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FAST TRACKPRODUCTION SOLUTIONS

Early Production FacilitiesModular Refineries Gas processing solutions

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About Pyramid E&C 2

Early Production Facilities5,000 BOPD Early Production Facility 310,000 BOPD Early Production Facility 4

Modular RefineriesField Diesel Unit 5Crude Oil Topping Unit 6Gasoline Refinery 7 Gas Processing SolutionsMini LNG Unit 8Modular Methanol Plant 9NGL Extraction Plant 10Modular Hydrogen Plant 11

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Fast Track Solutions Contents

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Pyramid E&C is a multicultural company having the core competence of delivering comprehensive solutions for Oil and Gas Production, Storage, Transportation and Refin-ing facilities. We endeavor to service Oil and Gas asset owners in all stages of development, commencing from Feasibility Studies through Engineering, Project Execu-tion, Delivery and Operation of facilities.Pyramid E&C specializes in fast track deliveries by invest-ing in pre-engineered and/or pre-fabricated equipment ready in stock. Most of the solutions offered by us are in modular construction and can be shipped in sizes to suit site logistics. Pyramid E&C has its own Modular Fabrication Yard mea-suring 20,000 m² with 8,000 m² of covered area. The yard is close to Mundra port in Gujarat, Western India. Due to its proximity to jetty, Pyramid E&C can ship large process equipment and modules weighing up to 800 tons in a sin-gle piece.Pyramid E&C has flexible business models to suit needs of asset owners including rentals of production systems with or without operation support or Build, Own and Operate services with option to purchase. We also car-ry out financial engineering and participation for qualified opportunities.

Our Clients:

About Pyramid E&C Fast Track Solutions

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Pyramid E&C has generic, pre-engineered modular units available for rental for 5,000 BOPD Crude Oil Production. These facilities fit into several containerised modules suitable for sea and road transport. The rental EPF is reasonably complex to provide saleable product for mid-range Crude Oil. The use of the unit on a rental basis allows the customer to start production and thus revenue generation as soon as possible. Our robust equipment design ensures hassle-free operation for customers.

Design BasisThe following lists the inlet parameters and product specifications for the 5,000 BOPD rental EPF.

Inlet Parameters • Capacity : 5,000 BOPD• Nature of Crude : Sweet• Crude Grade : API 22+

Product Specification• BS & W (volume) : 0.5 % • Salt Content : 8 PTB• RVP : 10psia

Process Description:Two-Phase Separation: The well stream fluid from the Inlet Manifold is flashed in the Two-Phase Separator which operates at a pressure of 20 bar(g).This provides the initial separation between oil and gas.

Crude Preheat Exchanger: The Oil from the Two- Phase Separator is heated in Stabilised Oil-Crude Interchanger by recovering heat from treated Stabilizer Column.

Three-Phase Separation: Heated Crude along with Condensate from the Flare Knockout Drum enters the Three-Phase Separator, which operates at a pressure of 5 bar(g) for oil, gas and water separation. Gas from the Separator is flared. The produced water is cooled prior to disposal.

Desalter (optional): The Oil from the Three-Phase Separator is pumped to the Desalter using Desalter Feed Pumps. Wash Water is pumped through a Wash Water Pre-Heater and then mixed with the Crude Oil using a mixing valve or static mixer. The brine is mixed with the produced water for disposal.

Crude Stabilizer: Desalted Crude is stabilized in a Stabilizer Column provided with Reboiler (Nitrogen Stripping optional). This process removes the H2S and also reduces the vapour pressure of the Crude. The gas from the Stabilizer is flared.Crude Oil Storage: Stabilized Oil is pumped through the Stabilized Oil-Crude Interchanger, where it is cooled by the Crude feed. The stabilized oil is further cooled by an Air Cooler and then stored in

Crude Oil Storage Tanks.Crude Oil Transfer: Stored Oil is pumped using Crude Oil Transfer Pumps to loading bays for truck loading.

Fast Track Solutions 5,000 BOPD EarlyProduction Facility

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Pyramid E&C has generic, pre-engineered modular units available for rental for 10,000 BOPD Crude Oil Production. These facilities fit into several containerized modules suitable for sea and road transport. The rental EPF is reasonably complex to provide saleable product for mid-range Crude Oil. The use of the unit on a rental basis allows the Customer to start production and thus revenue generation as soon as possible. Our robust equipment design ensures hassle-free operation for customers.

Design BasisThe following lists the inlet parameters and product specifications for the 10,000 BOPD rental EPF.

