The first two project phases focused on gasoline production in accordance with CAA standards. During Phase I, a continuous catalytic reformer (CCR) unit was designed and installed by revamping the existing CCR. This major modification, performed on a fast-track schedule, increased throughput by approximately 38%.
Phase II required Fluor to provide front-end process design for a naphtha prefractionator. This unit is a major component in meeting the overall benzene targets outlined in CAA and CARB requirements. Functioning in conjunction with the naphtha prefractionator, a new penex unit was designed. Through state-of-the-art techniques, Fluor enabled the refinery to reuse and reposition a large number of the existing reformer equipment into the new penex unit, resulting in significant cost savings to Chevron.
Additionally, a new tert-amyl methyl ether (TAME) unit was added to provide a reduction in the overall gasoline pool Reid vapor pressure and to furnish some of the oxygenates needed to meet federal and state reformulated gasoline requirements. Existing equipment was reused in this new unit at substantial cost savings.
Phase III included the redesign of the existing Chevron facility to comply with the CARB reformulated fuels specifications. To do this, the naphtha hydrotreater units were debottlenecked and modified to increase their olefin saturation capacity, reduce gasoline sulfur content and produce suitable quality feed for the new CCR unit. The capacity of one of these units was increased by approximately 50%. A new alkylation unit, together with a new C4 selective hydrogenation unit, was also added to replace the existing equipment.