69
Sannazzaro refinery June 2015
Sannazzaro refinery
June 2015
Sannazzaro Refinery outlook
HSE
History
Raw materials and products
Flow scheme
EST project
Organization chart
3
Organization chart
4
Sannazzaro Refinery
5
Employees: 661
Average age : 40
Education graduates 83 %
Training: 27.274 hours provided in 2014
Conntractors:
Average daily presence: 600 people
Peak: 2500 people (MTA 2007)
Sannazzaro Refinery
6
HSE
Hours worked ENI employees
7
0
200.000
400.000
600.000
800.000
1.000.000
1.200.000
1.400.000
1.600.000
2007 2008 2009 2010 2011 2012 2013 2014
Ore l
avo
rate
year
Hours worked ei employees
Injuries eni employees
8
2
1
0
2
0 0 0 0 0
1
1
2
2
3
2007 2008 2009 2010 2011 2012 2013 2014
N° i
nfo
rtu
ni
year
Injuries eni employees
Hours worked contractors
9
0
500.000
1.000.000
1.500.000
2.000.000
2.500.000
3.000.000
3.500.000
4.000.000
2007 2008 2009 2010 2011 2012 2013 2014
Ore lavo
rate
year
Hours worked contractors
Injuries contractor
10
11
Enviromental management system
ISO 14001 since 2004
EMAS Registration since 2007
OHSAS 18001 since 2012
I-000628
12
Enviromental management system
What is ISO 14000? The ISO 14000 family includes most notably the ISO 14001 standard, which
represents the core set of standards used by organizations for designing and
implementing an effective Environmental Management System (EMS).
ISO 14001 sets out the criteria for an Environmental Management System
(EMS).
It does not state requirements for environmental performance, but maps out a
framework that a company or organization can follow to set up an effective EMS.
It can be used by any organization that wants to improve resource efficiency,
reduce waste, and drive down costs.
Using ISO 14001 can provide assurance to company management and
employees as well as external stakeholders that environmental impact is being
measured and improved.
13
Enviromental management system
What is EMAS?
EMAS (Eco-Management and Audit Scheme) is a voluntary certificatione created
by the European Community to evaluate and improve the environmental
performance of a company.
All information about the environmental management of the company, are
provided to the public and to the other stakeholders.
In 2010, the latest EMAS Regulation (EMAS III) entered into force; the scheme
is now globally applicable, and includes key performance indicators and a range
of further improvements.
Objective of EMAS is to promote the rispect of all environmental aspects.
This action is based not only on the limits imposed by law, which remains an
obligation owed, but on the continuous improvement of environmental
performance, the creation of a new relationship with the institutions and the
public and the active participation of employees.
14
Enviromental management system
What is OHSAS 18001?
It is an internationally applied British Standard for occupational health and safety
management systems. It exists to help all kinds of organizations put in place
demonstrably sound occupational health and safety performance. It is a widely
recognized and popular occupational health and safety management system.
BS OHSAS 18001 specifies requirements for an OH&S management system to
help an organization develop and implement a policy and objectives, which take
into account legal requirements and information about OH&S risks. It applies to
all types and sizes of organizations and accommodates diverse geographical,
cultural and social conditions.
15
Enviromental management system CEMS
Continuous Emission Monitoring Systems (CEMS)
CEMS are required to be installed in facilities specified by ISPRA (Italian
Ministry of the environment).
The CEMS are used to continuously monitor the effectiveness of air pollution
control techniques and to determine if source control requirements are being
met. It is required for continuously monitoring compliance with a specific
pollutant emission limit or to monitor compliance with source and pollution
control device operating limits.
Continuous monitoring system is defined as the total equipment (sample
interface, analyzer, and data recording) required for determining emissions
and/or operating parameters.
The CEMS shall continuously monitor and record the concentration of gaseous
pollutant emissions on a wet or dry basis discharged into the atmosphere
consisting of subsystems for sample extraction, conditioning, detection,
analysis, and data recording/processing.