Inlet Parameters • Capacity : 10,000 BOPD• Nature of Crude : Sour• Crude Grade : API 15+

Product Specification• BS & W (volume) : 0.5 % • Salt Content : 8PTB• RVP : 10psia• H2S Content : 20 ppm wt

Process Description:Two-Phase Separation: The well stream fluid from the Inlet Manifold is flashed in the Two- Phase Separator, which operates at a pressure of 20 bar(g). This provides the initial separation between oil and gas.

Crude Preheat Exchanger: The Oil from the Two- Phase Separator is heated in Stabilized Oil-Crude Interchanger by recovering heat from treated Stabilized Crude flowing from Stabilizer Column.Three-Phase Separation: Heated Crude along with Condensate from the Flare Knockout Drum enters the Three-Phase Separator, which operates at a pressure of 5 bar (g) for oil, gas and water separation. Gas from the Separator is flared. The produced water is cooled prior to disposal.

Desalter (optional): The Oil from the Three-Phase Separator is pumped to the Desalter using Desalter Feed Pumps. Wash Water is pumped through a Wash Water Pre-Heater and then mixed with the Crude Oil using a mixing valve or static mixer. The brine is mixed with the produced water for disposal.

Crude Stabilizer: Desalted Crude is stabilized in a Stabilizer Column provided with reboiler (Nitrogen Stripping optional). This process removes H2S and also reduces the vapour pressure of the Crude. The gas from the Stabilizer is flared.

Crude Oil Storage: Stabilized Oil is pumped through the Stabilized Oil-Crude Interchanger, where it is cooled by the Crude feed. The Stabilized Oil is further cooled by an Air Cooler and then stored in

Crude Oil Storage Tanks.Crude Oil Transfer: Stored Oil is pumped using Crude Oil Transfer Pumps to loading bays for truck loading.

10,000 BOPD EarlyProduction Facility Fast Track Solutions

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Field Diesel Units are effective in areas where there is a ready supply of Crude Oil but limited supply of Diesel fuel, such as unpopulated areas, remote oil fields or drilling locations. A Field Diesel Unit can fulfill local fuel requirements for power generation and Drilling operation. This unit extracts the Diesel component from the Crude Oil and then blends rest of the products back to Crude Oil. The Field Diesel Unit is split into easily transportable skids; it is quick to install and self-sufficient. The unit can be started when needed and stopped when the tanks are full. The Diesel produced by these units largely depends on the type of Crude Oil, the lighter varieties will provide greater diesel yield and higher cetane number.Process Description:

The Crude Oil is pumped from Storage Tanks and pre-heated in Crude Interchanger before further heating. The temperature of Crude Oil at outlet of Heater is carefully controlled for optimal operation. The heated Crude Oil is flashed into vapour and liquid fractions in the flash zone of Distillation Column. At certain temperature, the Diesel fraction is drawn into

Diesel Stripper for flash point control and sent to storage after cooling.The light fraction (condensate) is condensed in Overhead Condenser and collected into Reflux Drum. Part of condensate is fed as reflux and balance is blended with the residue from the Column bottom and mixed with the Crude Oil. The uncondensed gases are burned in the Heater, or vented to Flare system.

Field Diesel UnitFast Track Solutions

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Pyramid E&C builds topping refineries which are suitable for light, low Sulphur Crudes to produce automotive fuels, i.e., Diesel and Gasoline from Crude Oil and Condensate. The building blocks of these refineries include Desalting, Atmospheric Distillation, and Side Stream Stripping. The yields and the treatment required depend on the API gravity, Sulphur and other properties of the Crude. Utilities include a Fuel Gas System and Tanks for product storage.

Equipment• Fired Heater• Desalter System• Distillation Column• Stripper Column• Flare System• Pumps• Chemical Injection System• Diesel Generator Set• Fuel Oil System• Steam Boiler• Storage Tanks• Truck Loading Terminal

Process DescriptionCrude Oil is first treated in a Desalter Unit where salt in water, or brine, is removed. The Crude Oil is heated in a Fired Heater from which it enters the flash zone

of an Atmospheric Column. Natural Gas condensate can also be included in the feed or introduced directly into the Column. The Crude Oil mixture is separated into different cuts by boiling range. The Crude Column produces Naphtha, Kerosene, and Diesel as the side streams. The Crude Column bottom product, also called Reduced Crude is used as Fuel Oil.

