2. •Modular Oil Refineries from 500 to 50,000 Barrels per Day for Crude Oil to produce Naphtha, Gasoline, Kerosene, Diesel 2, Heavy Fuel
Oil 6 and Asphalt .
•No need for process water, minimizing environmental emissions. Can be sited as close as possible to oil fields.
•Larger refining capacities can be provided by paralleling Modular Refineries with maximum flexibility and reliability.
•We can provide Minirefineries and Electric Power Generating Plants using their subproducts as fuels in a Turn-Key basis, including the
engineering, design, permitting, manufacturing, shipping, erection, installation, commissioning, start-up, training, operation and
maintenance.
•We can offer a variety of financing options depending on the needs of our Clients.
2
Our Group offers a wide experience in the international management, engineering, financing, sales, production, project management
and installation of Energy Systems in the Oil and Gas and in the Power Generation fields. We are proud to present our Modular
Refining Systems in conjunction with CHEMEX LLC, a leading manufacturer of Petroleum Processing Equipment since 1974. Another
added value is our association with Prime Energy & Chemical and our ability to provide Power Generation Systems to integrate a
complete Energy System from the oil well to the electrical power grid.
4. Project Experience
Since 1974, Chemex has
constructed or modified many
refineries worldwide. The client
list includes the following:
Bechtel
Torch Energy
Texaco
Veneco Energy
Chevron
GPC Sudan
Union Oil
Metro Oil & Refining
Shell Oil
McPherson Oil
Mobil Oil
Baker Hughes
Occidental
Flying ‘J’ Refining
Aera Energy
Goodway Refining
Corn Products
Hamilton Engineering
Seneca Oil
Georgia American Oil
Concorp International
U.S. Department of Energy
Redd Engineering
Santa Fe Energy
Fujairah Marine Service
Berry Petroleum
Natural Resources Group
Huntway Refining
Seadrift Coke
Beacon Refining
Whittier Oil
Pertamina Refining
Niger Delta Petroleum Corp.
DESOPADEC
Tri Wahana Universal
Golden Gate
High Sierra Energy
Pertro Source Partners
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5. Traditional Oil Refineries: The Old
Fashioned Way
• The traditional Oil Refineries process Crude Oil fractional
distillation to produce a variety of subproducts, such as
LPG, Gasoline, Kerosene, Diesel Oil, Heavy Fuel Oil,
Asphalt, etc. using their varying boiling points. These
subproducts which can be used directly as fuels,
enhance the economic value of the crude oil.
• Traditional Oil Refineries typically process from one
hundred thousand to several hundred thousand barrels
of crude oil per day. This means that a huge amount of
crude oil has to be transported from the oil wells to the
refineries with great transportation costs under
hazardous conditions along the way.
• The large scale and complexity of a traditional Oil
Refinery and the associated hazards make it very hard to
be able to site and build a brand new large refinery
because of its relatively high cost and environmental
impact.
• They use a relatively high amount of process and cooling
water which turns into wastewater that has to be
treated before discharging to waterways, adding to the
cost. There is an increasing amount of cost involved in
attenuating air emissions and solid waste to comply with
ever tighter regulations. As a result, no major refinery
has been built in the USA since Marathon’s Garyville,
Louisiana, refinery was installed in 1976 and many
others have been closed.
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6. Traditional Oil Refineries: The Old Fashioned Way
• Large scale and complexity.
• High capital & operation cost.
• Hazards - hard to site.
• Environmental Impact.
• High amount of process and cooling
water turning into wastewater to be
treated.
• Large volume of air emissions and solid
waste to comply with ever tighter
regulations.
• No major refinery built in the USA since
Marathon’s Garyville, LA refinery was
installed in 1976.
• Many have been closed.
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7. 7
Modular Oil Refineries: The Modern Way:
• New modular pre-fabricated design meeting ASME,
ANSI, API, FM USA-EPA and World Bank standards.
• Tailored to each client’s application, can be sited next to
oil wells minimizing transportation cost.
• Modular Refineries are air cooled. Do not need cooling
water.
• Gases produced are used to fuel the distillation process
instead of flared, minimizing the environmental effect.
• Reduce installed cost, time required for permitting,
shipping, erection, installation and commissioning.
• Modular Refineries are assembled and tested at the
factory, taken apart and shipped. No field welding
required, everything is flanged.
8. Modular Oil Refineries: The Modern Way:
• Modular Refineries take advantage of state-of-the-art
process techniques to automatically control the amount
of each desired subproduct according to the needs of the
client.
