Conoco-Phillips Refinery Rodeo
Conoco-Phillips proposed a 30% expansion of their San Francisco refinery located in Rodeo, California. The objective of the project was to produce cleaner fuels from current by-products, avoiding the necessity to import additional crude oil to the refinery. The proposed expansion would include facilities to process heavy gas oil, a hydrogen plant with a capacity of 120 million cubic feet per day, a hydrocracker with capacity of 23,000 barrels per day, a sulfur recovery unit of 200 tons per day, and a butane rail loading facility. The proposed $600 million additions would upgrade the refinery’s capacity to 1 million gallons per day.
Group Delta Consultants reviewed the existing geotechnical report and identified the potential for significant savings in grading and unsuitable soil disposal costs in the Sulfur Area where the existing geotechnical report recommended removal of 10 to 15 ft of existing fill. GDC took over as geotechnical engineer of record on the project and performed a design level geotechnical investigation and submitted reports for the Unicracker Facility Makeup Gas Compressor, REI Pad Area, Sulfur Area, Hydrogen Plant, Warehouse Area, Switchyard Area, Plant Access Road, and the MTC 23 Butane Loading Area. GDC also provided onsite geotechnical inspection during construction.
The use of surcharge in lieu of removal and disposal of more than 32,000 cubic yards of unsuitable soils saved the project up to 20 million dollars in disposal cost of the soils. The existing fill was consolidated in place by a surcharge of 7 ft. The surcharge was successfully completed within 60 days and the project units were successfully constructed.