16
The refinery CEMS provides to monitoring the emission points “continuously
monitored” and “not continuously monitored”.
Processing criteria used by the emission monitoring system for defining the
overall refinery data involves:
• extent of contributions from the emission points;
• processing of data acquired by the system for checking compliance with the
limits.
Enviromental management system CEMS
17
Emission points with continuous monitoring
The continuous measurement system for emissions from 10 stacks (which
constitute about 90% of total emissions) provides for the acquisition of the
following parameters:
• Sulfur Dioxide (SO2)
• Nitrogen oxide (NOx)
• Carbon Monoxide (CO)
• Oxygen (O2)
• Total Organic Compound (TOC)
• particulate matter
• Flue Gas Temperature / Pressure / Flow
The PC system provides the measurement of concentrations coming from
monitoring booths for NOx, SO2, CO and PM; the flue gas flow measurement
is related to oxygen prescribed for the emission point (3% or 15%).
Enviromental management system CEMS
18
Enviromental management system CEMS
NOx and particulate matter analyzer
Measurement of flue gas flow
SO2 and CO analyzer
O2 analyzer
19
Enviromental management system CEMS
Cooling system
Local PC server
20
Emission points not continuously monitored (estimated values)
The estimation procedures used for issuing points without continuous
monitoring system are:
• stechiometric calculation of SO2 (depending on the quality and quantity of
fuel used)
• estimation of emission values of NOx application emission factors;
• estimation of emission of CO through the application of emission factors;
• estimation of particulate emission values by applying emission factors;
• estimation of flue flow refers to the oxygen content laid down by
stechiometric calculations.
The estimated concentration data are expressed in mg/Nmc and are referred
to the oxygen content of the reference (3% or 15%).
The values (continuous measurement + estimated values) are immediately
available to calculate total emissions (Refinery “Bubble”).
Enviromental management system CEMS
21
Enviromental management system CEMS
Screen view of CEMS
emission points with
continuous monitoring
emission points with
estimated values
attention threshold
daily limits
Refinery total emission
(Bubble)
22
Enviromental management system CEMS
In accordance with the AIA, emission values are calculated as weighted ratio
between the sum of the masses of pollutants emitted and the sum of the
volumes of waste gas of refinery.
A “CEMS Manual” has been prepared to specify the requirements for CEMS
operation, reporting, and quality assurance/quality control (QA/QC).
Performance Specifications are used for evaluating the acceptability of the
CEMS at the time of or soon after installation and whenever specified in the
regulations.
Quality assurance procedures are used to evaluate the effectiveness of quality
control (QC) and quality assurance (QA) procedures and the quality of data
produced by any CEMS that is used for determining compliance with the
emission standards on a continuous basis as specified in the applicable
regulation.
23
Enviromental management system CEMS
24
Enviromental management system Air quality monitoring
Air quality monitoring
The control of air quality (Immissions) is carried out through a network of
detection stations located in the area of interest of the refinery as part of the
monitoring network of ARPA Lombardia. These monitoring stations, managed
directly by ARPA Lombardia, are part of a wider system, composed of about 190
stations located throughout the region.
The network is composed of 5
monitoring stations located in the
towns of
• Scaldasole,
• Ferrera,
• Galliavola,
• Mezzana Bigli/Casoni
Sannazzaro
25
Enviromental management system Air quality monitoring
In Sannazzaro Refinery there is also a meteorological station (located inside the
refinery).
The meteorological station records the following variables:
• wind speed and direction;
• temperature;
• relative humidity;
• temperature;
• pressure;
• precipitation;
• solar radiation
26
Enviromental management system Air quality monitoring
Daily ARPA transmits to the refinery a bulletin on air quality around the territory
where the refinery insists, on the basis of the data collected the previous day.
The intervention of a third party institution ensures the independence of the
results of the activities of control and monitoring.
