Fadhili

Fadhili Gas Plant (FGP) represents a significant increase in the company's gas processing capacity.

The program reflects Saudi Aramco's commitment to increase supplies of cleaner burning natural gas, reduce emissions, and free up more crude oil for value-added refining and export. It is also an enabler for the Kingdom's vision to reduce domestic dependency on oil burning to generate power, by increasing its production of sales gas to 12.2 billion scfd this year.

Fadhili is the first plant to treat nonassociated gas from both onshore and offshore fields, and Fadhili is the first Saudi Aramco plant designed from the start to use Tail Gas Treatment, allowing it to achieve a sulfur recovery of more than 99.9%.”

The Fadhili Gas Plant reached its design gas processing capacity of 2.5 bscfd after successfully completing its commissioning activities and as part of the company's Master Gas System (MGS) will help to meet the Kingdom's growing demand for energy.

One of the key enablers for success of the Fadhili project was the implementation of the Capital Management System (CMS).

This has enabled the project team to increase capital efficiency, and as a result of benchmarking of Fadhili against peers in the industry, Fadhili project is delivered at lower costs.

The program scored more than 210 million safe hours. This safety success was achieved by implementing a stringent safety program with more than 25,000 workers at the peak of construction,” FGP Projects manager Hisham U. Al Derhalli said.

Massive procurement efforts were made throughout the program, contributing to the local economy of the Kingdom by placing 46% of the purchase orders with local vendors.

With its five gas treatment trains, Fadhili is one of the first gas plants designed to process two different types of gas from two different fields — Hasbah Offshore and Khursaniyah Onshore.

While both the Hasbah and Khursaniyah fields produce nonassociated gas, the gas from Khursaniyah is of a lower energy content than the gas from Hasbah. So, while the 2 billion scfd of gas from Hasbah will be processed to supply sales gas to the MGS, the lower energy gas from Khursaniyah will be sent to an adjacent combined heat and power (CHP) plant at Fadhili, co-owned by Saudi Aramco, Saudi Electricity Company, and Engie. The CHP plant has a capacity of 1.5 gigawatts (gWs) partially for company use, with the remainder supplied to the national power grid.

With six sulfur recovery trains, Fadhili is the first Saudi Aramco gas plant designed to achieve a minimum of 99.9% sulfur recovery, protecting air quality from emissions.

Reducing CO₂ emissions and energy consumption 

In another first, a unique technology has been deployed in Fadhili utilizing turbochargers to reduce energy consumption by 55 gWs per year.

This is not only the first installation in Saudi Aramco, but also the first in the oil and gas industry worldwide.

A turbocharger utilizes the high pressure of the incoming gas stream and converts it to mechanical energy that drives our circulation pumps. This results in a significant reduction in our facility's energy requirements, reducing our carbon footprint and availing power to other users in the Kingdom.

These turbocharged pumps also offer significant environmental benefits, reducing CO₂ emissions by 60 tons per year.

Apply Safety standards 

Fadhili project planners were also careful to make sure that the most stringent safety standards were applied through all phases of the project. Project safety officials conducted three major safety initiatives to guide and monitor safe work practices at the worksite. That attention to detail paid major dividends.