In large Atmospheric Columns, pump arounds are used for intermediate heat recovery to the crude feed which reduces furnace firing. For small refineries of the order of 10,000 BOPD, allowing all heat removal to occur in the Overhead Condenser often minimizes

CAPEX.Products are withdrawn from the tower under temperature control; by modeling the tower, it is possible to predict the temperature, pressure, and number of trays required to produce the desired product specifications. The tower products are stripped of light ends using steam or Reboilers. This controls the inlet specification such as flash point of the product.

Depending on the viscosity, Reduced Crude can be used as Fuel Oil directly. Alternatively, Kerosene or Diesel can be blended with the Reduced Crude to produce Fuel Oil.

Crude Oil Topping Unit Fast Track Solutions

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Pyramid E&C builds plants for processing Naphtha to produce Gasoline for automotive usage. These plants, also termed as Hydro-Skimming Units, can be added downstream of the Topping Unit to consume Naphtha stream for production of Gasoline.

Equipment • Fired Heater • Distillation Column• Desalter System • Debutanizer • Naphtha Hydrotreater • Flare System / SRU• Light Ends Processing • Naphtha Splitter• Isomerization Unit • Reformer• Hydrogen Purification Unit • Pumps• Diesel Generator Set • Fuel Oil System• Chemical Injection System • Steam Boiler• Truck Loading Terminal • Storage Tanks

The building blocks of the Naphtha Treatment line include Hydrotreaters, Naphtha Splitter, Reformer and Isomerization Units. The yields and the treatment required depend on the properties of the Crude Oil and Product Specification. The Reformer also yields Hydrogen, which is utilized in Hydrotreating Gasoline to avoid catalyst poisoning in downstream units. The plants can be supplied complete with utilities including Hydrogen Purification and Sulphur Recovery Units.

Crude Oil is treated in a Topping unit, which yields Naphtha, Kerosene, Diesel and Fuel Oil as products. Amongst these, the Naptha stream is utilized for production of Gasoline. The wide Naphtha cut is fed into Debutanizer to separate LPG from Naphtha. Naphtha is then Hydrotreated using a catalytic process to remove Sulphur and fed into Naphtha Splitter to separate Light and Heavy Naphtha.The Light Naphtha is processed in an Isomerization Unit to increase its octane number prior to blending into the Gasoline pool. The Heavy Naphtha is processed in a Reformer, which creates aromatic rings to increase octane number and liberates Hydrogen. The Reformer is a fixed-bed, semi-regen type catalyst system. The Hydrogen is purified in a Pressure Swing Absorption Unit and used for Hydrotreating Naphtha. Produced Gasoline goes to Gasoline Storage Tank.

The Light Ends Processing System fractionates Butane for use in Gasoline Blending, or Propane and Butane for product LPG (Liquefied Petroleum Gas) which is stored in Mounded Bullets.

The Kerosene side stream goes to Kerosene Storage Tank, while Diesel product goes to Diesel Storage. Depending on the viscosity, Reduced Crude can be used as Fuel Oil directly. Alternatively, Kerosene or Diesel can be blended with the Reduced Crude to produce Fuel Oil.

Gasoline RefineryFast Track Solutions

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Pyramid E&C specializes in building optimized compact modular LNG plants by utilizing mixed refrigerant cycle technology. We optimize refrigerant conditions to precisely meet the refrigeration requirements for each application while minimizing compression power. Mixed refrigerant cycle process is contained in a perlite-filled cold box module, which simplifies installation and optimizes performance with minimal maintenance.Our LNG modular plant offers several advantages as indicated below:

• Plants are designed to be easily operated and maintained with minimal plant support.• Low OPEX for a small-scale LNG plant due to highly efficient, optimized mixed refrigerant (OMR) process.• Low CAPEX due to modular equipment offerings and minimal site work.• Designed with flexible operating range between 30% to 110% of design capacity.• Minimized field work by innovative packaging.• Rapid installation and re-deployment of plant mitigates long term project risks.

The process comprises of following steps:Pre-treatment: Feed gas from the gas station is filtered through an inlet filter Coalescer to separate any liquids/solids to prevent foaming in the acid gas removal unit. Filtered feed gas is sent to acid gas removal unit for removal of acid gases (Typical requirements for LNG: Max 50 ppmv CO2, Max 4 ppmv H2S) using a proprietary amine solution. Sweet gas from acid gas removal unit is than dehydrated in molecular sieve dehydration unit. The dehydration unit dries gas to remove water down to <0.1 ppmv. A mercury removal unit is provided after the molecular sieve

dust filters, for removal of any trace of mercury in the gas prior to entering the liquefaction unit.Heavy Hydrocarbon Removal Plant: This unit separates lighter hydrocarbon (used to produce LNG) from the heavier hydrocarbons, which would freeze at LNG temperature. The heavier hydrocarbons are further treated in fractionation unit to produce plant condensate.The heavy hydrocarbon removal plant design is dependent upon a detailed analysis of the range of components in the feed gas.