• Modular Refineries can be sited to optimize the
production of fuels that can be used in diesel engines
and gas turbines for distributed electrical power
generation.
• Modular Refineries require a minimum amount of
operating personnel since their automatic operation can
be monitored and controlled remotely through a SCADA
system and the operators digitally alerted of any alarms.
• Modular Refineries can be installed in a short time
without welding to coincide with the start of exploitation
of oil wells.
• They can be operational within 4 hours after a cold start.
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9. Crude Oil is composed of a widely varied Mix of
Hydrocarbons
9
Typical Assay of Leona 24 Crude Oil
10. Modular Refinery Capacities
• Our modular Minirefineries have the following refining capacities of crude oil:
500, 625, 1000, 2000, 3000, 6000, 10000, 120000, 15000 , 20000 and 30000 and
35,000 Barrels per Day .
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11. Modular Oil Refinery Yields
• Our Modular Oil Refineries offer subproduct yields depending on its configuration for the
desired subproducts based on the specifications of the Crude Oil being used.
• For example, the following chart shows the subproduct yield for a 20,000 Barrels per Day
Modular Refinery with a ADU/VDU/CRU/HDS processing heavy Crude from Ecuador to
maximize the production of high octane Gasoline and low Sulfur Diesel 2 (less than 400
parts per million). In this case, Off Gas and LPG are used in the distillation process,
Kerosene is used for reinjection back into the oil well to help the flow of the heavy crude
oil, Heavy Fuel Oil is used for electrical power generation and asphalt for roadway
construction.
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2%
2%
18%
7%
21%20%
29%
Off Gas
LPG
Gasoline (95 RON)
LS Kerosene
LS Diesel
HFO
Asphalt
12. We can provide the following Modular Oil Refining Process
Units:
• ATMOSPHERIC DISTILLATION UNIT (ADU) - separates the
different fractions of the crude oil according to boiling
range into naphtha, kerosene, diesel, and residuum
products. it operates at less than 15 psig.
• VACUUM DISTILLATION UNIT (VDU) - performs the same
function as an ADU, but operates at a pressure of less
than zero psig. it produces products like marine fuel oil
(MDO) and asphalt from the ADU residuum (heavy fuel
oil).
• CATALYTIC REFORMER UNIT (CRU) - produces high octane
gasoline from naphtha.
• HYDRODESULFURIZATION UNIT (HDS) - removes sulfur
and other impurities from naphtha and distillate fuels.
• HYDROCRACKER UNIT (HCU) - produces
naphtha, kerosene, and diesel from heavy feedstocks like
VDU distillates.
• DESALTER - removes salt from crude oil prior to
distillation to prevent fouling and corrosion.
• SPLITTER/STABILIZER - separates a feedstock into two
products.
• FLARE - combusts any excess vapor released by process
equipment. 1
2
Modular Refining
13. We can supply the following Modular Gas Processing
Components:
• FIELD COMPRESSION SYSTEM - raises the gas pressure
from the well heads to the pressure required for gas
transmission.
• AMINE TREATER - removes hydrogen sulfde (H2S) and
carbon dioxide (CO2) from the gas stream. Amine gas
treating, also known as gas sweetening and acid gas
removal, refers to a group of processes that use aqueous
solutions of various amines.
• GLYCOL DEHYDRATOR removes enough water to prevent
freezing during transmission or processing. Design
pressures are available from 230 psig to 2,160 psig.
• MOLE SIEVE DEHYDRATOR removes all of the water from
a gas stream. this unit is used when the gas is processed
to very low temperatures (less than -40 F).
• NATURAL GAS PROCESSING PLANT removes natural gas
liquids (ngls) from a gas stream. the gas is cooled until
the desired ngls condense. the raw natural gas must be
purified to meet the quality standards specified by the
major pipeline transmission and distribution companies.
these quality standards vary by pipeline and are usually
a function of the pipeline system design and the markets
served.
• NGL FRACTIONATOR recovers ngls by distillation in
demethanizing, deethanizing, depropanizing, and
debutanizing fractionation columns. Each fractionation
column removes a component from the ngl stream.
• FLARE combusts any excess vapor released by process
equipment.
• CLAUS UNIT recovers elemental sulfur from H2S1
3
Modular Gas Processing
14. POLYMER MODIFIED ASPHALT
Polymer-modified asphalt (PMA) is produced through
the addition of a polymer (and usually several other
chemical components in smaller amounts) to liquid hot
base asphalt. The purpose of producing PMA is to
provide asphalt that meets the new Superpave
requirements, with added strength and flexibility at a
wider temperature range than non-modified asphalt.
