Project Profile

Value: US$27-28-billion
Location: Pengerang, Johor, Malaysia
Refinery capacity: 300,000 bbl/day
Plant capacity: 250,000 metric tons of hydrogen peroxide, 220,000 metric tons of isononanol and 110,000 metric tons of 1-butene annually.
Start-up year: 2019

Located at Pengerang of Johor, RAPID or Refinery and Petrochemical Integrated Development, the project is aimed at building something larger than Kertih refinery and will eventually include multinational oil and gas companies as joint-venture partners. The proposed refinery will have a capacity of 300,000 barrels per standard day and will supply naphtha and liquid petroleum gas feedstock for the RAPID petrochemical complex, as well as produce gasoline and diesel that meet European specifications. There will be a new LNG receiving and re-gasification terminal within the RAPID facility to support the development of RAPID. RAPID is a project identified in the Economic Transformation Programme (ETP), which is led by the Performance Management & Delivery Unit (Pemandu). Rapid project complements plans for the independent deepwater petroleum terminal in Pengerang, which is to be the first deepwater terminal in South-East Asia.

PETRonAS and Evonik Industries AG signed a Letter of Intent (LOI) to jointly embark on the development of production facilities of specialty chemicals within PETRONAS’ Refinery & Petrochemical Integrated Development (RAPID) project in Pengerang, southeastern tip of Johor, south of Desaru in Malaysia. Under the LOI, the two parties will endeavour to form a partnership to jointly own, develop, construct and operate facilities for the production of hydrogen peroxide, C4 co-monomer and oxo-products within RAPID.

The plants are expected to have the capacity to produce 250,000 metric tons of hydrogen peroxide, 220,000 metric tons of isononanol and 110,000 metric tons of 1-butene annually. The hydrogen peroxide will be used on site to produce propylene oxide by the licensed, eco-friendly HPPO process Evonik had jointly developed with ThyssenKrupp Uhde. These projects are expected to come on stream in 2016. The oxo-alcohol INA is a precursor of the plasticizer DINP (diisononyl phthalate), which is used in soft PVC production. 1-butene is used as a co-monomer for production of the plastic polyethylene. Hydrogen peroxide is used as a bleaching agent in the paper and textile industries and for eco-friendly oxidation and disinfection.


Operator:

Petronas: Jointly operated with 40% interest

BASF: Jointly operated with 60% interest

Saudi Aramco: 50% share in \"selected ventures and assets\" of RAPID project
(This comprises a 300,000 bpd refinery, a 3 million-tonne-per-year steam cracker and derivatives units producing around 3.5 million tpy of products including ethylene, propylene and C4-6 olefins.)


Contractors:


CB&I (Lummus Technology): License and engineering design work for five petrochemicals units

Evonik: Production of 250,000 t/y of Hydrogen peroxide

INEOS Technologies (INEOS): EPC contract for the LL/HDPE portion

Itochu: Technology provider

Jacobs Engineering Group: Basic engineering package for sulfur recovery

Jacobs Leiden: Three sulfur recovery units

PTT Global Chemical

Technip: FEED contract

Versalis: Production of synthetic rubber

Zelan Construction Sdn. Bhd. (a subsidiary of Zelan Bhd.): Contract for the basic design, detail engineering, procurement, construction, and commissioning (EPCC) of the material offloading facilities (MOLF) jetty for Petronas’ planned refinery and petrochemical integrated development (RAPID) complex at Pengerang

BMT Asia-Pacific Pte. Ltd. (subsidiary of BMT Group Ltd): MOLF’s concept design

Sinopec Engineering: (EPCC) for RAPID

Technip with Fluor: Engineering, procurement and construction management contract by PRPC Utilities and Facilities Sdn. Bhd. for the RAPID project. Under this contract, the Fluor and Technip joint venture will be responsible for the utilities, interconnecting and offsites (UIO) scope of work. Technip’s operating centre in Kuala Lumpur, Malaysia, will execute the contract.

CTCI Corp: Contract for the residue fluid catalytic cracking units, LPG treating unit, propylene recovery unit, and caustic neutralization units.

Sinopec Engineering Group: Contract for the crude distillation unit, atmospheric residue desulfurization units, and hydrogen collection and distribution units.