The air quality in the area of interest of the Refinery is good: in the last few
years, for the totality of the pollutants studied, the measured values are well
below the limits established by law.
27
Energy Management System
Sannazzaro refinery obtained and maintain EMS certification since
last June 2012 as for Internation Standard :
ISO 50001
This means that the Refinery works under an Energy Management
System, it keeps monitoring and controlling for each energy source
utilization and search for continuous efficiency improvement.
28
Location
Pipeline
Crudes
Products
MILANO
TORINO
SAVONA
Multedo
VENEZIA
GENOVA
Ferrera
Lacchiarella
Volpiano
Chivasso
Rho
Arquata
Fiorenzuola
Fegino
ESSO
Trecate
Cap: 6.7
ENI
Sannazzar
Cap: 9.0
TAMOIL
Cremona
Cap: 5,0
ENI
P. Marghera
Cap: 3.5
IES
Mantova
Cap: 2.6
Location
30
History
1963 - 1970
1975
1987 - 1990
1992 - 1993
1993 - 2002
2004
CD Tech
2005
Belco
2006
Gasification
2008
Deasphalting
2009
SRU4
HDC2
Historic Evolution: 2004 – 2009 Growing conversion & complexity
37
Flow-scheme and Layout
38
GPL
Gasoline
Kero
Diesel
P
R
O
D
U
C
T
S
-
M
A
R
K
E
T
HDS1/2
HDS3
Reformer 2/3
TIP
ALK MTBE
O.C.
Bitumen
Pitch
T
o
p
p
i
n
g
1/2
HDC 1/2
VACUUM 1/2
FCC
VSB
IGAS
Syngas
ROSE
Sannazzaro refinery flow scheme – before EST
39
P
R
O
D
U
C
T
S
-
M
A
R
K
E
T
HDS1/2 Diesel
O.C.
Bitumen
Pitch
T
o
p
p
i
n
g
1/2
HDC1/2
VACUUM 1/2
FCC
VSB
IGAS
Syngas
ROSE
EST
Sannazzaro refinery flow scheme - with EST
LPG / Gasoline
Kero / Diesel
Pitch
40
EST Project
Technologies for Petroleum Residue Upgrading
9 M BPSD fuel oil produced in the world >90 M TPY petcoke produced worldwide
Several commercial technologies conversion of vacuum residua to lighter products
Increase of low H/C of residua to higher H/C of products via thermal or catalytic:
carbon rejection (thermal) hydrogen addition (catalytic)
Coking offers high feedstock flexibility but
poorer quality of distillates loss of liquid yield, ca. 30% wt of low value coke
Fixed/Moving bed (low metals content feed) Ebullating bed (relatively higher metals feed)
but limits the maximum conversion achievable fuel oil remains a fatal product
Gela
Livorno
Milazzo
Venice Sannazzaro
Taranto
Fixed Bed Hydroconversion RHU by Shell Chevron Lummus Global
25,000 BPSD - since 1995 • Low bottom conversion • Low feed flexibility • Limited run length
Coking 1 – DC by Kellogg 4,600 TPD - since 1963 Coking 2 DC by Conoco 3,300 TPD - since 1990 • Loss of liquid yield • Coke disposal
Visbroken tar Gasification SGP by Shell Global Solution 400,000 TPY - 200 MWe since 2005
• Product is electric energy
Ebullating Bed Hydroconversion LC-Finer by Chevron Lummus Global 25,000 BPSD - since 1998 • Residue stability at high conversion • Unconverted bottom disposal
A Superior Deep Conversion Technology is needed
Eni experience with Residue Deep Conversion Technologies
43
EST technology objective
Catfeed
Petroleum Residues
Extra Heavy Oils
Tar Sands
Bitumen Shale oil
EST
Hydrogen
Catalyst
Metals Sulfur
Nitrogen
6-20%
35-55%
12-55%
44
EST – Process Scheme
Recycle
Distillates
Feed
H2S removal
VGO
Pre
-fla
sh
Va
cu
um
HH
PS
Make up H2 R
eacto
r S
lurr
y
Spurgo Make Up Cat.
