Case Study Heavy Crude Upgrading Middle East

Metals Extraction Facility—PDVSA, Amuay Venezuela

GSAe undertook the CEP and BEP phases for a new plant to extract vanadium and nickel from
flexicoke.

This is an environmental solution for PDVSA to extract what is becoming an increasingly strategic metal, and based on the following considerations:

• • Vanadium and Nickel are the major metals in crudes.

• • They are transition metals, classed as heavy metals, and pose inhalation hazards.

• • Nickel salts are classified as class A carcinogenic to humans. (UK HPA)

Project Details:

• • Amuay Refinery - 630kbpd heavy crude

• • Generating 38,000 tonnes per year flexicoker residues (largest flexicoker unit Worldwide)

Production:

• • 4,500 tonnes per year vanadium pentoxide

• • 450 tonnes per year nickel

Strong business case:

• • CapEx $87m (class II est.)

• • Revenues $60m per year

• • Very tight environmental controls into Amuay Bay

In completing the work we undertook:

• • Pilot and commercial plant trials at our plant in Harwich, UK

• • Successfully completed the Conceptual and Basic Engineering Design Packages -

25,000 man-hours over 18 months

• • Worked with PDVSA to develop an implementation strategy

Commercially viable, environmentally