Esmeraldas Refinery’s Production Capacity Faces Substantial Reduction

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Researched by Industrial Info Resources (Sugar Land, Texas). The Esmeraldas refinery, owned by the state owned company Petroecuador, is facing major problems due to the catalytic reforming fire which occurred on May 3. The plant is currently processing 30% of its normal 110,000 barrels per day capacity since only six out of the total thirteen existing units are running.

Ecuador is the fifth largest oil producer in South America with a 532,000 barrels of oil per day (b/d) production capacity. Petroecuador owns three refineries: 43,000 b/d La Libertad; 110,000 b/d Shushufindi; and 110,000 b/d Esmeraldas Refinery. The latter processes 65% of Ecuador’s fuel production, 40% of which is used for internal consumption. Problems at this refinery started on February 15, 2007 when the regenerator’s combustor stopped working. After this unexpected shutdown, Petroecuador had to call for emergency bidding. This unit is to remain under maintenance work until June 2007. For details, view related April 18, 2007 news article – Ecuador’s Esmeraldas Refinery Faces Three Month Emergency Shutdown.

Problems during catalytic reforming have already been identified and are estimated to cost $500,000. Petroecuador is to replace sixteen furnace tubes and all the instrumentation and wiring of the unit; moreover, the unit startup is expected to take place during the first week of July 2007. Maintenance work in Crude 1 and Vacuum 1, previously planned to take place in September 2007, started on May 7 2007, when a furnace tube broke down. Total investment for this latter turnaround was estimated at $350,000. Due to these unplanned and rescheduled turnarounds, Visbreaking units 1 and 2 are currently running at 70%; HDS, HDT diesel, HDT Naphtha, SRU 1 and 2 and Nitrogen units are shutdown. Furnace tube problems in Crude 1 are being reflected by its low 80% production.

The Esmeraldas Refinery’s production capacity will be back to normal rates once maintenance work on Crude 1, Vacuum 1, FCCU and CCR is finished and once Petroecuador installs a decoking machine in Crude 1 to tackle the problems arising from coke accumulation in its furnace tubes.

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