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MODULAR REFINERIES

Modular Refineries – Build. Deploy. Operate.

Why Modular Refineries?

The world’s energy demand is growing at an unprecedented pace – every industry, every fleet, every household requires petroleum‑derived products. Conventional refinery projects demand huge capital outlays, lengthy construction timelines, and large land footprints.

Modular refineries break that cycle. Built in a controlled factory environment, shipped to a remote site, and brought online in weeks, they offer:

Feature
Benefit
Rapid time‑to‑market
18-24 months from order to operation
Low CAPEX & OPEX
30–50 % cheaper than conventional refineries
Scalable capacity
1,000 – 20,000 BPD modules that can be shifted or expanded
Remote‑site flexibility
Operate with local feedstock – perfect for offshore, upstream, or low‑income regions
Low environmental footprint
Closed‑loop systems, reduced emissions, and on‑site waste handling
Full lifecycle service
Design → Build → Deploy → Operate & Maintain

Our Integrated Offering

In today’s fast‑evolving energy landscape, the speed and reliability of every project hinge on how tightly the engineering, deployment, and operations stages are linked. We’ve built a turnkey, three‑phase framework that takes a refinery from concept to full‑production in record time—while slashing construction risk, cutting logistics spend, and delivering higher yields, lower downtime, and greener operation.

Phase
What We Do
How It Adds Value
Build
• Engineering & design of crude‑oil distillation, topping, hydroskimming, and full‑conversion modules.
 
• Fabrication of pressure vessels, heat exchangers, and control systems in our ISO‑certified factories.
 
• End‑to‑end testing (hydrostatic, vibration, safety)
• Zero‑risk construction – every component meets global standards before shipment.
• Faster procurement and lower logistics costs.
Deploy
• Pre‑assembly in modular bays, sea‑transport, or rail shipment.
 
• Site integration: foundations, pipelines, utilities, and security.
 
• Commissioning with real‑time process monitoring and remote‑support.
• 4‑to‑8 week turnaround from port to operating day.
 
• Seamless integration with existing upstream and downstream assets.
Operate
• Full‑service operation – fuel production, product blending, and environmental compliance.
 
• Predictive maintenance, asset‑integrity monitoring, and performance optimization.
 
• 24/7 on‑site support, training, and regulatory liaison.
• 10–15 % higher yields and 20–30 % lower downtime compared to conventional refineries.
 
• Reduced energy consumption and emissions thanks to advanced control systems.
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Components of a Modular Refinery

Our Services

REFINERY TURNAROUNDS

Turnarounds are scheduled events wherein an entire process unit of a refinery or petrochemical plant is taken offstream for an extended period for revamp and/or renewal. Periodically, refineries need to have preventive maintenance, renovations, or upgrades. These periodic circumstances allow the refineries to ensure safe operations, stay competitive, and meet government regulations…

MANUFACTURING

With our 8,000 sq foot shop facility located in Willis, TX, we have all the resources necessary to complete your fabrication project.

Whether it is is a pump skid with piping, a pressure vessel or heat exchanger, we are ready to fabricate equipment to meet your needs. 

Apache Refinery Services, serving the oil and gas industry since…

DESIGN & ENGINEERING

Apache Refinery Services offers professional industrial engineering capabilities to complement our other manufacturing, design, repair, and refinery turnaround services. No job is too large or too small for our experiences and resourceful staff to manage and execute. We are qualified to engineer both onshore and offshore structural and mechanical systems…