Chemex has extensive expertise in PMA blending for a
wide variety of applications. Our design flexibility will
reflect your company's needs regarding key design
parameters such as capacity, level of
automation, equipment preferences, and material
handling to ensure complete customer satisfaction.
Our process utilizes proprietary technology and the most
recent developments in formulation and equipment
configuration. Our design can be highly automated to
allow blending of a wide variety of polymers into a wide
variety of asphalt base stocks. Our process has the
flexibility to minimize modifier and operating costs while
maximizing product value.
Chemex PMA system advantages are as follows:
Proprietary Design - Chemex's formulation technology
and mechanical design provide the highest flexibility and
efficiency available by minimizing the quantity of
polymer and/or additives required to meet specification
requirements.
• Flexibility – Chemex's equipment configuration allows
for a PMA plant capable of blending up to 15% of
polymer concentrates into a wide variety of asphalt base
stocks, with operating viscosities of up to 8,000
centistokes.
• Chemex equipment can be designed to process from
250 to 1400 tons per day of PMA, while heating the
asphalt to the required mix temperature.
• Automated Process - The Chemex design controls the
polymer addition rate automatically, maintaining the
desired polymer concentration based on the asphalt
flow rate into the mixing tank. Chemex's automated
process provides improved metering and regulation
versus manual versions.
• Thorough Polymer Dispersion - Chemex's process
incorporates a combination of high temperature, high-
shear mixing, and automation that provide a thoroughly
dispersed polymer.
• Avoiding Phase Separation - The formulations used by
Chemex impede phase separation. Both mechanical and
chemical measures are used to provide a
stable, homogeneous, blended PMA product. Chemex's
proprietary design allows the polymer to "network"
within the asphalt, creating a homogeneous mixture.
1
4
15. 3-D Design and Rendering
SCHEDULE A - PROCESS
DESIGN PACKAGE
• process simulation;
• process fow diagram (PFD);
• piping and instrumentation
diagrams (P&IDs);
• electrical single line diagram;
• heat exchanger data sheets;
• air cooler data sheets;
• pump data sheets;
• ASMe Section VIII pressure
vessel data sheets;
• electrical and instrumentation
equipment lists; and
• process unit site plan.
SCHEDULE B - CONSTRUCTION
DESIGN PACKAGE
• structural steel design
drawings for skids;
• foundation design skids;2.
• equipment general
arrangement drawings;
• equipment drawings;
• piping drawings;
• electrical location diagram;
• instrumentation location
diagram;
• electrical wiring diagrams; and
• instrumentation wiring
diagrams.
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We can offer an Engineering and Design Package for the
Minirefineries, including On-Site advisory services for
equipment installation, commissioning, start-up and test run.
16. Fabrication
• Our Modular Refineries are designed with skid-mounted
modular equipment for placement on concrete slab
foundations. With conventional foundation-mounted
equipment, each piece of equipment is placed on its
individual foundation and welders pipe the equipment
together. This “stick-built” method requires longer
construction time than Chemex’s modular fabrication.
• Chemex manufactures brand new or refurbished process
units in its facilities in Bakersfield, California. We offer
clients the option of using refurbished process equipment
with a warranty equal to new equipment since using
refurbished process equipment can result in substantial
cost savings and accelerated completion schedules when
compared with new equipment.
• Our equipment is designed to be transported by land or
sea to any location. The equipment is fabricated in the
same configuration as the process unit site plan. All
piping, instruments, and electrical connections are made
among the skids and tested. after completion of
testing, the equipment is disassembled, packed, shrink-
wrapped, and shipped from Bakersfield or from the Port of
Houston.
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17. Installation
• We can provide personnel to advise the buyer of the final assembly
and construction at each site. We can also provide local project
management. When the equipment arrives at the facility site, it is
unloaded and set on the concrete slab foundations. Final skid
placement and elevations are checked against the drawings and skids
are shimmed and adjusted accordingly. After the equipment is in
place, assembly of the interconnecting spools begins. The equipment
is literally bolted together with very little welding required. The
process equipment can usually be assembled and ready to start up
within thirty days.
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18. Commissioning and Start-Up
• We can provide advisors for the
commissioning of the process equipment. All
rotating equipment, instrumentation, and
electrical equipment require preparation for
operation. Piping is pressure tested and/or
vacuum tested. The equipment is purged and
made ready for startup by our advisory crew.