510°C
300°C
430°C
160 barg
360°C
8 barg
430°C
160 barg
340°C
2Q 2003 Construction of the
Commercial Demo Plant 1,200 BPSD Capacity
2000-2003
Construction and operation of a
0.3 BPSD Pilot Plant
3Q 2005 CDP completion & start up
since November 2005 CDP has been
operating successfully
Today Demo of updated
schemes
EST: Development Road
Early 1990’s Start of the R&D activity
46
EST project realization in Sannazzaro has been decided because:
1) Increasing in diesel demand in Europe
2) ENI intention is to increase diesel production:
Increasing the capacity of Sannazzaro Refinery in term of processed Mln tons/year of
crude from 10 Mln ton/year to 11,1 Mln ton/year
Using “E.S.T” technology (ENI SLURRY TECHNOLOGY) licensed by ENI
3) Location of Sannazzaro Refinery:
Very central position for Europe market (presence of infrastructures and
pipelines for crude supply and distribution of products) Optimization and integration of processing cycle with existing refinery
Why EST project in Sannazzaro?
47
Refinery Material Balance
47
2012 MATERIAL BALANCE EST PROJECT IMPACT EXPECTED
Grezzi ATZ; 4737
Grezzi BTZ; 3520
Semilav.; 1103
Altri; 1088
0
2000
4000
6000
8000
10000
12000
CARICHE
kTo
n/y
Perdite e consumi; 892
Altri; 501
O.C. Bunker; 897
Diesel; 3379
Kero; 895
Benzina; 2505
Nafta; 497
GPL; 882
PRODOTTI
Grezzi ATZ; 5763
Grezzi BTZ; 2827
Semilav.; 1090
Altri; 1403
0
2000
4000
6000
8000
10000
12000
CARICHE
kTo
n/y
Perdite e consumi; 1256
Altri; 342
O.C. Bunker; 572
Diesel; 4157
Kero; 897
Benzina; 2332
Nafta; 646
GPL; 882
PRODOTTI
EST Sannazzaro : Design feed
•Design feed : TAR Vacuum / Visbroken Resid from crude Topping/Vacuum production line
RV Ural RV Basrah
Density @15°C (kg/m3) 1004 1039 Sulphur (%wt) 3 6 Nitrogen (%wt) 0,7 0,4
48
49
EST Sannazzaro Project – site
EST Plant - SNZ refinery
EST Sannazzaro Project – site
51
The EST complex has a capacity 23,000 BPSD of Vacuum Residue (Ural type or Basrah type crudes) as feedstock, and includes:
● Reaction Section, ● Fractionation Section,
● Products Upgrading Section, ● Purge Treatment Unit
The Sannazzaro EST Plant Complex
Utilities & Offsites
Vacuum Residue
FG LPG Naphtha Jet fuel HQ Diesel Catfeed
Sulfur Plant
Steam Reforming
Reaction Section
NG
EST Fractionation
Upgrading Section
PTU
Sulfur
Metals to reclaim
7.0-9.0, wt%
6.5-7.5, wt%
38-50, wt%
30-45, wt% (VB Tar)
52
Units in Sannazzaro EST / 1
EST complex will include the following Units:
1) Main EST plant:
Capacity: 160 t/h of heavy residue (23.000 BBPD)
Distillate yields almost 100%
2) Sulphur REcovery Unit (SRU)
Capacity: 160 t/d of produced Sulphur (two lines of 80 t/d each)
Recovery efficiency: 99,6%
3) Hydrogen Production Unit (HPU)
Hydrogen production: 100.000 Nmc/h
Both methane/fuel gas or light naphtha forseen as feed
52
53
Units in Sannazzaro EST / 2
4) Auxiliary Units
Amine Regeneration Unit (ARU), 5500 t/d
Sour Water Stripper (SWS), 100 m3/h
5) Services
Cooling water
Instrument air
Condensate recovery
Demi Water
6) Flare and blow down
New flare and blowdown designed for the new units
7) Purge Treatment Unit (PTU)
53
The Sannazzaro EST Project is a Fast Track one:
The Sannazzaro EST EPC Project
Basic Design Package (BDP) and Front End Engineering Design (FEED) by Saipem (formerly Snamprogetti) completed in 2008.
