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KRPC At a Glance

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).

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.