GAS CONDENSATE

TECHNOKONTROL REFINERY
Products and services insured by Thechnokontrol is a member of the
Typical application and allocation of Gas Condensate
Technokontrol Refinery (TK-CGMR)
Technokontrol Refinery Construction & Management

Application and allocation of Gas Condensate Technokontrol Refin-

ery (TK-GCMR)

Gas condensate is a typical by-product of both, gas- and oil production. In the gas field it is
generated in the gas drying process. In the oil field it forms a part of the associated gas and
such is mostly flared.

Instead of being flared, gas condensate could be used to produce valuable refinery products
by feeding them to TK-GCMR. The attached block diagrams demonstrate how TK-GCMR could
typically be integrated into gas field facilities (ATT01) or oil field facilities (ATT02).

Features of the TK-GCMR

TK-GCMR is a refinery supplied in pre-erected and pre-tested packages and designed to pro-
cess 25.000 BPD of gas condensate per single stream.

It is designed to optimise the output of mainly gasoline, jet fuel, diesel and fuel oil in high
quality. The design is based on industrially proven technology and is in accordance with inter-
nationally accepted rules, codes and standard as well as European environmental regulations.

TK-GCMR is equipped with modern and up-to-date integrated refinery information system for
monitoring & control of process and performance of the plant.

TK-GCMR is a rather comprehensive refinery which therefore includes various process units
like atmospheric distillation, refiner and reformer. (Therefore, it is important to distinguish
the skid-mounted TK-GCMR from e.g. simple topping plants which typically run on crude oil are
often skid-mounted and called mini refineries too).

The scope of the TK-GCMR includes besides the process units also off-sites and utilities accord-
ing to requirements on site. However, TK-GCMR could be designed as almost self-sufficient with
regard to utilities requiring water as only imported utility.

The TK-GCMR is offered on a LSTK basis or “Keys in hands” option. This means, that the required
EPC work (engineering, procurement and construction) will be realised by a general contractor
with single responsibility towards the client or a full package as required by the client.

Key Arguments for TK-GCMR

The key arguments for the TK-GCMR concept are as follows:

(1) Its high level of self-sufficiency makes TK-GCMR an almost independent source of gasoline,
jet fuel, diesel, fuel oil and even electricity for small,
remote and under-developed markets or oil- and gasproduction fields.

(2) The pre-assembled and pre-tested modules of the TK-GCMR result in short transport, erec-
tion and commissioning times and eventually smaller related cost compared to conventional
refineries.

(3) Due to modularised package concept, TK-GCMR could be easily removed to alternative prod-
uct markets or feedstock sources, if need be. For the same reason it is also easy in operation and
very well suited as pilot plant for testing and/or training purposes.
(4) The integrated refinery information system helps to optimise operational efficiency of the
plant and to maximise the business margin.

(5) Because of the favourable feedstock – gas

condensate instead of crude oil –TK- GCMR pro-
vides cost-effective high quality products which
exceed European as well as US-American qual-
ity standards .

(6) This and the fact that 100% of the feed is

converted into products results in a consider-
ably shorter pay-back period than comparable
crude oil refinery projects of similar product
output.

Technokontrol exclusive safety technology will

allow the refinery to benefit from a anti-explo-
sive, anti-bleve technology by introducing in all
of the possible areas our technology to prevent
any types of accidents, especially,gas explosion
s,fires,bleves,sabotage,etc.

(7) We also strive to reduce all possible con-

tamination by using our exclusive TK-Chimney
Contamination Filtering Technology.

(8) Technokontrol products and safety technology surpasses many International safety require-
ments including the guidelines of the US NFPA-United States National Fire & Prevention Associa-
tion guidelines regarding the prevention of Explosions US NFPA-69-2008 Guidelines.

(9) Technokontrol manufactures its safety products in the EU under full CE safety requirements
and follows full quality & safety guidelines from internationally recognized auditors as the ISO
Organization.

(10) Technokontrol prides itself in having quality certificates as the IS09000-ISO14000-ISO18000-

ISO23000 and is a member of the US NFPA.

(11) Technokontrol Safety Technology is used ,recommended or obligatory from the UK Health &
Safety Authorites, the Australian Fire Authorities, The International MotorBike Racing Authority(FIM),
to the World Professional Powerboat Association.(WPPA),etc.
The Process and the TK-Plant

2.1 Capacity of the Plant

The refinery is designed for an annual capacity of

Max. 937.500 t/a = 25.000 BPD Gascondensate

The operation time of the refinery is 8.000 hours per year.

