MODULAR REFINING SOLUTIONS

Field Diesel Unit

Topping Unit
Hydroskimming Refinery
Full Conversion Refinery
Bitumen Refinery
www.pyramidenc.com
Carbon Black Plants
 Modular Refining Solutions Field Diesel Unit www.pyramidenc.com

Field Diesel Unit

A Field Diesel Unit (FDU) is effective in areas where there is a Process
ready supply of crude oil but limited supply of fuel for power
generation and drilling operation. This unit extracts the diesel
Preheating and Desalting
component from the crude oil and blends rest of the products back to
Crude Oil from storage tank is pumped through preheat
crude oil stream. The FDU is supplied in easily transportable skids, it
exchangers to an electrostatic desalter and washed after mixing with
is quick to install and is self-sufficient. The unit can be started when
fresh water. The desalted crude is further heated in exchangers with
needed and stopped when the tanks are full. The diesel produced by
hot product streams before it enters the heater.
these units largely depends on the type of crude oil, lighter varieties
will provide greater diesel yield and higher cetane number.
Heating
The preheated crude oil from desalter is then charged to a heater
Standard Sizes (Crude oil throughput) fired by off-gas or one of the product streams. Crude oil enters the
• 200 BPD heater convection section, passes through the radiant section and
• 500 BPD exits the heater at appropriate temperature for fractionation.
• 1000 BPD
Distillation
Major Equipment The heated crude oil is flashed into vapor and liquid fractions in
• Desalter the flash zone of the distillation column. The vapor fraction rises
• Fired Heater / Hot Oil Heater through the wash zone fractionating trays of the column, whereas
• Distillation Column liquid fraction flows down to the bottom through the stripping section.
• Diesel Stripper Column Diesel fraction in vapor is condensed and drawn as product from the
• Heat Exchangers chimney trays into a diesel stripper. The lighter fractions go up and
• Chemical Injection System condense in overhead condenser. Part of condensate is fed back as
reflux and the balance is blended with the residue from the bottom
and mixed with the Crude Oil. The uncondensed gases are vented to
Flare system.

Flare

Reflux Drum
Reflux Water

Topping
Column

Desalter
Crude

Diesel

Heater

Red. Crude
Auxiliary systems
Flare Drain

Utility & Offsite systems

Inst. Air Nitrogen Power Storage
 www.pyramidenc.com Topping Plants Modular Refining Solutions

Topping Plants
A Topping plant is a simple refinery that allows for distillation of Process
crude oil into naphtha, straight run kerosene, diesel and fuel oil.
Pyramid E&C supplies these units complete with auxiliary and utility Preheating and Desalting
packages in modular construction to reduce site work and achieve Crude Oil from storage tank is pumped through preheat
faster execution. exchangers to an electrostatic desalter and washed after mixing with
fresh water. The desalted crude is further heated in exchangers with
Standard Sizes (Crude Oil throughput) hot product streams before it enters the heater.
• 2000 BPD
• 5000 BPD Heating
• 10000 BPD The preheated crude oil from desalter is then charged to the
• 25000 BPD heater which is fired by off-gas or one of the product streams. Crude
Oil enters the heater convection section, passes through the radiant
Major Equipment section and exits the heater at suitable temperature for fractionation.
• Desalter
• Fired Heater Distillation
• Distillation Column The heated Crude oil is flashed into vapor and liquid fractions in
• Stripper Columns the flash zone of the distillation column. The vapor fraction rises
through wash zone fractionating trays of the column, whereas liquid
fraction flows down to bottom. At certain operating temperature,
diesel and kerosene fractions in the vapor condense, flow back into
liquid phase and are drawn as products into the respective side
strippers for specification control. The lighter fractions including
naphtha go up and condense in overhead condenser. Part of the
condensate is fed back as reflux and the balance is drawn as full
range naphtha and LPG. The uncondensed gases are vented to the
flare system.

