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KIPIC Al-Zour Oil Refinery Project
Client
Kuwait Integrated Petroleum Industries Company (KIPIC)
Location
Al-Zour, Kuwait

The Al-Zour Refinery is located in Al-Zour, approximately 90 kilometers south of Kuwait City, adjacent to the existing Al-Zour South Power Plant. When completed, the new complex is expected to be one of the largest refineries in the world, producing 615,000 barrels per day (BPD).

Transportation of COOEC-Fluor Mods
Client's Challenge

KIPIC is a subsidiary of Kuwait Petroleum Corporation set up by the State of Kuwait to manage refinery, petrochemicals and LNG import operations in the Al-Zour complex. KIPIC is constructing a new world-class grass roots refinery in Kuwait to produce low sulfur fuel oil to replace high sulfur fuel oil used in local power plants.

This large-scale refinery is designed to process 615,000 BPD of light Kuwait crude oil or 535,000 BPD of heavy mix Kuwait crude oil.

This refinery uses the latest technology to comply with stringent environmental regulations to protect the local environment, and at the same time produces the latest environmentally friendly ultra-low sulfur diesel fuels for worldwide markets as well as jet fuel, kerosene and naphtha feedstock for petrochemical plants.

The Al-Zour Refinery will use a combination of conventional and proprietary licensed hydro processing technologies to convert the light and heavy crudes into low sulfur fuel oil (LSFO) and lighter products.

Transportation of COOEC-Fluor Mods
COOEC-Fluor's Solution

The project has employed a strategy of large-scale off-site pipe fabrication and pre-assembled rack and pre-assembled unit (PAR + PAU) modular execution. Module fabrication took place at the COOEC-Fluor Heavy Industries Co., Ltd. (COOEC-Fluor) fabrication yard in Zhuhai, China.

COOEC-Fluor delivered 188 modules in 20 separate shipments with a combined weight of 65,000 metric tons. In addition, the yard fabricated more than 95,000 pipe spools of carbon, alloy and stainless steel pipe.

The COOEC-Fluor yard completed the modular program over a period of 24 months from the start of steel fabrication to load out of the last modules. A relentless focus on health, safety and environmental performance achieved a total case incident rate of 0.06 and a lost-time injury rate of 0.02.

The final module shipment of 8,600 metric tons arrived in December 2019 at the project site in Kuwait.

Setting of COOEC-Fluor Mods
Conclusion

The Al-Zour Refinery is being built on a greenfield site located south of Kuwait City and will be one of the largest refineries in the world upon completion.