Following our process technology per example the following endproducts can be achieved.
The exact endproducts depend on the real gas analysis.
Gas condensate LPG t/y Benzine t/y Kerosene t/y Diesel t/y Fuel Oil t/y
100 % 28.125 487.500 121.875 225.000 62.500

t/y = tons per year

The above figures are based on a throughput of 937.500 t/y respective

25.000 BPD.

Additionally 7.500 tons/year (7.500.000 m³/year) of gas are produced, which will be used for
the own energy supply and therefore is no need to use additional gas from outside.

The plant is following international standards. The plant can go in operation after signing of
contract and clarification of all technical and commercial points in less than 2 years.
2.2 Main Equipment
The plant is supplied with all required units and the so-called off-sites, so it can go on stream
with this equipment. A Lay-out of the plant is attached. The required area for the plant is around
43.000m².

The equipment is as follows:

TK-tankfarm for the gascondensate (reserve for 7 days)
The desalination unit
The atmospheric distillation
The disulphurisation of benzine
The benzine splitter
The reformer unit
TK-tankfarm for endproducts (reserve for 3 days)
TK-Safety Technology

Off-sites
Water processing plant
Steam producing unit
Control- and pressure air
Slope system
Flare unit
Electr.power supply
TK-tankfarm for intermediate products (reserve 3 days)
Repair workshops
Spare parts package
Piping and instrumentation
Laboratory
Process control room
Administration and personnel’s dayroom
Fire fighting equipment
TK-Safety Technology

2.3 Installation and Putting in Operation

The units are supplied skid mounted and in part units. Therefore the total installation time will
only be 4-8 months, depending on local conditions.

Putting in Operation takes place in two steps:

- First will be training of personnel and dry run
- The second step will be going on stream.

The Process Control Room will be supplied in containers, full functioning, so the training of the op-
eration personnel can already start parallel to the installation. The Putting in Operation therefore
will be only 3 months.
2.4 Products produced and Quality
Benzene Normal benzene A - 76
Super benzene A - 93

Kerosene Sulphur content < 0,2 % (Mass.)

H2S-content Not tracable
Free water no
Spec. gravity (20°C) < 820 kg/m3
Ignition point > 40°C
poor point < -35°C
Cloud point < -25°C
Mech. impurities none

Diesel
General characteristics Sulphur content < 0,2 % (Mass.)
H2S-content Not evident
Free water none
Mech. impurities none
Following ASTM-D86 95 % of the boiling < 340°C

analysis
Marketing characteristics Summer diesel Winter diesel
Density (20°C) < 850 kg/m3 < 840 kg/m3
Ignition point < 40°C < 40°C
Poor point < -10°C < -35°C
Cloud point < -5°C < -25°C

This quality datas are experienced values which can be slightly changed by the feed character-
istic of the gascondensate.
2.5 Plant Description
2.5.1 Process Diagram / Refiner – Reformer
2.5.2 Lay Out
2.6 Emissions and Effluents

2.6.1 Waste Water

The waste water will be treated in the waste water treatment. This are 3 (three) basins made
from concrete. After the basins the water will be fed into a draining basin.

The content in the water is:

Oil < 10 mg/l
Salt < 10 ppm
Sludge from the basins cleaning 1 x / year.

Fuel Gas
The process furnaces are fired with refinery waste gas. The burners are designed this way, that
the emission levels as listed hereunder will be achieved.

g/m³ flue gas

CO content < 170
NOx < 250
SO2 content < 200
Dust < 50
TK-Refinery Consulting Services

3. Design, fabrication and installation of the plant

Putting in operation, test run, training of local personnel and sup-
port of operation for a certain period.

Based on a concluded supply contract a first class german general

contractor will, based on the process of TK- CONSULTING, design,
fabricate, purchase, deliver and install the plant on the site of the
client, turn-key ready for operation.

Within this supply contract a supervision team will take over train-
ing of local personnel, putting in operation of the plant and will
help operation of the plant for a period to be agreed.
Certificates & Associations

Additional Certificates Due in 2016-17

Certificados adicionales en 2016-17
Certificats supplémentaires en 2016-17