How it takes place at Antipinsky Oil Refinery
In July 2011, oil companies, the Federal Antimonopoly Service, Rostechnadzor (Russian Technical Supervision Service), and Rosstandard (Russian National Standard Organization) signed an agreement pursuant to which fuel manufacturers assumed obligations to pass over to production of higher quality petroleum product types before 2015, and by 2016, all oil refineries of the country must produce oil products of “Euro-5” class. In this connection, and due to the necessity to remain competitive in the dynamic market, oil processing plants actively perform modernization and put into operation new capacities. How is the technological process assets upgrading going on?
Excursus to the genesis
In July 2004, on the territory of one of the major oil and gas subjects of the Russian Federation – the Tyumen Region, where most of the Russian oil and natural gas reserves are concentrated, Antipinsky Oil Refinery was founded. Already at the end of 2006, a workflow phase with the design capacity of 400 thousand tons per year was put into operation. From that time, the enterprise fixed assets continuous modernization started. Due to the technical re-equipment, the line actual capacity reached 740 thousand tons per year by 2008. In May 2010, the plant second workflow phase with the capacity of 2.75 MIO tons per year was commissioned, what increased the refinery total capacity up to 3.5 MIO tons per year. At the end of 2012, in the process of the 2nd workflow phase modernization, its capacity was increased to 3.3 MIO tons per year. Thus, from November 2012, the plant total capacity (Crude Unit 1+ Crude Unit 2) is 4.2 MIO tons per year.
For the purpose of light petroleum products (gasoline, diesel fuel) shipment by railroad, Antipinsky Oil Refinery CJSC purchased and repaired the railway station of Antipino near which a finished product sector (FPS) was built. The FPS is connected with the plant main site by industrial pipelines of the total length of about 2.9 km.
On the territory with the area of 15 ha, a relay tank farm of 20 thousand m3 and two double service racks allowing simultaneous loading of 71 railway tanks (what amounts to the Russian Railways rate) are located.
Due to the FPS commissioning, the plant total oil products loading capacity increased up to 8 MIO tons per year. In addition, the area 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 oil processing capacity, in particular, for processing of oil delivered by railway. For today, on the whole, the plant tank farms volume is more than 315 thousand tons.
Construction of the 3rd workflow phase is to be performed in a few stages. It is planned that, at the first stage of construction which is to be completed in the 4th quarter of 2013, Crude Unit 3 with the capacity of 3.7 MIO tons per year will be commissioned. This will result in the plant crude oil refining capacity increase up to more than 7.5 MIO tons per year. Together with the unit, a number of off-site utilities will be put into operation: a commercial diesel fuel tank farm with the volume of 80 thousand tons, crude oil tank farm of 60 thousand tons, and modern effluent treatment facilities.
The second stage task is bringing the diesel fuel quality in line with the Euro-5 requirements (with sulphur content not exceeding 10 ppm) and ensuring the necessary setting point. This task settlement will make it possible to produce winter and arctic diesel fuel. To achieve the above parameters, a distillate hydro-treatment unit will be constructed following the Haldor Topsoe technology.
To support the hydro-treatment unit operation, a hydrogen production unit and free sulphur production units with a granulation section will be built. Completion time is the 4th quarter of 2014.
At the third stage of construction, it is planned to increase the oil processing depth up to 94% by putting into operation, in the 4th quarter of 2015, of a unit for vacuum tower bottoms delayed coking combined with an atmospheric residue vacuum distillation section. The process licensor and basic design developer is American company Foster Wheeler. The result will be diesel fuel output increase up to 50% of the total processing volume.
In 2016, Antipinsky Oil Refinery will pass over to production of “Euro-5” standard top bracket gasoline with the octane number of at least 95 points by the research method. This will be possible due to commissioning of a continuous catalytic reformer and isomerization plant.
