Abadan Refinery Upgrade & Modernization Project
SEC Scope
- Design + Material take-off + Fabrication Drawing Preparation for 28 Units Towers 480 Tons
- Design + Material take-off + Fabrication Drawing Preparation for 72 Units Pressure Vessels 680 Tons
- Design + Material take-off + Fabrication Drawing Preparation for 8 Units Storage Tanks 940 Tons
Project Details
Licensed Processes:
- UOP FCC Naphtha Hydrotreatingfor sulfur reduction
- Axens Prime-G+™for desulfurization
- Topsoe Hydroprocessingcatalysts for diesel upgrading
- BASF Refinery Catalystsfor catalytic reforming
Key Upgradation Units:
- Crude Distillation Unit (CDU) Revamp
- Vacuum Distillation Unit (VDU) Expansion
- Hydrotreating Units (Naphtha, Diesel)
- Sulfur Recovery Unit (SRU) using Claus Process
Isomerization Unit for light naphtha upgrading
Key Specifications
Capacity & Output:
- Crude Processing:360,000 barrels per day (bpd)
- Euro 5 Gasoline Production:+12 million liters/day
- Ultra-Low Sulfur Diesel (ULSD):+8 million liters/day
- Sulfur Recovery:9% efficiency
Process Conditions:
- Hydrotreating Reactors:340-380°C, 50-70 bar
- FCC Unit:530-550°C, 2-3 bar
- Sulfur Recovery:280-320°C, 1-1.5 bar
Operational Challenges
Brownfield Constraints: Integration with existing 100-year-old infrastructure
Materials Selection: Handling sour crude with high sulfur content (>2.5%)
Emission Control: Meeting stringent environmental regulations
Heat Exchanger Fouling: Managing crude preheat train efficiency
Strategic Importance
- Eliminates 25% of Iran’s gasoline imports
- Reduces environmental pollutionthrough ultra-low sulfur fuels
- Preserves historical refinerywhile modernizing operations
- Creates technical expertisein refinery revamp projects
Engineering Opportunities for Sabz Engineering Co.
Detailed Engineering:
- Pressure vessel design for hydrotreating reactors
- Pipe stress analysis for high-temperature lines
- Foundation design for new compressor packages
Software Solutions:
- Refinery Energy Optimization Software
- Corrosion Monitoring Systemsfor sour service
- Digital Twinfor refinery operations
Project Management:
- Phased construction planningto maintain refinery operations
- Vendor coordinationfor international equipment procurement
- Risk managementfor brownfield integration
Sustainability Features
☆ Carbon Footprint Reduction: 30% lower CO2 emissions per barrel
☆ Water Recycling: 80% wastewater reuse
☆ Zero Gas Flaring implementation
☆ Energy Recovery: 40 MW from waste heat
Project Economics
Parameter | Value |
CAPEX | $2.8 billion |
Duration | 5 years (phased implementation) |
ROI | 22% (considering import substitution) |
Payback Period | 4.5 years |