In January 2013 Antipinsky Oil Refinery, the first phase of which had been commissioned in 2006, refined the 10 millionth ton of oil. Over the past 30 years it is the first private oil refining enterprise of such capacity built from scratch on the territory of the Russian Federation within record short time period using most up-to-date technologies. The 2012 revenues of the company exclusive of the VAT grew by 27% as compared with the year 2011 making up 55.7 billion rubles. The net profit of the refinery grew by 10% making up 1.25 billion rubles. The refinery has managed to achieve such indices due to its clear investment program on corporate development the stages of which are scheduled until the year 2018. The volume of investment in the project for the period between 2010 and 2015 only has been planned at the level of USD 2 billion.
CONDITIONS FOR EURO-5
In May 2010 the second workflow phase with the capacity of 2.75 million tons p.a. was put into operation. After the second workflow phase commissioning the capacity of the enterprise amounted to 3.5 million tons of products p.a. At the end of 2012 the capacity of the second phase increased to 3.5 million tons p.a. in the course of its modernization. As a result the aggregate capacity of the refinery amounts to 4.2 million tons since November 2012. As of today the projects on further increase of capacity up to 7.5 million tons p.a., improvement of the maximum processing depth of fuel up to 94%, as well as on the output of Euro-5 oil products, are being implemented at the enterprise. What is meant is the third workflow phase construction which is carried out in several stages.
Thus, ELOU-AT-3 unit with the capacity of 3.7 million tons p.a. will be commissioned at the first stage, as a result of what the enterprise’s crude oil refining capacity will swell to more than 7.5 million tons p.a. Together with the unit several off-site facilities will be commissioned: the tank farm for commercial diesel fuel with the volume of 80 thousand tons, the tank farm for crude oil with the volume of 60 thousand tons, up-to-date treatment facilities. To be completed in the fourth quarter of 2013.
Diesel fuel hydrotreating unit will be built at the second stage for the purpose of improving the quality of diesel fuel as required by Euro-5 standards (with the sulfur content not exceeding 10 ppm) and for the purpose of ensuring the necessary freezing temperature so that winter and arctic diesel fuels can be produced. To guarantee the operation of the hydrotreating unit hydrogen and elemental sulfur production units with the granulation block will be constructed. To be completed in the fourth quarter of 2014.
The oil processing depth will reach up to 94% at the third stage of the third workflow phase due to the commissioning in the fourth quarter of 2015 of a combined deferred tar carbonization unit with a fuel-oil vacuum distillation block. As a consequence, the output of diesel fuel will grow up to 50% of the total volume of refining.
In the first and second quarters of 2016 it is planned to begin the production of high-octane gasoline of Euro-5 standard with the octane number of no lower than 95 points under research method due to the commissioning of the gasoline reforming unit with the catalyst permanent regeneration and isomerization block.
In 2017-2018 it is planned to build and commission the vacuum gasoil hydrocracking unit, and the refinery’s own vacuum gasoil from the deferred carbonization unit and the vacuum block will be used as the raw material for it. In addition to that the second hydrogen production unit and off-site facilities will be built.
STANDARD REQUIRES PURITY
Being a sustainable and dynamically developing enterprise Antipinsky Oil Refinery cannot stay aside from current challenges of today’s reality carrying out efficient activity in the area of industrial and environmental safety. The enterprise is trying to comply with international quality standards and fulfills all requirements of the Russian Federation’s legislation, as well as of its own regulatory documents and standards forming the basis for prevention of breakdowns, accidents, and incidents at a hazardous industrial facility.
A number of technological solutions were taken into account already at the design stage of the refinery making it possible to minimize the impact on the environment, and, among other things, significantly reduce water consumption what means a considerable decrease of sewage discharge, pollutant emissions into the atmosphere, and prevent oil and oil-product spillage in the soil, surface and underground waters.
Such solutions include: the use of burner units in process furnaces which comply with the most stringent environmental requirements; the application of a sealed system within the entire process flow; the control, computerization, and telemetry of technological processes to prevent accidents, as well as to minimize pollutant emissions to the atmosphere by strict adherence to established technological parameters; the provision of a leak-proof filling of light oil products with gas removal to tanks via gas equalizing lines; the use of air-cooling systems in process flows; the use of water removal systems which prevent wastewater discharge to surface waters; the construction of concrete platforms for processing equipment and oil loading racks with guard rails and ladders. Implementation of these solutions minimizes environmental damage.
The commissioning of the third workflow phase of the refinery will not only provide the Tyumen Region with Euro-5 motor gasoline and diesel fuel, but also significantly reduce environmental pressure of vehicles on the ambience of the south of the region.