Test Run
• The twenty-four hour test run confirms the
design of the process equipment. Our advisors
advise the operating personnel about the
proper operation of the equipment to achieve
the intended results.
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19. Sample Modular Refinery Projects
• Indonesia, 6,000 BPD
• Atmospheric Distillation
Unit
• Vacuum Distillation Unit
• Shipped in 10 months
after contact signing
• Commissioned in 2009
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20. Sample Modular Refinery Projects
• Nigeria, 1,000
BPD
• Atmospheric
Distillation Unit
• Shipped 9
Months after
contract signing
• Installation in
Progress
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21. • We are very proud of our association with SynChem
Technologies, LLC, a Subsidiary of Prime Energy &
Chemicals, LLC, and manufacturer of the Pulsor™ technology
which provides effective, responsible solutions to Heavy
Hydrocarbon problems in the global Oil and Gas industry. The
Pulsor™ process utilizes proprietary hydrocarbon solvents that are
100% biodegradable, non-toxic, non-corrosive and refinery
compatible. These solvents maximize production rates through
the removal of paraffin wax and asphaltenes deposits. Their flash
point is much higher than competing solvents, providing increased
safety and lower transportation cost. They are effective in a wide
range of climatic conditions.
• The Pulsor™ Series powerful suite of solvents is designed to solve
the problems normally associated with organic deposition (wax
and asphaltenes) from down hole activities to refinery
operations, and to tackle the environmental and personnel safety
challenges that confront today’s oil producers and refinery
operators.
• Pulsor™ has been successfully applied in multiple-field
applications to enhance production levels and to break down
heavy Hydrocarbon compounds in tubular pipes, flow lines and
other associated equipment. The products not only act many
times faster than competitive solvents but with a greater retention
value. These solvents have proven to continue breaking down
Hydrocarbon deposits from upstream activities to pipelines and
storage tank facilities.
• The Pulsor™ solvents are not only biodegradable, but they are also
benign to the refining process, eliminating the need to remove the
products prior to the refining process. The Pulsor™ Series Solvents
are considered to be refinery friendly in every aspect. 21
Pulsor™
Solvent Wax Asphaltenes
PL-35 √√√
PL-50 √√ √
PL-65 √ √√
PL-95 √√√
Crude Oil Solvents PE&C
22. Prime Energy & Chemical - Technologies
• Non-toxic, Biodegradable Solvents to
allow heavy Crudes Oils to be extracted
from new or old capped wells.
22
23. Prime Energy & Chemical - Technologies
• Several actual
older capped
wells reactivated
by our Solvents.
23
24. Power Generation
• The main cost over the lifecycle of a Diesel engine or
Combustion Turbine Generating Unit by far is the cost of
fuel, which can be reduced by installing the generating
equipment as close as possible to a Minirefinery to reduce the
transportation cost of the fuel.
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25. Power Generation
25
• The Diesel distillates and the Heavy Fuel Oil produced in a
modular Minirefinery can be used in electrical power
generating plants in several configurations which we can
provide on a Turn-Key installed basis.
26. Power Generation
• HFO medium speed Diesel engine generating units with HFO
filtering, heating and centrifuging treatment. These are
typically in the 1 to 15 Megawatt range in simple cycle to
produce electricity or in a cogeneration system to also
produce hot water, process steam or steam for flash
distillation desalination or absorption chilled water systems.
26
27. Power Generation
• Industrial Combustion Turbine Generating units rated 40 to 75 MW
use Diesel 2 or HFO with a filtering, heating and centrifuging system.
Can be supplied in simple or combined cycle with a Heat Recovery
Steam Generator feeding Steam Turbine Generating units to minimize
the fuel consumption rate, or to a flash distillation desalination
process or absorption chilled water system.
27
28. Power Generation
• Diesel 2 can be used in high speed Diesel
engine generating units from 500 KW to 3 MW
for standby or peaking use.
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29. Power Generation
• Diesel 2 or Kerosene (Diesel 1) can be used in Aeroderivative Turbine
Generating units from 3 to 100 MW or in Industrial Combustion Turbine
Generating units from 40 to 200 MW. These Industrial Combustion
Generating units can also be used in combined cycle to improve fuel
efficiency.
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30. Contact Information
For any further information contact:
KUAI Energy Systems
3301 NE 183 Street, Suite 1205
Aventura, Florida 33160, USA
Telephone: +1-954-608-1786
E-mail: rarrondo@gmail.com
cvillegas@kuaienergy.com
Website: www.kuaienergy.com
Skype: rpower2
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