Manama, Dec. 18 (BNA): The Bapco Modernisation Project (BMP) is set to become one of the largest energy initiatives in the history of the Kingdom of Bahrain. Representing the most significant capital investment in Bapco Refining’s 90-year history, this multi-billion-dollar project aligns the company with the evolving energy landscape and aims to ensure its long-term sustainability in line with Bahrain’s Vision 2030.

Objectives of the BMP

The BMP is designed to increase refining capacity, enhance the product slate, improve energy efficiency, and ensure environmental compliance. The refinery’s crude capacity will rise by 42%, reaching 400,000 barrels per day, while the Resid Hydrocracking Unit (RHCU) will convert 78% of lower-grade feedstock into high-value distillates, such as diesel and kerosene. Additionally, the project will improve the Energy Efficiency Index (EII) through the introduction of new, efficient units and the decommissioning of older facilities.

Success for the BMP is defined by an incident and injury-free project, while meeting standard project metrics for cost and schedule management. Additionally, success will be measured upon the smooth startup and reliability of the integrated BMP facilities until the first major Turnaround and Inspection (T&I) event.

Resid Hydrocracking Unit

One of the cornerstone components of the BMP is the Resid Hydrocracking Unit, which will have a capacity of 65,000 barrels per day and be among the largest of its kind globally. Powered by Chevron Lummus Global technology, the unit will convert 78% of vacuum resid feed into intermediate products that will be further refined into high-margin kerosene and diesel. Spanning an area equivalent to 10 football pitches, the RHCU underscores the scale and ambition of the BMP.

New Crude and Vacuum Units (7CDU/7VDU)

The project also includes a new Crude Distillation Unit (7CDU) and Vacuum Distillation Unit (7VDU), which will replace older units that have been operational for over 80 years. These state-of-the-art facilities will process 225,000 barrels per day, maximising output with minimal energy consumption. Equipped with advanced features such as two-stage desalters, a two-drum overhead system, and the refinery’s largest energy-efficient heater, the new units will contribute significantly to optimising yield performance and increasing production capacity. The crude column will stand at 160 feet tall, while the vacuum column will reach 142 feet, with both designed to maximise product yields while minimising energy use.

Second Hydrocracker Unit (2HCU)

Another critical component is the second Hydrocracker Unit (2HCU), which will process 58,000 barrels of Vacuum Gasoil per day. Using Chevron Lummus Global technology, this single-train unit features a two-stage reaction process and an intensive waste heat recovery scheme, enhancing energy efficiency. Together with the RHCU, the 2HCU will play a pivotal role in increasing refinery profitability by converting low-value feedstock into higher-margin final products, including kerosene, naphtha, and diesel.

Sulphur Plant

The #3 Sulphur Plant is also a vital addition to the BMP, consisting of 11 integrated process units that recover hydrogen sulphide from the refinery’s processes and convert it into liquid sulphur. This liquid sulphur is then solidified and exported. The plant, strategically located adjacent to the existing Low Sulphur Diesel Production Complex, will increase sulphur production capacity by 600 metric tonnes per day, bringing the total to 1,100 metric tonnes per day. Using advanced technology, the plant ensures 99.9% recovery of hydrogen sulphide while maintaining environmental compliance.

Environmental and Social Commitments

Environmental considerations have been central to the BMP, with more than 50 environmental and social studies conducted to ensure compliance with local regulations and international standards. The project will achieve a 50% reduction in sulphur dioxide emissions, a 5% reduction in nitrogen oxide emissions, and a 9% reduction in treated wastewater discharge.

Facts and Figures

Spanning approximately 2 million square metres, the existing refinery includes extensive processing facilities and a tank farm in Sitra covering over 1 million square metres. The two tank farms are interconnected by a complex network of transfer lines, and refined products are exported through the Sitra Wharf, which has six berths and also serves Bapco Gas and GPIC.

Transforming Bahrain’s Energy Sector

At its peak, the BMP has involved more than 20,000 contractors and represents a transformative step for Bapco Refining. By enabling higher throughput, improving product quality, and ensuring compliance with environmental standards, the BMP aligns with Bahrain’s Vision 2030 and strengthens the company’s competitiveness in the global energy market.

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