Fuel Gas

Reflux Drum
Reflux Water

Naphtha

Desalter
Crude
Topping
Column Kerosene

Heater

Gas Oil
Steam

Fuel Oil

Auxiliary systems

Flare Drain

Utility & Offsite systems

Inst. Air Nitrogen DM Water Effluent Treatment

Product Logistics Storage Steam Generation Power

 Modular Refining Solutions Hydroskimming Refinery www.pyramidenc.com

Hydroskimming Refinery Reforming

A Hydroskimming refinery comprises of atmospheric distillation unit,
naphtha processing complex to produce gasoline from straight run Heavy naphtha is sent to the catalytic reformer where it gets
naphtha and a distillate hydrotreater to produce low sulfur kerosene converted into a stream comprising of aromatic components with high
and diesel. Pyramid E&C designs the open art systems and octane number in the range of 90 to 100. The reforming unit also
integrates with third party licensed packages. The refinery is generates streams rich in hydrogen and fuel gas.
supplied complete with auxiliary and utility packages in modular Isomerization Unit
construction to reduce site work and achieve faster execution. Light naphtha from the Naphtha Hydrotreater is fed to the
Standard Sizes isomerization unit with hydrogen rich gas from reformer unit. Here the
• 10000 BPD • 25000 BPD naphtha is converted to high octane isomerate, stored in intermediate
tanks and then blended into gasoline pool.
Major Units
• Atmospheric Distillation • Naphtha Stabilizer LPG Recovery
• Naphtha Hydrotreater • Naphtha Reformer The naphtha fraction is stabilized by separating C3 and C4
components which form part of LPG pool. The LPG stream from
• Isomerization Unit • Distillate Hydrotreater stabilizer is mixed with that from the reformer and sent to the
• Sour Water Stripper • Sulfur Recovery de-propanizer to achieve required blend. The overhead vapors are sent
• Hydrogen Purification / Generation to the sweetening unit for use as fuel gas. Stabilized naphtha is sent to
the hydrotreatment unit.
Hydrogen Purification
Process The hydrogen-rich gas from reformer is treated in a pressure swing
Distillation adsorption (PSA) unit that purifies hydrogen for usage in hydrotreating
The topping unit is first unit in Hydroskimming refinery which process. The PSA will typically deliver hydrogen with a purity higher than 95
produces straight run naphtha, kerosene, gas oil and residue. The mol%. Off-gas from the PSA unit is used as sweep gas for the flare system.
straight run products are fed to downstream treatment units. Distillate Hydrotreating
Naphtha Hydrotreatment The intermediate distillates from the topping unit are combined, mixed
Stabilized full range naphtha will undergo further processing in the with recycled hydrogen and then brought to the reaction temperature by a
Naphtha Hydrotreater to remove sulfur, nitrogen, and other heater prior to being fed to the Diesel Hydrotreater. By-products of the DHT
impurities, that would poison the catalyst used in the downstream reaction include un-stabilized naphtha, fuel gas and sour gases which are
catalytic reforming process. Sulfur removal is also required to meet routed to a stripper for acid gas removal. Stripped liquids are heated and
gasoline product specifications. fed to a splitter column to be separated into kerosene and diesel and then
routed to Jet Fuel and/ or low Sulfur diesel blending and storage.