EPC phase and works on site already in progress. EPCM contract awarded to Saipem. Assembling of high-pressure reactors between October 2009 and March 2011 Oil in by 2Q 2013.
Slurry Reactor slice at GE yard, Massa (Italy)
Reactor cap
Total Reactor weight: ca. 2,000 ton
EST EPC Project is huge: about 1,300,000 Home Office hours, 3.000 man months for supervision, 32 months of yard duration, about 7,500,000 construction hours, 17,000 ton equipment, 36,000 ton of bulk material and piping, 700 km instrumentation wiring
The industrial reactor /1/
The industrial reactor /2/
EST Sannazzaro Project – Reactors vessel trasportation
57
14 items to be transported through 3 ships
Escort: 3 cars of technical staff+police (>140 tons)
Time: 4 weeks
Road–sea transport: items ≥123 tons Road transport: items <123 tons
58
EST Sannazzaro Project – Reactors vessel lifting - VIDEO
GRUPPO ELEMENTO VALORE UNITA’ DI MISURA
GENERALE
Area impianti 240.000 mq
Area cantiere 190.000 mq
Durata cantiere 24 mesi
Presenza media 900 uomini/mese
Presenza massima 2000 uomini/mese
INGEGNERIA P&I 280 cad
PROCUREMENT Gare 105 cad
COSTRUCTION Montaggi 7.500.000 ore
MATERIALI
Items 390 cad
Piping 16.000 ton
Carpenteria 20.000 ton
Cavi strumentali 700 km
Cavi elettrici 1300 km
Ingegneria/procurement:1.320.000 ore
Gestione / Supervisione: 2450 M/U
Progetto EST di Sannazzaro – Quantità
60
Progetto EST di Sannazzaro – Costruzione ad aprile 2011
61
Dopo 11 mesi
Progetto EST di Sannazzaro – Costruzione a marzo 2012
62
Crude slate and main products
63
Throughput
81067792 7991
83568720
8432 84028618
9141 90518614 8635
9053 8860 8847
93869013
9234 9085
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
throughput
Raw materials
64
Crude via pipeline from Genova
crudes tipology 2014
russian nigerian Middle East Italian Residue and s/l others
65
Quality crudes throughput in 2014
0.0 500.0 1000.0 1500.0 2000.0 2500.0 3000.0
Ural Exp.Blend 34
Azeri Light
Siberian Light
Sahara Blend
CPC Blend
Arabian Light
Iranian Light
S/L
Main Crudes
66
Products
Kton 2005 2007 2010 2014
LPG 152 154 150 176
GASOLINE 2535 2291 2841 2650
JET FUEL 958 984 862 816
DIESEL 2988 2785 3551 3711
FUEL OIL 888 618 473 747
BITUMEN 363 114 105 116
SULPHUR 41 51 64 85
PROPYLENE 50 75 53 61
SYNGAS 0 699 675 626
67
Prodotti 2006 - 2014
7.9 7.5 8.9 8.8 9.27.4 11.6 9.2 9 8.6
31.6 30.9 28.6 28.5 27.2
46 46.1 49.1 48.5 49.8
7.1 3.9 4.2 5.2 5.2
0
20
40
60
80
100
120
2006 2008 2010 2012 2014
product %
c+p gpl+syngas benzine distillati fuel+bitumi+zolfo
Product delivery
Pipeline : 80 %
Truck: 17%
Railway: 3%
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END OF PRESENTATION
