TURKEY - İZMİT REFINERY, UNICRAKER AND ASSOCIATED UNITS

Tekfen Job No:

186

Location:

İzmit, Turkey

Client:

TÜPRAŞ, Turkish Petroleum Refineries Co., Inc.

Contractor:

Tekfen Construction and Installation Co., Inc. - Snamprogetti SpA (Italy) Consortium

Tekfen Portion:

36%

Commencement:

26/11/1993

Completion:

26/11/1996

Since its foundation in 1957, Tekfen has become a leading name in the hydrocarbon industry both in Turkey and abroad. Tekfen has participated in the construction and upgrading of five refineries and three petrochemical complexes in Turkey at various capacities from de-bottlenecking to off-site piping, from instrumentation to complete unit erection works.

Unicracker and Associated Units including Continuous Catalyst Regenerator (CCR) (‹zmit Refinery) is among the major accomplishments of Tekfen in this field. The main purpose of the project is erecting a new Unicracker Unit and introducing Continuous Catalyst Regenerator Unit to the existing 3rd reformer unit.


THE PROCESS UNITS IN THE SCOPE OF THE PROJECT
Name Capacity Description
Unicracking Unit 1.113.000 t / year
Cracking of Heavy Vacuum Gas Oil / HVGO with hydrogen, under high pressure and heat is realized at this unit.
The yield distribution is:
313.000 t / year gasoline
21.000 t / year LPG
368.000 t / year gas oil
243.000 t / year jet fuel
CCR Reformer Unit 548.290 t / year

Aims to increase the octane number of naphta by continuous catalyst regeneration.

Hydrogen Unit 40.000 t / year

In this unit, pure hydrogen is obtained from natural gas or naphta as feed stock to the Unicracker Unit.

Gas / DEA Unit 77.500 t / year

This unit processes the H2S rich fuel gas coming from the Unicracker Unit.

Sulphur / Tail Gas 29.700 t / year
Erected to obtain sulphur from the H2S gas processed Treatment Unit in the Gas / DEA Unit. In this unit while 90 t of sulphur is produced daily, emission of acid gases are minimized to meet the environmental requirements.
Turbo Generator 15 MW

Erected for the independent energy supply of the Unicracker and Associated Units.

Cooling Tower 8.800 m3 / hr

This unit, consisting of two groups of reinforced concrete cooling towers with five cells in total, is erected to supply cooling water to the process units.

Flare Main flare: 243.000 kg / hr
H2S flare: 4.000 kg / hr
Erected to burn the non - condensable hydrocarbon and H2S gases before discharcing into the atmosphere.
Air Compressor 2 x 3.000 m3 / hr
These compressors are erected for instrument and service air requirements of the units.


The project was overtaken by Tekfen - Snamprogetti Consortium on turnkey basis.

The Unicracker introduces a new technology, in processing the Heavy Vacuum Gas Oil (HVGO) to obtain jet fuel, high standard gasoline, gasoil and LPG.

Introduction of a Continuous Catalyst Regenerator (CCR) unit to the existing 3rd reformer unit, serves to increase the productivity of the unit by shortening catalyst regeneration time while upgrading the octane of gasoline from 96 to 101.


QUANTITIES OF MAIN ACTIVITIES:
  • Piling: 1.250 m
  • Reinforced Concrete: 26.000 m3
  • Piping: 4.500 t
  • Steel Structures: 3.000 t
  • Equipment Erection: 8.000 t
  • Electrical Cables: 331.000 m
  • Instrument Cables: 200.000 m
  • Instrument Installation: 3.900
  • Pipe Insulation: 76.650 m2
  • Equipment Insulation: 6.250 m2
  • Painting: 126.000 m2
  • Fire Proofing: 1.250 m3