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Modular processing solutions · KHU Modular Upgrader

Built in America. Deployed where the oil is.

Processing capacity is tailored to each project and delivered as transportable modules, so upgrading can sit close to production, even in remote regions where conventional infrastructure is costly or impractical.

Discuss a modular project See the deployment sequence
Built
Manufactured, assembled and tested in the USA
Capacity
Tailored to the project, train by train
Shipped
Road · sea · barge
Installed
At or near the field, including remote sites
Fig. 1 — Phased trains · planSchematic
Plan view of a site pad: two installed process trains, each made of two modules bolted end to end (Module 01 Conditioning and Module 02 Conversion), and space for a third train in future. The trains tie into a common pipe rack that carries heavy crude in and upgraded blend out to a blend tank. N SITE PAD · PREPARED IN PARALLEL MODULE 01MODULE 02 TRAIN 1 · PHASE 1 MODULE 01MODULE 02 TRAIN 2 · PHASE 1 MODULE 01MODULE 02 TRAIN 3 · FUTURE ↓ FEED IN SITE CONTROL · UTILITIES BLEND TANK BLEND OUT → 1 2 3
  1. 1 Train · M01 + M02
  2. 2 Common pipe rack
  3. 3 Blend tank
Each train is Module 01 Conditioning plus Module 02 Conversion. Capacity is tailored to each project, and further trains can be added as production grows. Not to scale.
01Deployment sequenceDetail B · Fig. 2

From a US shop floor to a remote pad.

Modules are manufactured, assembled and tested in the United States before they are transported to the production location and installed. Most of the work happens under controlled conditions, so less of it happens in the field.

Fig. 2 — Deployment sequence · manufacture → installUse the stage timeline
Representative sequence for one train, Module 01 Conditioning and Module 02 Conversion, not to scale. Step through the stages or scrub the timeline. Drag to rotate.
  1. 01

    Manufacture

    Structural skids, vessels and pipe spools built in a US fabrication shop.

  2. 02

    Assemble

    Equipment, piping, instruments and controls integrated on each skid.

  3. 03

    Test

    Factory acceptance testing before any module leaves the shop.

  4. 04

    Transport

    Shipped within a transportable envelope by road, sea or barge.

  5. 05

    Install

    Set on a prepared pad, connected and commissioned at the field.

02The module, exploredDetail C · Fig. 3

Two modules. One complete process train.

A KHU train is two skid-mounted modules bolted end to end. Module 01 Conditioning carries the feed pumps and fired heater; Module 02 Conversion carries the reactor, effluent cooler, separator and controls. Capacity is scaled train by train, not by building a bigger plant.

Representative module. Proprietary engineering details, catalyst formulations and reactor design are not shown.

Fig. 3 — KHU train · skid explorerInteractive
Drag to rotate. Select a number to inspect equipment. Step through Trains 1–3 to see how capacity scales: each train is Module 01 Conditioning plus Module 02 Conversion.
Process equipment
Reactor, heater, separation and transfer equipment, sized to the project.
Piping & tie-ins
Pipe spools and flanged tie-in points for fast interconnection at site.
Instruments & controls
Installed and checked in the shop, then reconnected in the field.
Structure & lifting
A steel skid frame with designated lifting points for handling and transport.
03Why modularDetail D · Table 1

Upgrading without the central plant.

Conventional upgrading, such as delayed coking, concentrates capital in large facilities that are usually far from remote fields. A modular approach moves smaller, standardized capacity to where the crude is produced.

Table 1 — Centralized upgrading vs KHU modular · qualitative
FactorCentralized upgradingKHU modular upgrading
01 · CapexCapitalCentralizedLarge, up-front investment in a single facility, such as a delayed coker.KHU modularCapacity added train by train, matched to the project and phased with production.
02 · LocationLocationCentralizedSited where infrastructure already exists, often far from remote fields.KHU modularInstalled at or near the field, close to production.
03 · LogisticsLogisticsCentralizedHeavy crude and diluent moved long distances to the plant, and products moved back out.KHU modularUpgraded product can serve as the blending component, so fewer inbound diluent shipments.
04 · ScheduleScheduleCentralizedLong construction programs, largely in the field.KHU modularFabrication in a US shop runs in parallel with site preparation, with less work in the field.
05 · GrowthScalabilityCentralizedSized up front for forecast throughput.KHU modularFurther trains can be added as production grows.

Qualitative comparison. Outcomes depend on crude properties, project conditions and location.

04Fabrication & qualityDetail E · Photo 1

Manufactured, assembled and tested in the USA.

Photo 1 — Module under fabricationUSA
A steel skid-mounted process module under fabrication in a bright fabrication shop, with pipe spools, a vertical vessel and overhead crane rails.
Representative fabrication shop. Modules are built and checked indoors before shipment.

Building in a shop rather than in the field gives every module the same quality controls, the same trained crews and a predictable schedule, wherever it is going.

  1. A

    Factory acceptance testing

    Each module is tested before it ships, so issues are found on the shop floor, not at a remote site.

  2. B

    Controlled conditions

    Fabrication and assembly happen indoors, with consistent quality, safety and schedule control, independent of field weather.

  3. C

    US supply chain

    Steel, equipment and fabrication sourced through established US industrial supply chains.

  4. D

    Codes and standards

    Modules are designed and fabricated to recognised industry codes and standards, specified per project, with HSE requirements built into design, FAT and commissioning.

05Transport & installationDetail F · Fig. 4

Shipped to remote environments. Installed at the field.

Modules are designed to a transportable envelope set by the route to site. Where the route or site access requires it, a module can be disassembled into transport units and reassembled at the field.

Route
Road, sea or barge, planned around the limits of each leg of the journey.
Site
The pad, foundations and tie-in points are prepared while modules are built.
Install
Modules are set, interconnected and commissioned, with Kalvera commissioning support.
Remote
Suited to locations where conventional infrastructure is costly or impractical.
Fig. 4 — Transport envelope · side elevationSchematic
Side elevation of a process module on a heavy-haul trailer. A dashed red outline and dimension lines mark the transportable envelope. A split line shows where the module can be disassembled. SPLIT LINE TRANSPORTABLE ENVELOPE HEIGHT · PER ROUTE 1 2 3 4
  1. 1 Process module
  2. 2 Skid base
  3. 3 Lifting points
  4. 4 Heavy-haul unit
  5. Split line, where appropriate
  • RoadHeavy-haul to site
  • SeaOcean freight to port
  • BargeInland waterways
Envelope limits depend on the route to site. Dimensions are set per project. Not to scale.
06Project lifecycleDetail G · Fig. 5

With you from feasibility to operations.

Kalvera works alongside producers, refiners and engineering firms through every stage of a modular project. Select a stage to see what happens and what you receive.

Stage 01 of 07

Feasibility

Under NDA, we review crude properties, site conditions and project economics, and outline what KHU could do for your barrels.

Where
With the client
You receive
A feasibility outline and next-step plan
07Commercial inquiriesForm KAL-INQ

Let’s size a module train for your field.

Share your crude properties, location and production plans. Our engineering team will outline how modular KHU capacity could fit your project. All discussions are under NDA.

All discussions are under NDA

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