In 2017-2018, it is planned to build a vacuum gas oil hydrocracker unit using as the raw material the company own vacuum gas oil from the vacuum tower bottoms delayed coking unit and vacuum distillation unit. In addition, a second hydrogen production unit and off-site utilities will be constructed. Project investments in the period from 2010 to 2015 are planned at the level of 2 billion US dollars. One of the steps within the enterprise planned development strategy was signing in March 2012 of a multicurrency facility agreement on granting to Antipinsky Oil Refinery CJSC of a term loan facility and a revolving line of credit for the total amount of up to 750 MIO US dollars. This multicurrency agreement was signed with JSC “Gazprombank”, Raiffeisen Bank International AG, and CJSC “Raiffeisen Bank” together with Glencore International AG, Vitol S.A., CJSC “Globexbank”, and West LB AG (London). The credit with the maturity in March of 2017 consists of three tranches in US dollars and in Russian rubles, with the security in the form of pre-export and export financing elements
Antipinsky Oil Refinery uniqueness is determined by the fact that it is a private, not a state, project, the capacity of which will reach 7.5 MIO tons per year (2013), the petroleum products quality will conform to the Euro-5 standard (2014), and the processing depth will increase up to 94% (2015). About 345 thousand tons from deposit Tarkhovskoye owned by a partner company have been extracted and processed.
Today, Antipinsky Oil Refinery is the only commercial oil refinery plant in the Urals Federal District. The plant location is advantageous: near a well-developed logistics network: railway and motor road infrastructures. Besides, the Antipinsky Oil Refinery is connected to JSC “Transneft” oil trunk pipelines with the total capacity of 6 MIO tons per year, taking into account the enterprise development, including the third workflow phase. The high demand for oil products distinguishing the Tyumen Region can also be considered the plant competitive advantage. Moreover, Antipinsky Oil Refinery has a possibility to ship fuel to enterprises directly from the plant, loading small road tankers of 5-30 tons. Shipment of product in small volumes results in economy.
The issue ecological aspect
Lately, at the background of growing oil extraction and processing volumes, issues of environment protection and industrial safety are of the top priority for both state authorities and oil processing companies. An acute need in complex measures aimed at minimization of oil processing facilities industrial operation harmful impact on the environment is observed at modern oil refinery plants. Due to this fact, special attention is paid to application of high environmental standards at the time of Antipinsky Oil Refinery construction.
The plant accredited chemical and analytical laboratory environment department constantly controls the state of the environment, surface and waste water. To reduce the load on the environment, at the time of the plant engineering, a number of technological solutions were applied that allowed to reduce to the minimum the water consumption and, consequently, waste water discharge, pollutant emissions into the atmosphere, and to exclude pollution of the soil and subsoil waters with oil and oil products.
In addition, within the framework of the third workflow phase construction, modern effluent treatment facilities are being constructed, which will ensure industrial and domestic waste water treatment to the required level allowing to use treated waste water again or to dispose it into a fishery water body.
The treatment facilities total area is 10.73 ha. The complex consists of three main units: a physical-and-chemical waste water treatment unit (Separation Specialists impeller flotation), biological waste water treatment unit (GE Water and Process Technologies membrane biological reactor), waste water final purification unit (process of dual filtration through carbon absorption filters, then waste water ultraviolet decontamination until it meets SanPiN (Sanitary Rules and Regulations) standard 22.214.171.1240-00 (“Hygienic Requirements to Surface Water Protection”).
Charity is one of the main trends of Antipinsky Oil Refinery social policy.
For the period of its existence, the enterprise has developed key charity support trends: support is provided not through charity organizations and foundations, but directly to orphanages, foster homes, clubs, cultural institutions, the Tyumen Region organization of the All-Russian Society of the Disabled. This is evidenced by the formed friendly relations with Municipal Educational Establishment “Orphanage No. 66” for orphans and children deprived of parental care. The enterprise does not ignore the sports trend either financing one of Tyumen Junior Judo clubs.
The enterprise social policy provides for programs and measures aimed at ensuring employees social security, creation of healthy and safe labor conditions. The enterprise management is not only concerned with providing high quality medical service, employees support using the system of various types of material aid and compensations, but, what is especially important, uses its best efforts to improve their living conditions. At present, a block of 152 apartments is being built for the enterprise specialists, which will be commissioned already in this year.
View in prospect
In the near future, Antipinsky Oil Refinery may become the only private enterprise with the capacity of 7.5 MIO tons per year, petroleum products quality meeting the Euro-5 standard, and the processing depth up to 94%.
The Tyumen Region where Antipinsky Oil Refinery is located has concentrated 72% of the Russian oil reserves and 91% of gas reserves within its territory. But, until now, its light petroleum products requirements are satisfied due to export from adjoining areas. Today, experts more and more often speak about a threatening fuel crisis. By 2015, gasoline deficit in the Russian market may increase 70 times. Of course, one refinery cannot solve such a problem at the level of the country, but it is quite capable of improving the fuel situation in the region.