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Nigerian National Petroleum Corporation, NNPC, Energy, Nigeria
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February 26, 2017
Kaduna Refining & Petrochemical Company (KRPC)
VISION

To be the pride of the Nation

MISSION

To Refine Crude Oil into high Value Petroleum and Petrochemical Products and also Manufacturing Packaging Products efficiently. 

CURRENT BUSINESS DIRECTION

  •   KRPC will transit from a cost center to profit center.
  •   Carry out comprehensive capacity development programme focused on performance management.

  •   Stimulate upgrading and Rehabilitation of the Refineries.

·         In line with NNPC transformation journey, KRPC is not only concerned about domestic situation but also to be a major global player. This will be achieved through technological updates and re-engineering. 

The structure in Fig. I show the Managing Director as the Chief Executive and under him are the two Executive Directors in-charge of Services and Operations Divisions. Within each division are various Departments, Sections and Units.

QUALITY POLICY


KRPC LIMITED is in the business of refining crude oil into high quality petroleum products and the manufacturing of petrochemical and packaging products to the satisfaction of her customers. In pursuance of this policy, our Management team shall lead the quality process and all our employees shall be committed to meeting and continually improving all aspects of our Quality Management System (QMS), our products and services.

PERSPECTIVE

REFINERY PROJECT DECISION

The decision to construct the third Nigerian National Petroleum Corporation (NNPC) refinery in Kaduna was taken in 1974 along with that of the second NNPC refinery located at Warri. However, it was decided that work would commence on the construction of the third refinery whenever the projection of the consumption of petroleum products justifies it.

By early 1975, in view of the fuel shortages experienced then, the Federal Government decided that work on the third refinery should be advanced. It was envisaged that the refinery was to be a simple hydro skimming type refinery in order to meet up with the fuel demand then. 

Based on the feasibility studies carried out, which took into consideration the consumption of the various petroleum products within the Northern Zone, and adequate means of disposal for the surplus products, a Refinery with crude oil capacity of 42,000 barrels per stream day (BPSD) could be easily justified. Hence, the refinery was designed for a capacity of 60,000 BPSD. It was much later that the Federal Government decided that the capacity for any refinery in Nigeria should not be below 100,000 BPSD. However, this would have led to the production of large quantity of heavy ends. And one practical and viable solution is reprocessing the heavy fuel oils. 

In order to do this, the whole project plans had to be modified so that what initially was planned to be simply a hydro skimming type refinery, developed into an integrated refinery. The refinery would now be able to produce a wider variety of petroleum products, some of which should be lubricating base oils. Hence, it became necessary to import suitable paraffinic based crude oil from Venezuela, Kuwait or Saudi Arabia.

Products from the Refinery include; Fuels for use as Liquefied Petroleum Gas (LPG), Premium Motor Spirit (PMS), Automotive Gas Oil (AGO) or Diesel oil, Kerosene, Fuel Oil, Sulphur and those from the lubricating oils complex are Base Oils, Asphalt (Bitumen) and Waxes.

The lubricating oil complex of Kaduna Refinery is the first of its kind in West Africa and one of the largest in Africa. The consulting firm, KING WILKINSON of Hague, Holland, in conjunction with NNPC engineers, developed the plan for the refinery. The contract for construction was awarded to CHIYODA CHEMICAL ENGINEERING & CONSTRUCTION COMPANY OF YOKOHAMA, Japan in 1977. 

The Refinery project was completed and the Fuels Plant was commissioned in 1980. However the Lubes Plant was commissioned in 1983 and Petrochemical Plant much later in 1988. The initial operation and maintenance was carried out by Nigerian Staff and expatriate personnel as technical back up. By 1985, Nigerian staff had virtually taken over all the maintenance and operations.

SITE LOCATION

From the results of an extensive market research carried out on the petroleum products demand pattern throughout the whole country, the northern zone showed an increasing demand pattern. Through research, it became apparent that it would cost less to transport the crude oil by pipeline than it would to transport the refined products to growing Northern markets by rail or road. This factor contributed greatly to the decision to construct the third refinery. Kaduna proved to be a central location for distributing petroleum products to depots in the northern zone, as the Warri and Port Harcourt refineries proved for the supply of petroleum products to depots in the southern and middle belt zones.

PLOT PLAN

Kaduna Refinery occupies an area of 2.89 Square Kilometers. The plot plan is designed with safety and ease of maintenance in mind. The design also attempts to minimize operating costs. While it is necessary to minimize pipe length to facilitate quick delivery of products from one process unit to another, it is nevertheless not advisable to transport highly viscous fluid over long distances. To achieve this, intermediate tanks are placed close to the various process units in the plot plan thus using minimum length of pipe, which, to a large extent reduce cost of piping.

OUR BUSINESS

KRPC LIMITED is in the business of refining crude oil into high quality petroleum products and the manufacturing of petrochemical and packaging products to the satisfaction of her customers

The refinery was designed to process both imported paraffinic and Nigerian crude oils into fuels and lubes products and was constructed by Chiyoda Chemical Engineering and Construction Company (now Chiyoda Corporation) of Japan. In December 1986, the design capacity of the fuels plants of the Refinery was successfully increased from 50,000 BPSD to 60,000 BPSD, bringing the total refinery installed capacity to 110,000 BPSD.

