kerosene and Diesel.
On January 16, 1972, the Government of Pakistan took over the management of the Refinery under the Economic Reforms Order.
The overall managerial directions were entrusted to the Ministry of Production.
The growth in demand of fuel products in the subsequent years,
after installation of first Lube Refinery, impelled the need for further increase in refining capacity.
In the year 1974, National Refinery Limited signed an agreement with Industrial Export and Import of
Romania to construct a Fuel Refinery having crude refining capacity of 1.5 million tons per year on turnkey basis.
Since the Fuel Refinery was to be integrated with the first Lube Refinery, a site on the same premises was selected.
NRL's Fuel Refinery was a fresh addition on the country's growing industrial landscape.
The Fuel Refinery was commissioned in 1977 for producing LPG, Motor Gasoline, HOBC, Naphtha, Kerosene,
Jet Fuels (JP-l), (JP-4), High Speed Diesel Oil (HSD), Furnace Oil.
In order to meet country's demand of petrochemicals/solvents Benzene,
Toluene and Xylene, particularly Toluene, to meet Defense requirements,
installation of a BTX plant was seen feasible. Feedstock to BTX plant was also available from the Fuel Refinery.
A Petrochemical BTX plant was therefore installed in 1979, which was capable of producing 25,000 Metric tons per Annum of Benzene,
Toluene and Xylene.
The country's first petrochemicals unit was integrated with the units of the Fuel Refinery. Currently it is out of operation.
Propane Recovery Unit (PRU)
In order to meet high purity Propane requirement for extraction and refrigeration
at various units of Lube Refinery, a Propane Recovery Unit was installed and commissioned in 1980.
Detailed engineering and fabrication for the entire plant was done locally.
The plant is designed to produce 1,200 tons per annum of high purity Propane,
which meets the requirement of both Lube Refineries.
Second Lube Refinery
In early 1980's the industrial growth in Pakistan changed the petroleum products supply demand scenario.
Fuel business was saturating whereas there was a captive market of lube oils in the region.
In view of this, NRL installed its second Lube Refinery, which was commissioned in 1985 for producing 100,000 tons of Lube Base Oils.
The feedstock for this Lube Refinery was available as surplus Furnace Oil from Fuel Refinery, which was upgraded to Lubes.
Basic engineering and design work for this project was carried out by CE Lummus of U.K under
consultation with Taxaco Development Corporation of USA As a result of concerted efforts,
a refinery representing the latest technology appeared in the highly impressive NRL Complex.
The completion of second Lube Refinery created the largest and the most comprehensive crude oil
refining complex in the country.
Fuel Refinery Revamp
Demand of fuel products in the country had positive growth rates in the late eighties.
However, the cost effectiveness of the projects gained prior importance.
Thus, in order to keep-up the pace with modern refineries and to reduce the processing cost per barrel of crude,
NRL implemented its Fuel Refinery Revamp Project in 1990. The revamp project was based on Energy Conservation,
enabling the capacity increase by 15,000 BPSD without increasing energy consumption. After the revamp,
the total crude processing capacity of NRL was enhanced to about 2.71 million tons per year.
The balancing and modernization of platforming unit was undertaken in 1995 and installation of larger sized reactors in 1997.
Increased production of High Octane reformat by 70%, gave potential for production of high quality, unleaded motor gasoline.
The corporate control of National Refinery was transferred to the Ministry of Petroleum & Natural Resources.
Self Power Generation
Based on the principle of cogeneration from high-pressure steam boiler,
a 7.5 MW power generation unit has been installed to decrease dependence on purchased power supply.
With the commissioning in year 2000, beside energy conservation and supplying low cost electricity,
the Self Power Generation is helping in reducing production losses due to interruption in power supply.
Lube II Refinery Dewaxing Unit Revamp Project
In order to meet the growing demand of LBO, a Lube Revamp Project was undertaken with the Technical Assistance
of Exxon Mobil in year 2005. On completion of the Project, the production capacity of the second Lube Refinery
was enhanced by 14,800 TPA. Dilchill Crystallization Process Technology was utilized for production of High
Viscosity Bright Stock (BS HVI) grade of Lube Oil.
Addition of Storage Tanks
In order to meet the rapidly changing market demands and to increase the operational flexibility,
the storage capacities of crude oil and various products i.e Furnace Oil, Lube Base Oil, HSD, Asphalt and JP-1 were enhanced
by addition of nine storage tanks.
New Water Reservoir
To cater for acute shortage of water during summer season,
a new water reservoir having capacity of three million gallons has been added.
Product Metering System
Company has implemented Product Metering System at refinery and Keamari Terminal for custody transfer of product to Oil Marketing Companies (OMCs). Initially project is handling HSD pumping to OMCs.
Radar Gauging System
Radar Gauging System for accurate measurement of tanks for custody transfer has been installed on 105 tanks.
The company has a strong information technology capability. Computerized instrumentation and auto-tank gauging are being applied. The technical staff uses a variety of computer software for process design, performance monitoring, simulation and engineering design.
NRL had implemented an Enterprise Resource Planning (ERP) solution, SAP(version 4.6C) in the year 2004 with following modules:
- · Finance and Controlling (FICO)
- · Material Management (MM)
- · Sales & Distribution (SD)
- · Plant Maintenance (PM)
- · Human Resource (HR)
During 2015-16, the Company has successfully up-graded its ERP system to ECC6, the last available SAP version, for improved Management and Financial Reporting, with some added features and following additional modules:
Nitrogen Gas Generator
- · Projects Systems (PS)
- · Audit Information Systems (AIS)
- · Quality Assurance (QA)
For the purpose of financial economization, Nitrogen Gas Generator having capacity of 400 Normal Cubic Meter/Hour has been installed. Nitrogen Gas will be used as inert media for MEK Units. The Project was successfully commissioned in November 2015.
