Modular Facility Design & Phased Capacity Growth
The plant is built around modular processing trains, each originally sized for 30,000 barrels per day, with site infrastructure designed for an ultimate four-train, 120,000 barrel-per-day buildout. ZAP subsequently executed a capacity uprate and Phase 2 addition that raised per-train and total throughput, with several systems verified to as much as 172,000 barrels per day. Key equipment includes inlet surge vessels, inlet heaters, low-fouling heat exchangers, three-phase separators, a stabilizer tower, reciprocating overhead compressors, natural gas liquids bullets and pipeline pumps, and a packaged product cooling system — all supported by full balance-of-plant utilities and a manned control room.
High-Paraffin Crude & Wax Management
The defining technical challenge was the high-paraffin crude, containing up to 10 percent wax. This drove excess thermal surface area on oil-service exchangers, regenerable and switchable cooling arrangements to melt and flush deposited paraffin, and carefully controlled minimum wall and film temperatures throughout. ZAP also engineered for a wide inlet temperature range, large slug and flare loads, and cold-weather operability.
Process Safety & Regulatory Compliance
As a process-safety-managed facility, the project required layer-of-protection analysis, safety requirement specifications, and siting review. ZAP’s integrated approach ensured all safety and regulatory requirements were addressed across every phase of the design — delivering a facility built for reliable long-term performance.