Tecnicas Reunidas SA: Contract for the kerosene hydrotreating unit, diesel hydrotreating unit, naphtha hydrotreating unit, cracked-naphtha hydrotreating unit, and continuous catalytic reformer units.

Petrofac International (UAE) LLC and Petrofac E&C Sdn. Bhd.: Contract for the amine recovery units, sulfur recovery units, sour water stripping units, liquid sulfur storage unit, and sulfur solidification units.

Toyo Engineering Corp. and Toyo Engineering & Construction Sdn. Bhd.: Contract for the steam cracker complex.

UEM Builders Bhd. and Projek Penyelenggaraan Lebuhraya Bhd.: Contract for EPCC of temporary common-camp installations and infrastructure.

Zelan Construction Sdn. Bhd.: Contract for the basic design and EPCC of the material offloading facilities jetty at Tanjung Setapa

WCT Bhd.: Contract for common construction access and permanent roads within the project site.

Syarikat Ismail Ibrahim Sdn. Bhd.: Contract  for the temporary access road within the project site.

Bumi Dagang Sdn. Bhd.: Contract for construction of the main haulage road as well as an access road outside the project site.

Gadang Engineering (M) Sdn. Bhd. and Menta Construction Sdn. Bhd.: Contract for the Phase 2 site preparation works.

Yokogawa Kontrol (Malaysia) Sdn. Bhd.: Front End Engineering and Design (FEED) as the Main Automation Contractor (MAC) for RAPID. Yokogawa will supply the CENTUM® VP production control system and the ProSafeR-RS safety instrumented system for RAPID, as well as advanced process control and plant information management systems which will ensure high productivity and safety at the complex.

Punj Lloyd Group: US$581 million RAPID Tank Farm order. Punj Lloyd’s scope of work in the RAPID Tank Farm project includes Project Management, Design, Engineering, Interface with other Contractors and third parties, Procurement, Construction, Inspection and Testing, Pre-Commissioning and Commissioning. The RAPID Tank Farm will be a critical project requiring expertise in the construction of different types of tanks including storage tanks, LPG tanks, mounded bullets, Light Cracked Naphtha storage, transfer pumps and additive packages.

Axens: Technology provider for PETRONAS’ Refinery and Petrochemicals Integrated Development (RAPID) project located in Pengerang. Axens was initially selected in October 2010 for a Detailed Feasibility Study, after which their technologies were selected following an open bid in January 2012. The following technologies from Axens was selected for the RAPID project:
- Naphtha Hydrotreating (NHT), this process purifies naphtha removing dienes, olefins compounds, sulfur and nitrogen species with a feed capacity of 21,000 BPSD;
- OctanizingTM a continuous catalytic regenerative (CCR) reforming process for maximizing the production of reformate from heavy hydrotreated naphtha , with a feed capacity of this unit 14,000 BPSD;
- Prime-KTMa catalytic process achieving hydrotreatment of a kerosene cut, with smoke point improvement and deep desulfurization, its feed capacity is 30,000 BPSD;

Linde Malaysia Sdn. Bhd: Build a grassroots air gas plant of two large air-separation units (ASU) and associated gas installations. (September, 2016)
- air-separation technology

Petronas Gas Bhd: Build a grassroots air gas plant of two large air-separation units (ASU) and associated gas installations. (September, 2016)

General Electric International Inc: Provision of a mix of equipment designed to enable uninterrupted power supplies to RAPID in the event of unexpected electrical outages at the site. (September, 2016)
- 17 emergency diesel generator (EDG) packages, five transportable switch rooms, as well as the electrical balance of the plant.


Sub-contractors:


Technip: Contract by Tecnicas Reunidas to supply three hydrogen reformers as part of the hydrogen production facility at RAPID project. The reformers will produce 344,500 Nm3/h of hydrogen and syngas products. It will supply high quality export steam to the refinery steam network. The supply of the reformers is based on Technip’s proprietary top-fired steam methane reforming technology. The reformers are expected to come on-stream in 2018. Prior to the supply of the hydrogen reformers, Technip was involved in the front-end engineering design for the RAPID project. The reformer project will be executed by Technip’s office in Zoetermeer, the Netherlands. (October 2015)