Fuel Gas

LPG Recovery LPG

Isomerization

Naphtha NHT
Stabilizer

Reforming Unit Gasoline

PSA Unit
Crude Oil Desalting Hydrogen Rich Gas
/ CDU Kerosene

Distillate Hydrotreater Diesel

Fuel Oil
Auxiliary systems

AGRU HGU Sour Water Stripper Flare

Utility systems

Inst. Air Nitrogen D M Water Cooling Water Storage

Effluent Treatment Logistics Steam Generation Power Fuel System

 www.pyramidenc.com Full Conversion Refinery Modular Refining Solutions

Full Conversion Refinery

Pyramid E&C offers full conversion refineries along with auxiliary, The hydrocracking process occurs over a catalyst in a hydrogen
utility and offsite units in standard sizes and modular construction. rich environment at elevated temperature and pressure. In this
The full conversion refinery adds bottom upgrade section to process, the high-boiling, high molecular weight hydrocarbons are
Hydroskimming refinery for conversion of heavy oil fractions into cracked into lower-boiling, lower molecular weight hydrocarbons.
high value automotive fuels.
Fluid Catalytic Cracking
Standard Sizes If Gasoline production needs to be maximized, an FCC unit can be
• 25000 BPD • 50000 BPD provided where a fluidized bed of catalyst particles is brought into
contact with VGO along with steam injection to break down VGO
Major Units into short chain molecules.
• Atmospheric Distillation • Vacuum Distillation
Alkylation
• Reformer / Isomerizer • Distillate Hydrotreater
Should there be a requirement of high octane gasoline, an
• Hydrocracker and/or • Fluid Catalytic Cracker alkylation unit can be provided to improve octane number by
• Alkylation • Visbreaking/ Coking converting light olefins produced by the FCC or Coking unit into a
gasoline blending component (alkylate), consisting of branched
chain paraffinic hydrocarbons (iso-heptane and iso-octane).
Process Visbreaking/ Coking
Vacuum Distillation (VDU) The vacuum column residue can be treated in couple of ways to
obtain either heavy liquid products or the solid coke.
The bottom stream from atmospheric distillation column is drawn
into a vacuum column to separate the gasoil from residue. From the The visbreaker unit may be supplied to crack large hydrocarbon
VDU overhead, vent gases are routed to fired heater, steam molecules into naphtha, gasoline and residue by heating in a
condensate is sent to the Sour Water Stripper and the vacuum gasoil furnace. The cracked products are quenched and flashed into a
stream (VGO) is sent to hydrocracking unit, distillate hydrotreater fractionator to separate light and heavy liquid streams.
unit or storage. Depending on the oil properties and market conditions, a Coking
unit can be considered to process the VDU residue to produce gas
Hydrocracking oil and petroleum coke (Petcoke).
The gasoil(VGO) from the VDU is fed to hydrocracking unit for
conversion into lighter products LPG, reformer grade naphtha, Ultra
Low Sulfur Kerosene (ULSK) and Ultra Low Sulfur Diesel (ULSD).

Fuel Gas

Light Gases
Saturated Gas
Recovery LPG
Iso paraffins

Unsaturated
Isomerization
Gas Recovery

Naptha Naphtha
Hydrotreater Reformer
Gasoline

Gas Oil Desalting Kerosene

/ CDU Distillate
Hydrotreater Kerosene

Gas Oil Hydrocracker

Diesel

Fluid Catalytic Naptha

Cracking
Gas Oil
Gas Oil Coking or Coke
Visbreaking
VDU

Fuel Oil
Auxiliary systems

SRU AGRU H2 Generation Sour Water Stripper Flare PSA

Utility systems

Inst. Air Nitrogen Fuel System Power Effluent Treatment Drain

Storage Logistics Steam Generation DM Water Cooling Water

 Modular Refining Solutions Bitumen Refinery www.pyramidenc.com

Bitumen Refinery
Pyramid E&C offers Bitumen production refineries complete with
auxiliary and utility units to monetize heavy crude oil and also get
straight run diesel product. The flexible design allows production of
different bitumen grades.
grade of bitumen. Preheating sections of atmospheric and vacuum
distillation are integrated to maximize heat recovery and thus
minimize fuel consumption. Steam is used to strip vacuum residue at
the vacuum column bottom to ensure that the bitumen properties
meet desired commercial grades.

Standard Sizes Bitumen Blowing Unit

• 5000 BPD This unit blows air into hot vacuum residue stream to produce
• 10000 BPD desired grade and properties of

bitumen. The vacuum residue is sent to the unit using gear

Major Equipment pumps through charge heaters. The feed residue is contacted with
• Atmospheric Distillation air steam mixture using a set of spargers. A suitable temperature
• Vacuum Distillation is maintained by controlling steam and air injection rates. The off
• Bitumen Blowing Unit gases from top are either flared or incinerated and converted
bitumen is poured into the drums and left for cooling and
• Distillate Hydrotreater solidification.
• Sour Water Stripper
• Sulfur Recovery Auxiliary and Utility Systems
• Hydrogen Purification The auxiliary units required for operation include sour water
stripper, flare, effluent treatment unit, fire detection and protection
Process systems. Major utility systems required are instrument and plant air,
steam, power and process water.