In March 1988, the 30,000 MT/Yr. Linear Alkyl Benzene Plant under the then PETROCHEMICAL Sector of NNPC was commissioned. The Plant is designed to derive its entire raw materials including utility supplies from the Refinery.

In 1988, it was decided that the two plants should merge into a single subsidiary company of NNPC in view of their interdependence, common goal and proximity. The company thus formed is the Kaduna Refining and Petrochemical Company Limited (KRPC).

OPERATIONS DIVISION

PROCESS PLANTS & OIL MOVEMENT UNITS

KRPC's operation is highly dependent on adequate supply of water and power for these utilities. Water is obtained from Kaduna River at the Raw Water Intake facilities located at about 13 kilometers from KRPC installations. The water is chemically treated to meet quality specifications for the various process units and steam generation.

FUELS PROCESS PLANT:               

The Fuels Plant of KRPC is designed to process Nigerian crude oils in the No.1 Crude Atmospheric and Vacuum distillation Units (CDU 1) while the rest of the Fuels section is designed to process a mixture of light and medium fractions from the domestic crude as well as from the imported crude oil used in the Lubes Plant. Products from the Fuels Plant are: Liquefied Petroleum Gases (LPG), Premium Motors Spirit (PMS), Dual Purpose Kerosene (DPK) for household and aviation usage, Gas Oils, Fuel Oils and Sulphur Flakes. 

LUBES PROCESS PLANT:

The Lubes Plant, consist of eight (8) units as shown in the diagram below has the capacity to process 50,000 BPSD of imported crude oil into Lube base oils, Asphalt and waxes. Sulphur is also produced from the off gases derived from the imported crude. The Lubes Plant is designed to process heavy crude oil from Kuwait, Venezuela (Lagomar), Saudi Arabia (Arabian Light Crude) or Russian (Urals).

The Arabian Light crude oil is currently being processed, the change over from the Lagomar crude, processed since plant inception, to Arabian Light crude was in October, 1988 to solve the bottom of the barrel problem.

THE LINEAR ALKYL BENZENE (LAB) PROCESS PLANT:

The Linear Alkyl Benzene process used in KRPC Petrochemical Plant is licensed from Universal Oil Products (UOP) of Des Plaines, Illinois, USA.

The plant has a capacity to produce 30,000 metric tons of Linear Alkyl Benzene a year, enabling Nigeria to substantially reduce import of this product for the local manufacture of detergents.

The plant comprises of five process units namely: Kerosene Hydrosulphurisation, Molex, Thermal Hydrodealkylation (THDA), Paraffin Conversion to Olefins (PACOL) and Detergent Alkylate units.

Commissioned in March 1989, the plant was designed to produce 30,000 metric tons/year of Linear Alkyl Benzene from Kerosene and Reformate feedstock from the Fuels plant


FINISHED PRODUCTS FROM THE REFINING & PETROCHEMICAL PLANTS

•             PREMIUM MOTOR SPIRIT (PMS)

•             KEROSINE (AVIATION AND DOMESTIC)

•             LIQUEFIED PETROLEUM GAS (LPG)

•             AUTOMOTIVE GAS OIL (AGO-DIESEL)

•             LOW POUR FUEL OIL (LPFO)

•             HIGH POUR FUEL OIL (HPFO)

•             LUBE BASE OILS

•             HYDRO-FINISHED WAX

•             ASPHALT

•             LINEAR ALKYL BENZENE

•             BENZENE

•             HEAVY ALKYLATE

•             KERO SOLVENT

•             NORMAL PARAFFINS

•             TOLUENE

•             AROMATIC SOLVENT

•             HEAVY PARAFFINS

·                         SULPHUR FLAKES


No

Product 

Production Rate 

PMS  3,857 MT/DAY 
2 KEROSENE  1,686 MT/DAY 
AGO [DIESEL]  3,000 MT/DAY 
ASPHALT  1,796 MT/DAY 
LAB  91 MT/DAY 
BASE OILS  657 MT/DAY 
LPG  620 MT/DAY 
FUEL  2,100 MT/DAY 
     

POWER PLANT & UTILTIES SUPPLY

The objectives of the Power Plant and Utilities Department are Provision of:

(a)          Electrical Power, steam of various pressures and temperatures, compressed air, nitrogen for smooth and continuous operation of the process plants and PPU.

(b)          Various grades of water including portable water and

(c)           Treatment of the Refinery and Petrochemical effluents to the statutory quality specifications.


The Plant has five (5) steam generating sets or boilers. Each boiler has a design capacity of 120 tons/hr. of steam. The installed capacity is 600 tons/hr. Design Pressure/Temperature is 46kg/cm at 412oC. There are four (4) 14MW/hr.  Steam Turbines with total capacity of 56mw/hr.


RAW WATER INTAKE FACILITIES

Raw Water Intake facilities are located beside Kaduna River, about 13 kilometers from the KRPC complex. The river water is pre-treated at the Intake before being pumped through a 13km water pipeline into two large storage tanks on site. Each of the raw water tanks has a storage capacity of 75,000 cubic meters. The stored water can meet the demands of the refinery and petrochemical complex for a period of 10days.


Contact/mailing Address:
(Please include division/department and designation you intend to contact e.g. The Managing Director, Manager Admin & Personnel etc.)

Kaduna Refining & Petrochemical Company Limited
KM 16 Kachia Road
P.M.B 2252
Kaduna.