Reverse Osmosis Plant
250,000 gallon per day of Reverse Osmosis Plant has been installed and Commissioned in May 2014. Considering the scarcity of water and its requirement for refinery operations, Company has installed Reverse Osmosis plant IV having capacity of 250,000 gallons per day. The Plant has been commissioned in June 2016.
Effluent Treatment Plant
The Effluent Treatment Plant is used to clear water from contaminants. The recovered oil is re-used and water is diverted as feed stock for RO plants. The plant has been installed and commissioned in June 2016.
UPGRADATION OF NRL 2017
In mid 2017, NRL has commissioned UOP licensed Diesel Hydrotreater Unit having capacity to produce 29,765 BPSD of Euro II specification diesel which contains less than 500 ppm of sulfur. The plant has a capacity to reduce sulfur content to as low as 10 ppm. Commissioning of Isomerization unit with a capacity of 6,793 BPSD is in process. Both the plants will run at 70% capacity and process the entire production of HSD and Light Naphtha. The remaining capacity will be utilized after the completion of upcoming projects of topping unit and Phase II of integrated project.
1.) NEW PROJECTS COMPLETED
Some brief introduction of the plants is as follows which are duly completed on planned dates as per schedule.
Fuel Refinery Revamp 2017
Diesel Hydro De-sulfurization Unit
The Project includes the revamping of the existing Fuel CDU refinery to increase the throughput by modifying the existing equipment and adding new equipment. The increase in throughput of 53,000 BPD is achieved and the project completed in March 23, 2017.
New regulations regarding environmental sustainability are big challenges for oil producing companies today. HSD is the core profitable fuel product and it is very important that it remains as per the stated governmental regulations and thus, as a marketable fuel. To comply with this requirement, NRL is equipped with a UOP licensed Diesel Hydro-treating unit with a capacity to treat 29,765 BPSD of HSD. The unit needs hydrogen, which is produced by a hydrogen plant with a capacity of 11.5 MMSCFD. The project was completed in June 2017.
With new units expelling sulfur-containing compounds, the presence of facilities to recover and deal with such harmful species is essential. Sulfur Block at the NRL fulfils this purpose. The Block is composed of an Amine Treating (sour gas sweetening) unit, Sulfur Recovery Unit, and a Sulfur Solidification Unit. The product of Sulfur Block is elemental Sulfur, which extends NRL's scope of products beyond hydrocarbons now. NRL can produce 38 TPD of sulfur product at the existing facility. The project was completed in June 2017.
Non-Phenolic Sour Water Stripper
Sour water from these new units will be treated at this facility, which will remove sour components like H2S and then this stripped sour water will be used as wash water in our new process units. This unit can treat 810 TPD of sour water. The project was completed in June 2017.
Amine Treatment Unit
To attain environmental sustainability and operational stability all accumulated sour/Acid gases from Diesel Hydro treating unit and Naphtha block were treated in this unit. The Unit is designed to convert 14,500Nm3/hr of sour gases into Sweet gases by using (MDEA solvent) after Phase-II. Currently, After Phase-I completion it is handling 1945Nm3/hr. H2S from the solvent is further recovered and then transferred to Sulfur recovery unit for further treatment. The sweet gases having H2S less than 100ppm is being used as the fuel gas in the refinery. The project is completed in June 2017
8.2 Mega Watt Generator
In order to cope up with the increasing Electric Power demands as a result of new process plants installation at National Refinery Limited, an 8.2 MW Diesel Generator has been installed and successfully commissioned in the June 2017, as an Extension to the Existing Power Generation Plant. With this new addition to the National Refinery Power Grid, providing self-reliable and stable power can ensure the continuous operation of New Plants.
85-Ton Steam Boiler
To accommodate the increasing steam requirement of NRL up gradation project a new boiler having Gross Capacity of 85 TPH has been commissioned in May 2017, this boiler has net capacity of 70TPH of steam for addition into NRL steam system.
07 Mega Watt Turbine Generator (New)
LP and MP steam was conventionally produced at NRL by letting down the pressure of HSS steam .The installation of this new Back Pressure Steam turbine generator helps NRL to supply LP and MP steam to new units by generating additional 7 MW of electric energy which ruled out any losses due to Let down of steam by conventional method. This project has been completed in June 2017
2.) NEW PROJECT UNDER COMMISIONING
Keeping in view the increasing demand of Gasoline in the country, NRL included in its complex the Naphtha Block consisting of Light Naphtha Splitting, Light Naphtha Hydro-treating, and Light Naphtha Isomerization units so that Light Naphtha could be isomerized. The resulting isomerate product will be blended into gasoline pool to increase the production of Motor Spirit. Total isomerate production capacity of the NRL is 6,793 BPSD. The project is under commissioning phase.
07 Mega Watt Turbine Generator Up gradation
As a step towards energy optimization, the existing Condensing type Steam Turbine was replaced with a new 7.2MW backpressure Turbine. The additional benefit of this turbine leads towards the extraction of MP and LP steam. These multi pressure streams of steam will suffice steam requirement of the complex by eliminating the letdown stations and conserving energy loss by Pressure reducing valves. The Unit cost produced by the New Turbine will be less than the old Turbine. Project activities are completed while commissioning of Turbine is expected in September 2017.