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YASREF is applying state-of-the-art technology and Best Available Techniques (BAT) in order to protect the environment and meet the most stringent local and international environmental regulations and requirements. As an example, the Flare Management Plan (FMP) has been developed in order to meet standards of the Saudi Presidency of Meteorology & Environment, Royal Commission (RC) Environmental Regulations, the Kingdom of Saudi Arabia and YASREFs own Flaring, Health, Safety and Environmental Policies.

Concerning emissions, YASREF has taken the initiative to install a fully integrated Carbon Adsorption/Absorption Hydrocarbon Vapor Recovery Unit (VRU) to recover and recycle the volatile organic compounds (VOC) that are generated by loading operations at YASREF loading facilities. The VRU is capable of meeting the most stringent worldwide emission standards with efficiency of 99.5 % of VOC recovery.

In order to ensure quality work from the contractors, a relentless inspection process was undertaken to inspect work on an ongoing basis. In addition, an aggressive Operation training program was undertaken led by top management to ensure young and inexperienced Saudi operators would be prepared to operate the plant from day one. While peak total workers on site numbered 40,000 during construction, these were supplemented by 700 young Saudi apprentices in key Operations and Maintenance roles. These young men represent the future of the company as it is expected the majority will serve as long term employees for many years to come.

The Refinery has been configured with the following major units and technologies to assure high-quality products:

• 400k bpd Crude Distillation Unit
• 124k bpd Chevron Lummis Global Hydrocracker
• 177k bpd UOP Diesel Hydrotreater
• 85k bpd UOP Naphtha Hydrotreater
• 84k bpd UOP Continuous Catalytic Reformer
• 20k bpd UOP Isomerization Unit
• 20k bpd Benzene Extraction Unit
• 117k bpd ConocoPhillips Delayed Coker Unit
• 262 mcf per day Hydrogen Unit
• 3.4k tons per day Sulfur Recovery unit

This allows YASREF to produce 263k bpd ultra-low sulfur diesel, 90k bpd low sulfur gasoline, 6.2k tons per day of Petroleum Coke, 1.2k tons per day of Pelletized Sulfur and 140k tons per year of benzene.

YASREF’s Delayed Coker Unit is one of just two in the region and the by far the largest. An expansion project to allow the facility to produce a high-grade coke used by the aluminum industry is currently being evaluated. This potential project would allow for the expansion of the region’s manufacturing capability, including the production of automobiles and light-duty trucks.

The use of Best Available Techniques to safeguard the air, water and fishery has been the cornerstone of the YASREF project. The project used BATs in the construction or the use of the following:

• Waste Water Treatment Unit
  • Two Parallel-Operated API-Type Gravity oil-water separators
  • Induced Gas Floatation Unit
  • Thermal Oxidizer
• On Line Analyzers for Waster Water
• Waste Water Composite Sampler
• Waste Water Diversion Basin
• Stormwater Basin
• Tankfarm infrastructure
• Ultra Low NOx Burners for Heaters/Combustion sources
• Continuous Emission Monitoring System
• Stacks and Flare systems (high combustion sources allow for better dispersion)
• Flare Gas Recovery Unit
• Reinforced Slab on Delayed Coker Unit
• Vapor Recovery System for loading facilities
• Sulfur Recovery Unit