- New Crude Units
Our team executed front end, definition and detailed engineering and procurement services for the Eagle Ford Crude Projects at Valero’s Corpus Christi and Houston refineries. One objective was to maximize a “cloning” concept for the base inside battery limits (ISBL) portion of the project even though the capacities of the two projects were 70,000 BPD in Corpus Christi and 90,000 BPD for Houston.
- Front end engineering
- Detailed engineering
Valero developed this project to take advantage of the new Eagle Ford Shale discovery. The Eagle Ford Shale contains both natural gas and hydrocarbon liquids. The hydrocarbon liquids consist of both light hydrocarbons (condensate) and light/sweet crude.
We developed the process design for a new grassroots 70,000 and 90,000 BPD crude units. In FEP-1, our team produced the process design and a +\-50% estimate. FEP-2 expanded the process design to consider alternate feed cases, develop preliminary piping and instrumentation diagrams and produce a +\-30% estimate. FEP-3 developed a +/-10% and allowed Valero to fully fund the projects. Detailed engineering and procurement services followed full funding of the project.
- Crude Preheat — The crude preheat design consists of a three-part system with desalter and flash drum, and a fired charge heater with convective steam coils.
- Fractionation — The fractionation design of the new crude unit includes an atmospheric fractionation column, naphtha, jet, diesel strippers, three pump-around heat removal circuits and product stream pumping, and cooling for naphtha, jet, diesel, and atmospheric tower bottoms (ATB). At one site, jet product is treated by clay treating; at another a Jet Merox unit sweetens the jet product followed by clay treating.
- Overhead System — Due to different product needs and differing existing infrastructure, the atmospheric overhead systems are different at each refinery. One site uses a debutanizer, naphtha splitter, amine treater, naphtha merox unit, and deethanizer tower. The other site uses a divided-wall depentanizer, debutanzier, naphtha and liquefied petroleum gas (LPG) merox unit, and modifications to an existing gas plant to produce light naphtha heavy naphtha, fuel gas, propane and butane products.
- Outside Battery Limits (OSBL) — The process feed and infrastructure to store and transport products to other parts of the refinery for further processing or for product sales are included in the project design. Infrastructure upgrades allow existing utility systems to support the new units. Where existing systems cannot support the project, new utilities systems or upgrades are provided to fully integrate the new unit into the refinery.