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Sitra Refinery | Bapco Modernization Program Page 

Historical Development

The Sitra Refinery holds the distinction of being the first refinery constructed in the Arabian Gulf outside of Iran. Key historical milestones include:

• 1936: Original construction with 10,000 bpd capacity
• 1945: Opening of the Arabia-Bahrain (AB) pipeline for Saudi crude supply
• 1968: Major expansion increasing capacity to 250,000 bpd
• 1997: Full ownership transfer to the Government of Bahrain

The refinery has undergone continuous upgrades to maintain competitiveness:

• 2005: $1.1 billion modernization program initiation
• 2007: Ultra-low sulfur diesel complex development
• 2011: $430 million lube base oil plant inauguration
• 2013: $120 million wastewater treatment plant and $108 million steam turbo-generators installation

Processing Capacity and Configuration

Pre-BMP (BABCO Modernization Program) until end of 2025

Pipeline Upgrade (AB4 Pipeline)

• Total Length: 115 kilometers
• Initial Capacity: 350,000 bpd
• Design Capacity: 400,000 bpd
• Route: Abqaiq (Saudi Arabia) to Sitra Refinery
• Sections: 43 km onshore Saudi Arabia, 41 km subsea, 31 km onshore
• Bahrain Investment: $350 million
• Completion: 2018

Processing Units:

• Crude Processing: 267,000 barrels per day (bpd)
• Products: Approximately 260,000 bpd of refined products including 40,000 bpd of ultralow sulfur diesel

Conversion Units:

• No. 1 VGO Hydrocracking Unit: Processing vacuum gas oil
• Fluid Catalytic Cracking (FCC) Unit: Converting heavy fractions to lighter products
• Hydrodesulfurization Units: Sulfur removal from various product streams

Product Treatment and Utilities

• Sulfur Recovery Units: Processing H₂S to elemental sulfur
• Hydrogen Production Units: Supporting hydroprocessing operations
• Steam Generation and Power Systems: Integrated utility infrastructure

Bapco Modernization Programme (BMP) - Major Expansion by End of 2025

The Bapco Modernization Programme represents the largest capital investment in the refinery's 90-year history, with a total project value of approximately $6 billion. The expansion will increase processing capacity from 267,000 bpd to approximately 400,000 bpd by Q4 2025.

New Major Processing Units

• Residue Hydrocracking Unit (#1 RHCU): 
  • Technology: LC-Fining by Chevron Lummus Global (CLG)
  • Configuration: Two-train system
  • Capacity: 65,000 bpd vacuum residue processing
  • Plot Size: 260m x 260m (equivalent to 10 football pitches)
  • Global Significance: Among the largest LC-Fining units worldwide (fewer than a dozen exist globally)
  • Conversion Rate: 78% of vacuum residue feed converted to distillates
     
• New Crude and Vacuum Distillation Units (#7 CDU/ #7 VDU)
  • Integrated Capacity: 225,000 bpd crude processing
  • Crude Column: 160 feet tall, 34'9" diameter
  • Vacuum Column: 142 feet tall, 37'1" diameter at widest point
  • Heat Duty: 445 MM Btu/hour with 36 low NO_x burners
  • Desalting System: Two-stage desalters with two-drum overhead system
  • Replacement Scope: Replaces five existing distillation units (CDUs 1,2,3 and VDUs 1,3,5)
     
• Second VGO Hydrocracking Unit (#2 HCU)
  • Design: Single train, two-stage reaction system
  • Capacity: 58,000 bpd vacuum gas oil processing
  • Conversion: 99% of feed converted to middle distillates (kerosene and diesel)
  • Notable Features: Heaviest and tallest columns in the refinery
  • Heat Recovery: Advanced waste heat recovery scheme for energy efficiency
     
• New Sulfur Recovery Plant (#3 Sulfur Plant)
  • Configuration: 11 integrated process units
  • Length: 500 meters (one of the longest blocks at BMP site)
  • Additional Capacity: 750 tonnes/day sulfur recovery
  • Total Refinery Capacity: 1,535 MT/day total sulfur production (previously 1,100 MT/day)
  • Technology: Two-stage Claus process with 99.9% H₂S recovery efficiency
  • Product: Liquid sulfur converted to solid pellets for export
     
• Hydrogen Production and Recovery
  • Two Hydrogen Units: 125 MMSCFPD capacity each
  • Hydrogen Recovery Unit: Advanced recovery system for process optimization
  • Integration: Supporting all new hydroprocessing units

Storage and Terminal Enhancements:

• Sitra Tank Farm Upgrades:
  • Location: Sitra area covering over 1 million square meters
  • Integration: Elaborate network of transfer lines connecting to refinery
  • Capacity: Enhanced storage for increased throughput
     
• Sitra Wharf Improvements:
  • Berths: 6 total berths for refined products export
  • Shared Usage: Facility also utilized by Bapco Gas and GPIC
  • Marine Access: Direct connection to international shipping routes

Feed Supply and Processing Flexibility

Feedstock Sources Pre-BMP

Crude Oil Supply:

• Bahrain Field: ~17% (approximately 45,000 bpd)
• Saudi Arabia Pipeline: ~83% (approximately 220,000 bpd sweet Arab crude)
• Abu Safah Field: Shared production with Saudi Arabia

Post-Expansion Feed Strategy

Enhanced Feed Flexibility:

• Heavier Crude Processing: Capability to process heavier, more challenging crude grades
• Diversified Supply: Moving beyond exclusive reliance on sweet Arab crude
• Bottom-of-Barrel Optimization: Advanced residue conversion capabilities
• Feed Adaptability: Ability to adjust to changing crude availability and economics

Product Portfolio and Market Reach

Product Slate Pre-BMP

Major Refined Products:

• Liquefied Petroleum Gas (LPG): Domestic and export markets
• Naphtha: Petrochemical feedstock
• Jet Fuel/Kerosene: Aviation and industrial applications
• Ultra-Low Sulfur Diesel: 10 ppm sulfur content
• Gasoil: Marine and industrial applications
• High Sulfur Fuel Oil: Marine bunker and power generation
• Asphalt: Road construction applications
• Elemental Sulfur: Chemical industry feedstock

Post-BMP Product Enhancements

Yield Improvements:

• Ultra-Low Sulfur Diesel: 72% production increase
• Jet Fuel: 90% production increase
• Naphtha: Significant yield enhancement for petrochemical applications
• High-Value Distillates: Substantial increase in middle distillate production

Market Distribution

Export Profile:

• Export Percentage: 85-89% of total production exported
• Primary Markets: East Africa, Southeast Asia, Far East, India, and Middle East
• Crude Oil Marketing: 150,000 bpd Abu Safah crude on behalf of Government of Bahrain
• Monthly Fuel Oil Exports: 150,000-200,000 tonnes (expected to decrease post-BMP)

References

List of source material is available here.