Clean oil processing

24.03.2013

Antipinsky Oil Refinery will meet the strictest environmental requirements

“I have come across such figures: today’s level of solid domestic waste (SDW) processing in Russia does not exceed 4-5%, and the level of industrial effluent treatment — 35%. All the rest is disposed in landfills. Maybe, this year declared by President Putin the Year of Environment Protection will become a turning point? Anyway, we have decided at our modern oil refinery plant that its environment-friendliness must be also modern – in next July we commission new effluent treatment facilities. Waste water treatment will be performed with a complex approach using state-of-the-art technologies, Antipinsky Oil Refinery CJSC General Director Gennady Lisovichenko says. - In terms of its attitude towards the environment, the enterprise seeks to meet the international standards of quality and complies with the requirements of the Russian Federation law”.

14 years of continuous development

The above is quite in the spirit of Antipinsky Oil Refinery CJSC establishers. This group of entrepreneurs, having started with a small oil processing business in the Tyumen Region with the capacity of 400 thousand tons per year, having not even had enough time to rejoice at the first ruble from the new plant proceeds, decided to develop the plant into a major enterprise in line with the latest achievements of oil refining technologies. And in 2008, two years after the first workflow phase commissioning, they completed its technical re-equipment that allowed to increase the enterprise capacity up to 740 thousand tons of oil per year. In May 2010, the second workflow phase was commissioned – for 2.75 MIO tons. The resulting total capacity grew up to 3.5 MIO tons. The second workflow phase modernization allowed to increase the oil refinery total capacity up to 4.2 MIO tons by November 2012.

Approximately by that time, the company purchased and repaired the Antipino railway station, built near it a finished product sector (tanks with the total capacity of 20 cubic meters, two double service racks allowing simultaneous loading of 71 railway tanks) for light petroleum products shipment. The finished product sector (FPS) increased the plant total possible oil products loading capacity up to 8 MIO tons per year (3 MIO tons - basic loading capacity and 5 MIO tons - FPS) and decreased the burden on existing oil cargo piers on the oil refinery main site. The enterprise main site tanks that became available due to this fact will be used as relay tanks what, in prospect, will allow to enhance the processing facilities operation reliability and to improve the enterprise processing capacity.

Today, the refinery is building the third oil processing workflow phase. It will be created in a few stages. At the first stage (before the end of 2013), an oil processing unit with the capacity of 3.7 MIO tons per year is to start working. Thus, the refinery processing capacity will exceed 7.5 MIO tons. In addition, a number of off-site utilities will be commissioned: a commercial diesel fuel tank farm (80 thousand tons), crude oil tank farm (60 thousand tons), and modern effluent treatment facilities. In the second stage, the task of bringing diesel fuel quality in line with the Euro-5 requirements (sulphur content not exceeding 10 ppm) is to be solved, and production of winter and arctic diesel fuel is to start. For this purpose, before the end of 2014, a distillate hydro-treatment unit will be constructed under the license and according to the design of Danish company Haldor Topsoe, with a hydrogen production unit and free sulphur production unit with a granulation section.

At the third stage, the oil processing depth will be increased up to 94%. Such result will be achieved due to the unit for vacuum tower bottoms delayed coking combined with an atmospheric residue vacuum distillation section (the license of American company “Foster Wheeler”) which, in 2015, will increase diesel fuel output up to 50% of the total processing volume. The coke resulting from vacuum tower bottoms coking is a precious end product, highly demanded in metallurgy.

And in the first half of 2016, Antipinsky Oil Refinery plans to put into operation a continuous catalytic reformer with isomerization plant ( company “UOP”) what means manufacturing of “Euro-5” standard gasoline with octane number of at least 95 points by the research method.

And finally, in 2017-2018, it is planned to build a vacuum gas oil hydrocracker unit and a second hydrogen production unit.

In the result, after 14 years of continuous development, for the first time in the past 30 year, a powerful oil processing greenfield enterprise (beside the oil refinery being built by Taneco) created by a private company will appear. Antipinsky Oil Refinery is the only one behind the Urals, a region with a high demand for petroleum products. The products quality will meet the Euro-5 standard, and the processing depth will be 94%. Besides, the oil refinery impact on the environment will meet the strictest requirements of environmental standards. And it is quite important that a powerful and clean enterprise appear in the Urals Federal District where industrial enterprises built as long ago as in the Soviet era are concentrated. In addition, fuel from Antipinsky Oil Refinery will reduce the toxic impact of the Urals vehicles emissions.

Not to spill a single drop

Production environmental aspect was taken into account at each stage of the refinery development. At the time of engineering, to reduce the burden on the environment, a number of technological solutions were applied that allowed: to reduce the area required for the treatment facilities, to decrease twice, in comparison with the traditional technologies, emissions of harmful (pollutant) substances into the atmosphere and waste formation; to reduce to the minimum water consumption in the production process and, consequently, waste water discharge; to exclude pollution of the soil, surface and underground waters with oil and oil products; to minimize operating costs. Reduction of waste formation and pollutant emissions into the atmosphere will be achieved through using modern automated process equipment that will allow to reach the set goals in the field of industrial and environmental safety and to use in production to the maximum extent resultant oil containing waste.

In the second half of 2013, Antipinsky Oil Refinery CJSC plans to reduce the volume of water intake from natural sources by way of effluent recycling after putting into operation of modern treatment facilities. Equipment of effluent treatment facilities manufactured by Russian and foreign companies will allow treatment of all industrial and stormwater effluent and domestic waste water. A few treatment stages are provided for – preliminary, physical-and-chemical treatment (separators and impeller flotation), biological treatment (membrane bioreactor), deep final purification and decontamination (process of dual filtration through carbon absorption filters and ultraviolet decontamination), and, finally, dehydration of trapped oil products, residue, and excess sludge.

After treatment, about 60% of purified waste water will be used again at the enterprise, and 40% will be brought in line with the requirements to surface waters protection and forwarded to the river of Tura. This will result in preservation of not only the ecological state of this river, which, by the way, supplies water to a number of cities, including Tyumen. The Tura is the Tobol river confluent which, in its turn, joins the Irtysh. The complex approach to organization of oil refining processes environmental safety testifies to the social responsibility of the Antipinsky Oil Refinery team. The state of environment of an enormous region populated with millions of people and enjoying a unique Siberian ecosystem depends on the enterprise clean operation.

Project investments in the period from 2010 to 2015 will be 2 billion dollars. For the purpose of the current plans implementation, in March of the last year, a multicurrency facility agreement on granting of a term loan facility and a revolving line of credit, with the maturity in March 2017, was signed with Gazprombank, Raiffeisen Bank International AG, and CJSC Raiffeisen Bank together with Glencore International AG, Vitol S.A., Globexbank, and WestLB AG (London).

Antipinsky Oil Refinery strategic partners are companies VITOL, GLENCORE, MERCURIA, LITASCO. The company proceeds for 2012, VAT exclusive, grew by 27% and reached 55.7 billion rub. The refinery net profit increased by 10% in 2012 in comparison with the previous year of 2011 and exceeded 1.25 billion rub. EBITDA for 2012, taking into account the other Group companies, amounted to 190 MIO dollars.


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