The project includes the construction of a new full-conversion refinery complex to process 400,000 barrels of oil per day. It will be realised in Yanbu Industrial City located on the west coast of Saudi Arabia along the Red Sea.
thyssenkrupp was commissioned with the delivery by the general contractor Techint Engineering & Construction, through its regional Italian headquarters, at the end of 2011. The general scope of supply includes the following: transportation of petroleum coke from the delayed coker unit to the storage, sulfur stocking to the storage, and loading of petroleum coke and pelletized sulfur into ships at the port.
The detailed scope of supply comprises a conveyor system consisting of 12 conveyors and seven transfer towers (with a total conveying length of more than 7 km), two traveling stackers, two portal reclaimers, one circular storage system and two shiploaders. Three of the 12 conveyors are designed as curved conveyors, with conveyor lengths between 710 and 1,740 meters and a curve radius of only 500 meters. Its long-standing experience in the design of curved conveyors and its ability to realize this challenging radius were decisive reasons for the contract award to thyssenkrupp Industrial Solutions.
The handling capacity of the conveyors and stockyard machines varies between 800 t/h and 2,000 t/h; the two shiploaders have a capacity of 2,000 t/h. As parts of the handling system are designed to transport sulfur as well as petcoke, special attention was paid to the varying material properties. Consequently, the shiploaders are equipped with three automatic belt cleaning devices to avoid pollution, spillage and mixing of both materials. Furthermore, all hazardous areas are equipped with explosion-proof components to prevent combustion.
The design engineering scope has been executed in close cooperation with the USA division of thyssenkrupp Industrial Solutions in Denver, which has been responsible for the complete electrical and instrumentation portion based on NEMA standards (NEMA, National Electrical Manufacturers Association). The project required that 3D models of virtually every part of the plant be developed during the engineering phase. These 3D models made it possible to demonstrate to the client the various functions and special features of the single system units already in the design phase.
Manufacturing of the structural steel components for the belt conveyors and the machines took place in Saudi Arabia as well as in the neighboring countries of Qatar and Dubai under the supervision of thyssenkrupp’s personnel. In total, more than 7,500 tons of steel have been fabricated in the Arab region. Mechanical components were predominantly supplied from Germany, while electrical components including motors, switchgear or control units were supplied from the USA.
This prestigious and challenging contract represents another cornerstone in thyssenkrupp’s already extensive track record in the supply of complete materials handling systems. Moreover, it demonstrates the companies’ continued technological excellence. Following the successful realization of numerous projects in the Arab region during the past years, the Yanbu contract additionally underscores the growing presence of thyssenkrupp Industrial Solutions in one of the Middle East´s most dynamic economies with enormous market potential.