Vacuum Distillation
The atmospheric residue from atmospheric distillation unit is
processed in a vacuum column to separate the gasoil and residue.
The residue drawn should be suitable for desired commercial

TO SRU

TO FUEL GAS
ACID GAS

AGO
H2
Gas Hydrotreater
Treatment AGO

OFF GAS
NAPHTHA

Desalter NAPHTHA
CRUDE

NAPHTHA
ADU Naphtha Stabilizer KERO
Heater
KERO Kerosene
AGO
VGO

VGO

VGO
ATM VDU
RESID Vacuum Heater
VAC Bitumen
RESID. Bitumen
Blowing Unit

Auxiliary systems

PSA Unit H2 Gen. Unit SWS SRU Incineration Flare

Utility & Offsite systems

IA/PA Nitrogen DM Water Steam ETP

 Modular Refining Solutions Carbon Black Plants www.pyramidenc.com

Carbon Black Plants

Pyramid E&C has experience of Basic Design, Detailed Storage
Engineering, Procurement and Construction management for
The unit has adequate storage facilities for all the raw materials
carbon black plants of capacities in multiples of 40 TPD. Pyramid
and finished products. Carbon black feedstock received from
E&C can also engineer and supply process units, offsite and utilities
refineries and molasses received from sugar industries are unloaded
required for Tread, Carcass and Specialty Black Plants.
into isolated storage area in fixed roof tanks. Feedstock and
The basic process consists of atomizing the Carbon Black Feed
Molasses are stored at an average temperature of 50°C through
Stock (CBFS) i.e. Fuel Oil of suitable properties, into the combustion
external steam heating. Additives are stored in raw materials
zone of the reactor where the combustion of fuel instantly vaporizes
godown. Steam generation is carried from waste heat in inline
the feedstock and decomposes into primary carbon black and
boilers and tail gas fired boilers. The excess steam will be utilized in
hydrogen. The remaining feedstock reacts with excess oxygen in the
captive power plant.
primary combustion stream to maintain the reaction temperature for
carbon formation. COLD AIR

The hot, heavy carbon black smoke from the reactors enters the air HOT AIR

preheater where thermal energy is transferred to preheat the primary Carbon Black
Reactor SMOKE
Air Pre-
Heater SMOKE
Oil Heater
SMOKE
Waste Heat
SMOKE
Quench
Tower

combustion air. The reaction products are quenched rapidly with HOT CBFS

water sprays in quench tower. SMOKE

From the air preheater the lowering of temperature in a tower from

TAIL GAS TO BOILLER AND TO COMBUSTOR

Bag Filter Process Bag Pellitiser Pin Mixer

which then enters the bag filter that separates the fluffy carbon black
Surge

product from the off gases. Carbon black particles are deposited TAIL GAS

outside the bag-filter and hot process gases filters off for utilization
Silos
Bucket

as fuel for specially designed boiler system to generate high

Elevator

Dryer Packaging

pressure steam and in a specially designed dryer combustor furnace Unit

to supply energy requirement in pelletizing and drying section. The

quantum of high-pressure steam which is generated through burning
3D Model Snapshot
of these off gases meet the plant requirement of steam and power.
The fluffy density carbon black is then conveyed to the wet
pelletizers where water is added to transform the product into wet
granules. Dry palletization in rotating drums is also practiced for
certain applications. The wet pellets are then dried in a rotary dryer
where finished product goes to storage silos

Handling
All the raw materials and finished products are handled as per the
standard practice in the closed systems. Finished product handling
is in closed system. The finished product will be stored in silos.

Completed Plant at BKT, Gujarat, India, Nov. 2019

 Pyramid E&C is an international technology and EPC company having core competence of supplying modular
process plants for Automotive Fuels, Fertilizer and Petrochemicals production from Oil and Gas resources.
We enable oil and gas asset owners enter downstream market at the lowest cost and produce a range of
hydrocarbons to serve regional market, thus maintaining a tight operation insulated from commodity price
fluctuation and international product suppliers.
Our services cover all stages of development; from feasibility studies through financial engineering,
manufacturing, equipment supply, project management, installation, commissioning and operation of facilities.
Pyramid E&C engineering and project management centers in Houston, London, UAE and India have capability to
deliver and operate projects worldwide.
Pyramid E&C specializes in fast track deliveries by using standard plant configurations and modularization. Our
fabrication facilities in US and India have capabilities of equipment manufacturing, process automation and deliver
process modules up to 1,000 tons in a single piece thus ensuring quality and most efficient execution.

Web Contact
URL : www.pyramidenc.com
Enquiry : sales@pyramidenc.com

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Anant Bajpai Vijay B. Millicent Herman Makrand Palkar

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