Since water is needed for refining oil and oil products at the units the construction of the third workflow phase of the enterprise began with the building of water intake, water conditioning, and sewage treatment facilities. Treatment facilities occupy the area of 10.73 hectares. Wastewater treatment process consists of five stages: preliminary treatment, physical and chemical (separators and impeller floatation), biological (membrane bioreactor) treatment, advanced post-treatment and disinfection (the process of dual filtration using sorption carbon filters and UV disinfection), and, finally, dehydration of trapped oil products, residues, and excess sludge. The application in treatment facilities of new technologies and equipment will make it possible to: prevent any changes of the Tura River bottom and any limitations of water traffic when using water intake structures; provide the refinery with water of required quality complying with regulations imposed on equipment installed in the basic and auxiliary technological units; reduce the area of construction four times as compared with traditional treatment technology at primary and secondary sludge basins (biological wastewater treatment technology); minimize operational costs (low power consumption equipment, use of advanced chemical agents, etc.); reduce the impact of harmful factors (such as noise, vibration, emissions, and discharges, etc.) on the environment and employees . Only high-technology equipment of such Russian enterprises as “Komsomolets” Tambov Plant OJSC, LIT Research and Production Association, EKO-Umvelt CJSC, TEKO-FILTR Production Enterprise LLC, as well as of such foreign companies as Zickert (Sweden), Separation Specialist (USA), GE Water & Process Technologies (Hungary), will be used at the new facility of the refinery. Besides, up-to-date methods applied to the treatment of industrial, rainfall and domestic sewage waters will enable the refinery to reuse up to 60% of treated wastewaters for its technical purposes, to make the remaining 40% of water meet hygienic requirements applied to surface water protection and channel it to the Tura River. Wastewater quality control will be exercised at all stages of wastewater treatment using modern equipment of the accredited ecological and analytical laboratory of Antipinsky Oil Refinery CJSC. According to General Director of Antipinsky Oil Refinery CJSC Gennady Lisovichenko it is impossible to accomplish the ambitious objective regarding the provision of the Tyumen Region with top-quality high-octane Euro-5 fuel without strict compliance with ecological standards applicable to technologies and principles of production organization.
The principles of efficient business organization observed at the enterprise imply the establishment of a unified well-controlled system ranging from crude extraction and finished-product output to implementation of social and charity programs. In order to apply such approaches Antipinsky Oil Refinery CJSC creates its own resource base. As of today Tarkhovskoe LLC, corporate partner of Antipinsky, has already owned licenses for prospecting and operating six sites. In the year 2012 alone 345 thousand tons of oil were delivered to Antipinsky Oil Refinery from Tarkhovskoe LLC.
Social policy pursued by the enterprise includes a broad range of programs due to which healthy and safe labor environment has been created for the employees. It consists of high quality medical service, support of employees through the system of various kinds of financial assistance, compensations, and bonuses. Catering service subsidized by the owners of the enterprise has been organized for personnel at the refinery’s canteen. Sports events and corporate picnics which contribute to the maintenance of favorable psychological climate in the team are held on a regular basis. Thus, by resolution of the Board of Directors an apartment house with 152 flats will be built for specialists and foremost workers of the enterprise in 2013.
The enterprise has also determined key areas of charitable activity and is working in them. Assistance is not rendered through charitable organizations and foundations, but directly to orphanages, boarding schools, clubs, cultural institutions, the Tyumen regional organization of the Russian national society for the disabled. Friendly relations are maintained between the refinery and Orphanage No. 66 Municipal Educational Establishment for orphans and children deprived of parental care serve as an example. In addition to that Antipinsky Oil Refinery develops junior sports projects, including its financial support to one of the junior judo clubs of Tyumen. Having a number of advantages among which, in addition to the latest technologies and equipment, there are its favorable position from the viewpoint of logistics and its connection to the oil trunk pipelines of Transneft JSC with the total capacity of 6 million tons p.a. taking into account the development of the enterprise including its third phase, Antipinsky Oil Refinery CJSC has good prospects for long-term development which circumstance enables the refinery’s management board to draw up far-reaching plans and implement ambitious investment projects.
— For the purpose of determining priorities of the refinery development, Gennady Lisovichenko points out, — we comply with the principles of harmonious development and responsibility for business, first and foremost. Such an approach has already yielded fruit. Today the enterprise has a reputation of not only a reliable partner in the area of manufacture and supply of oil products, what is a significant factor of capitalization itself, but also of socially oriented company thinking of both, profit and improvement of living standards in the region.