Suez Oil Processing Company (SOPC) is the first national oil refining company in Egypt since 1921. The company is wholly owned by the Egyptian General Petroleum Corporation (EGPC). SOPC was subjected to many upgrading projects throughout its history to cope with the overgrowing local market demand of petroleum fuel products, and to cope with the strategic EGYPT PLAN 2030, which defines Egypt as an energy hub for the MENA.
The refinery was originally designed to process 3 MM ton/year of heavy Land Belayiem and Marine Belayiem crude oils. SOPC refinery utilizes the delayed coking technology to minimize fuel oil production. The existing refinery was composed of the four main processing complexes; two atmospheric distillation units (CDU-1 and CDU-2); catalytic reforming complex, which contains naphtha hydro treating, naphtha reformer and VRU; a delayed Coking Complex, which is currently out of service; and a lube oil complex, where all units are demolished except the vacuum distillation unit.
EPROM has a long standing cooperation with SOPC, based on this, EPROM has recommended to SOPC to establish a new project; its Coker complex re-habitation project (CORP), which EPROM won the Owner Representative (OR) agreement in Feb, 2021, and was mobilized to Suez during the same month. This agreement is valid for two years period starting from the signing date and can be extended. According to the agreement, EPROM dedicated experienced teams in all the project disciplines. The EPROM-SOPC team cooperating on this project managed to put recommendations on the project activities that saved about 59 mUSD/Year and up to 106 mUSD/year which can be translated into about 64% of the expected operating costs.
In addition to that, EPROM has performed several activities such as reviewing the HPU Revamp Project feasibility, which has concluded that the intended revamp capacity will not be sufficient for the DHTU. Further, EPROM has reviewed the Sulphur Recovery Unit (SRU) design basis and supported SOPC in the licensor and EPC contractors' meetings.
The EPROM/SOPC team has updated the energy management philosophy, EPROM/SOPC team has agreed with ENPPI to base the EnMS MRQ and application sheet on the updated philosophy which describes the existing units’ description; the intended units’ description; energy management system description & functions; and system visualization, handles and reporting.
NEW ASPHALT UNIT PRE-COMISSIONING AND COMISSIONING PROJECT
SOPC builds a new Vacuum Distillation Unit (VDU) for asphalt production. The new unit is designed to process the AR produced from the atmospheric distillation units which process Land Belayiem crude oil.
In order to help achieving this goal, EPROM had to assist SOPC in performing a CDU (2) Mechanical and Process Assessment Project where SOPC has assigned EPROM to perform the mechanical and process assessment for all the unit equipment. In addition, The Turnaround activities implemented included engineering inspections as well as management for all maintenance activities. In addition, and as a part of EPROM Scope, SOPC requested the evaluation of the improvements from the process point of view. SOPC has assigned EPROM to perform a process assessment for all the unit equipment. Based on actual and design process data; EPROM has issued the process assessment report by the end of September, 2021
Based on the success of the activities performed and implemented at SOPC, EPROM is planning to have a project for the Asphalt Unit Operation and maintenance. This is in addition to the Refinery Management System Improvement (RMSI) and the SOPC Modernization Projects as well as the New Coker Complex Commissioning, start up and (O&M).
REFINERY MANAGEMENT SYSTEM
The refinery management system is a system designed to manage aspects of the refinery such a quality management policies and its implementation, its 3D modelling, its energy management policies and its implementation, its electronic documents control and management system, all aspects around maintenance and asset integrity management. The system can manage the resources control and management aspects and their implementation including capacity building and training. The system will result in enhancing the operating manual and procedures of the plant as a whole. It will provide the plant with updated HAZOP with their validation studies based on managed concepts.