Liquefaction Plant: The liquefaction plant cools and liquefies the feed gas from approximately 18°F to -260°F. The Optimized Mixed Refrigerant (OMR) liquefaction plant process, comprises a simple vapor compression cycle using a mix of refrigerants providing a close fit of cooling curves in the main cryogenic heat exchanger (cold box).The mixed refrigerant vapour from cold box is compressed by a centrifugal compressor directly driven by a highly fuel efficient, low emissions gas turbine (Optionally Electrical Motor). Air coolers remove the heat of compression followed by propane refrigerant coolers, causing mixed refrigerant to condense partially. Pre-cooled mixed refrigerant will be separated in liquid and gas. Each liquid and vapour stream will be fed to main cryogenic exchanger separately.

The High-pressure mixed refrigerant (HPMR) is then fully liquefied in the cold box and expanded (partially flashed), using Joule-Thomson expansion, providing refrigeration for the system. The flashed low-pressure mixed refrigerant (LPMR) provides the refrigeration in the cold box and cool mixed refrigerant vapor returns to the compressor via the suction scrubber. The liquid stream also cooled in cryogenic exchanger and flashed to low pressure and fed to shell of the exchanger providing cooling to process side gas.

Mini LNG Unit Fast Track Solutions

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Pyramid E&C offers a cost-effective, small-scale modular methanol production plants. The modular plants are offered with ~200 TPD of chemical grade Methanol. This technology consists of 2-step reforming process which includes a methane steam reformer and a high-temperature secondary reformer (HTCR) with a boiling-water methanol reactor to produce crude methanol.Methanol production technology using natural gas as feed is divided into following sections: 1) Gas Treatment and Compression2) Reforming3) Methanol Synthesis 4) Methanol Purification

Gas Treatment and Compression: Feed gas will be compressed, if battery limit pressure is low. Gas will be treated in gas treatment section to remove natural gas liquids, water and acid gases. The treatment requirements will depend on inlet gas quality. Hydrogenator and sulfur removal beds will be used to remove traces of sulfur prior to reforming. The gas (containing hydrogen) from methanol synthesis loop is used for hydrogenation of sulfur compounds.Reforming: The two-step reforming process features a combination of tubular reforming (primary reforming) followed by oxygen-fired adiabatic reforming (secondary reforming). This technology can be used for large and small-scale plants and offers several advantages compared to conventional steam reforming indicated below: • CO, CO2 and H2 produced are in stoichiometric ratio, thus minimizing feed consumption. • Syngas generation pressure is relatively higher(about 40 bar) thereby reducing the energy requirement for make-up gas

compression (single stage compressor). • Steam Reformer load is substantially reduced Consequently, smaller sized reformer and lower quantity of fuel is required which further reduces the required size of associated equipment in the flue gas duct area.

Methanol Synthesis: The methanol synthesis step involves conversion of synthesis gas into raw methanol. Raw methanol is a mixture of methanol, small amount of water, dissolved gases and traces of by-products (DME, higher alcohols, other oxygenates and minor amounts of acids and aldehydes). The methanol synthesis catalyst and process are highly selective in nature. The conversion of hydrogen and carbon oxides to methanol is described by the following reactions:

CO2 + 3H2 → CH3OH + H2O CO + 2H2 → CH3OH

The methanol synthesis is exothermic in nature and maximum conversion is expected under low temperature and high-pressure conditions. A challenge in the design of methanol synthesis process is to remove the heat of reaction efficiently and economically (i.e. at high temperature) and at the same time to equilibrate the synthesis reaction at low temperature thus ensuring high conversion per pass.

Methanol Purification: The two-column distillation unit represents the low-cost unit and three-column distillation unit is the low-energy system. Two column and three column distillation unit is used to produce grade AA methanol (typical chemical grade) and a single column distillation unit is used for production of Fuel-grade methanol (blending component for gasoline).

