NCRA Mcpherson Refinery Upgrade Project
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Summary Information

  • Ownership: NCRA
  • Website: http://www.ncrarefinery.com/
  • Wiki Page: NCRA Mcpherson Refinery
  • Location: McPherson, Kansas, USA
  • Capacity:
    • Before: 4.25 million tons/annum & 85,000 bbl/day
    • After: 5.00 million tons/annum & 100,000 bbl/day
  • Nelson Complexity:
  • Project Stage: Planning
  • Expected Completion: 2015
  • Budget:

The Project

  • Project Type: Expansion & Upgrade
  • Project Summary:
    • National Cooperative Refinery Association (NCRA) has proposed a “Heavy Crude Expansion Project (HCEP)” and a “Benzene Reduction Project (BRP)”
    • The HCEP will enable NCRA to feed approximately 50% heavy, sour Canadian crude
    • The refinery’s capacity will also be expanded from approximately 87,000 to 100,000 barrels per day.
  • Main Contractors
    • Technip: Hydrogen Unit

Refining Units

  • Proposed refinery modifications associated with these two projects include the installation of a new Delayed Coker Unit designed to convert asphalt into refined products and petroleum coke, a petroleum coke crusher, a crushed coke conveying system and associated railcar/truck load-out facility, a steam reforming hydrogen unit (#2 Hydrogen Unit) to supply hydrogen for hydrotreating refined products, a new amine regeneration unit, a third Claus sulfur recovery unit (#3 Sulfur Recovery Unit) to recover the additional sulfur from processing sour Canadian crude oil, 12 new tanks, and two new flares (Main Plant Flares A and B) to serve multiple refinery units.
  • The BRP will involve the construction of a new distillation tower and associated support equipment, and will include replacing a vertical feed heat exchanger in the platformer with a larger heat exchanger.
  • Changes will be made within the No. 2 Crude Unit, Vacuum Unit, Distillate Hydrotreater Unit, Naptha Hydrotreater Unit, HF Alky Unit, Platformer Unit, No. 2 Sour Water Stripper, ATS Units, and tank farm.
  • The two process heaters and some of the equipment from the existing delayed coker unit will be used to provide additional capabilities for processing high sulfur crude and increasing throughput in the No. 2 Crude Unit.
  • Other parts of the exisiting delayed coker unit will be permanently removed from service, including its three drums, the drum vapor blowdown system, and the three existing Internal Combustion (IC) engine driven compressors.
  • The main plant flare and seven or eight tanks will be permanently removed from service.
  • In the Fluid Catalytic Cracking (FCC) Unit, five IC driven compressors will be shut down and replaced with one or more electric motor-driven compressors.
  • Other changes will be made throughout the refinery to accommodate the new and modified equipment.

Terminal Capacity

  • Crude Oil:
  • Refined Products:

Crude Supply

  • The HCEP will enable NCRA to feed approximately 50% heavy, sour Canadian crude

Products Produced

  • Production of Coke, Diesel and Clean Gasoline will be increased

History

  • 2008 - The EPA awarded an emission permit
  • 2013 - Technip awarded hydrogen plant contract

Other Information

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Relevant Links

  1. AIR EMISSION SOURCE CONSTRUCTION PERMIT
  2. Technip awarded contract by NCRA for a hydrogen plant in Kansas (USA)

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