Modular Methanol Plant Fast Track Solutions

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Pyramid E&C delivers compact modular NGL plants worldwide supported by our global after sales service network. These plants have several advantages: • Flexibility to operate in ethane rejection mode• The pre-engineered modular packages with minimized footprint helps easy transportation and quicker installation. • Higher NGL recovery• Lower power requirement • Rapid installation and re-deployment of plant mitigates long term project risks.

The process comprises of following steps:Inlet separation skid (Feed gas Conditioning): Feed gas is first pass through a coalescing filter/separator designed to remove solid particles and liquid droplets that may carry over from upstream processes. If gas is sour, it is treated in gas sweeting unit for removal of acid gas compounds in an absorption process. Then feed stream is compressed, unless it is already at required pressure.

Dehydration: Gas is dried to avoid ice and hydrate formation in the cryogenic section of the process, the water content of the gas is reduced to an acceptable level through adsorption in molecular sieve desiccant beds. Downstream of the adsorption beds, the gas passes through a dust filter to remove any particulate carryover before subsequent processing. The Regeneration of molecular sieve beds is achieved by heated gas.

Feed Cooling & Separation: Dehydrated gas flows into the cold section of the process, where cooling of inlet gas takes place by exchanging heat with the cold residue gas in a brazed aluminum plate-fin heat exchanger. Condensed liquid is separated from gas in cold separator. The liquid from cold separator is sent to lower section of demethanizer column. Gas from the cold separator is partially sent to turbo expander and remaining gas flows through reflux exchanger. The expansion of gas cools it further and results in additional condensation.

The cold gas from expander is sent to the de-methanizer column. Cooled gas from reflux exchanger is expanded via J-T valve and send to reflux separator. Liquid from the bottom of reflux separator is sent to de-methanizer column. All cooled gas and liquid streams are fed to de-methanizer column. The cold streams are fed to column at different sections column depending on temperatures.The expansion turbine used in the process can also be configured to recompress the gaseous methane effluent, which ultimately results in lower energy costs.The NGL plant produces liquid rich in C2, C3, C4 and higher hydrocarbons from bottom and a residual gas from top of demethanizer. NGL’s are fractionated into ethane, propane, butane and C5+ in tailor-made processing plants as per specific requirements of the regional markets and customers.

NGL Extraction PlantFast Track Solutions

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Pyramid E&C offers cost-effective, small-scale modular hydrogen plants capable of producing Hydrogen using natural gas and other hydrocarbon feedstock. The process scheme consists of a methane steam reformer and a sift conversion reactor. The process comprises of following steps: • Gas Treatment and Compression• Reforming• Shift Conversion• Hydrogen Purification

Gas Treatment and Compression: Natural gas is pre-treated to remove liquids, water and acid gases. If battery limit pressure is low than feed gas is compressed and preheated in the waste heat section of the reformer. After preheating gas is feed to hydrogenator where the organic sulfur compounds are converted into H2S. H2S is removed by adsorption of it on solid bed scavenger. Purified hydrogen gas is used for hydrogenation of sulfur compounds.

Reforming: Treated gas is prereformed in pre-reformer. Mixture of natural gas and steam is preheated in waste heat recovery section and sent to prereformer resulting in stable and mild operating conditions for steam reformer. Pre-reformed gases are further preheated and sent to main reformer. Here, conversion of hydrocarbons to hydrogen, carbon monoxide and carbon dioxide takes place over a reforming catalyst. Product gas from the reformer is cooled by producing steam

before entering the shift converter. CH4+H2 O →CO+3H2 CH4+2H2 O →CO2+4H2

Shift Conversion: The cooled gas from the reformer sent over the shift catalyst to lower the concentration of carbon monoxide in the gas and increase the yield of hydrogen. The water gas shift (WGS) reactor converts carbon mono oxide and steam to hydrogen and carbon dioxide. The gas from shift converter is cooled further to ambient temperature before entering the PSA unit.

CO+H2 O →CO2+H2

Hydrogen Purification: High purity hydrogen product is obtained in Pressure Swing Adsorption (PSA) Unit. At high pressures off gases are adsorbed on adsorbent and pure H2 is obtained in main gas stream. Off-gases are released during low pressure cycle. The off-gases from the PSA unit are used in the reformer as fuel supplemented with natural gas fuel. In PSA unit the high purity can be easily reached at relatively low cost. Minimum four PSA columns are provided depending on capacity of the plant. The waste gas that normally contains a lot of combustible gases is sent to the reformer to be combusted and generate heat for the reforming.

Modular Hydrogen Plant Fast Track Solutions

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