Companies appear in Russia for which environmental protection becomes a natural part of their production policy.
A new sewage water treatment system has been built at Antipinsky Oil Refinery in Tyumen.
The new complex of treatment facilities occupy the area of about 10 hectares.
“We have used the most up-to-date technology and equipment of Russian and foreign companies specialized in treatment systems. Due to focusing on most advanced things we have managed, in part, to reduce the area intended for treatment facilities almost four times as compared with traditional technologies. In addition to that, it has become possible for us to minimize operational costs, considerably reduce water consumption and wastewater discharge, accordingly, minimize pollutant emissions into the atmosphere, and prevent oil and oil-product spillage in the soil and underground waters,” says Dmitry Mazurov, Chairman of the Board of Directors of Antipinsky Oil Refinery CJSC.
From a Small Unit to a Large Enterprise
Currently a third workflow phase for oil refining is under construction at Antipinsky Oil Refinery founded in 2004 in the rural settlement of Antipino (the Tyumen Region). By the end of this year the refining capacities of the enterprise will exceed 7.5 million tons of oil p.a. due to the commissioning of the third primary oil refining facility. But everything began from 400 thousand tons – the ultimate capacity of a small American distillation unit which became the first workflow phase of the future major oil refinery. In 2008, two years after this unit commissioning, technical modernization was accomplished at the refinery which made it possible to swell the refining capacity of the enterprise up to 740 thousand tons of oil p.a. In May 2010 the second workflow phase with the capacity of 2.75 million tons was put into operation. The aggregate capacity of the refinery grew to 3.5 million. The second workflow phase modernization made in possible to improve the aggregate capacity of the enterprise up to 4.2 million tons.
In addition to that the company acquired and repaired Antipino Railway Station, built its finished product sector nearby (tanks of the total volume of 20 thousand cu. m., two either-direction tank filling racks making it possible to load 71 rail tankers at a time) for light oil-product shipment. The Finished Product Sector (FPS) has increased the total estimated oil-product loading capacity of the refinery up to 8 million tons p.a., it also lessened the load of functioning fill/discharge racks situated in the main area of the refinery. Empty tanks of the main site will be used as intermediate what will make it possible in the future to enhance the performance reliability of processing facilities and raise the enterprise’s productivity. Today the total volume of tank farms makes up 315 thousand tons. Moreover, an oil pipeline connecting the refinery with Transneft JSC piping system was built. Today Antipinsky Oil Refinery is connected to the oil trunk pipelines of Transneft JSC with the total capacity of 6 million tons p.a. considering the development of the enterprise including its third phase.
And now - the works on building facilities of the third workflow phase are in full swing. The entire scope of works is divided in several stages.
The third primary oil refining unit with the capacity of 3.7 million tons p.a. will be commissioned at the 1st stage in the 4th quarter of 2013, what will make it possible to enhance the enterprise’s capacity to more than 7.5 million tons. Together with the unit several off-site facilities will be commissioned: the tank farm for commercial diesel fuel, the tank farm for crude oil, as well as the most up-to-date treatment facilities meeting the strictest environmental standards.
The diesel fuel hydrotreating unit will be built at the 2nd stage in the 4th quarter of 2014. It will make it possible to improve the diesel fuel quality as required by Euro-5 standard. To guarantee the operation of the hydrotreating unit hydrogen and elemental sulfur production units will be constructed. To be completed in the 4th quarter of 2014.
The oil processing depth is planned to reach up to 94% at the third stage due to the commissioning at the 3rd stage in the 4th quarter of 2015 of a combined deferred tar carbonization unit with a fuel-oil vacuum distillation block. The output of diesel fuel, as a result, will grow up to 50% of the total refining volume.
In 2016 (1 and 2 quarters) it is planned to transfer to the production of Euro-5 high-octane gasoline on due to the commissioning of the gasoline reforming unit.
There's more to come. In 2017-2018 a vacuum gasoil hydrocracking unit, as well as the second elemental sulfur block and one more section of treatment facilities, are planned to be constructed.
Neither Noise, Nor Dirt
Oil refinery is a rather hazardous production process. It should be noted that most harmful substances form during deeper conversion, for example, in the cause of catalytic cracking. All in all, about one hundred types of harmful substances are formed, among which there are heavy metals, dioxin, chlorine, benzene. “Is is very important for the environment of the Urals Federal District in which industrial enterprises built way back in the Soviet times and incompliant with environmental standards to obtain an efficient and environmentally friendly oil refinery,” says Dmitry Mazurov. “Now, strictly according to the plan, we have finished a very serious stage of preparing for enhancing the enterprise’s capacity – we have built a complex which is to guarantee complete ecological safety of operation of all production units of the refinery.”
New treatment facilities of Antipinsky, the commissioning of which took place in the Year of Environmental Protection declared in Russia, constitute the entire system of technological solutions of the world companies-leaders in the sphere of industrial effluent treatment which system will provide for purification of all industrial, rainfall, and domestic wastewaters of the enterprise. The system consists of five treatment blocks: preliminary treatment, physical and chemical (impeller floatation), biological (membrane bioreactor) treatment, advanced post-treatment and disinfection (the process of dual filtration using FSU sorption carbon filters and UV disinfection), and, finally, dehydration of trapped oil products, residues, and excess sludge. Derived oil products will go back to refinery, dehydrated and harmless solid residues will be used by constructors for filling trenches and pits. As for the water used in production, approximately 60% will be channeled back to the industrial contour after treatment, and 40% of water meeting environmental safety standards will be discharged to the Tura River. They thought at the enterprise even of the fact that the discharge of water under pressure should not change the profile of the river bottom what is important for uninterrupted water traffic. One may recognize that the ecological issues of industrial production were, in fact, considered at the company at each stage of the enterprise’s development. According to Dmitry Mazurov: “When complying with the requirements of the laws of the Russian Federation and internal company rules and regulations we do our best to comply with the most stringent international quality standards in parallel.”
By the way, oil products output by Antipinsky will also in the nearest future comply with the standards applied in the Western Europe. Since the refinery will produce fuel complying with Euro-5 standards, therefore, its use will reduce the toxicity of the Ural transport, which circumstance is directly connected with environmental improvement. Even now up-to-date technologies are applied in refinery processes. Thus, burner units meeting the most stringent environmental requirements are used in process furnaces. The entire process flow is absolutely leak resistant. Oil products are loaded hermetically, too, and vapors are removed to special tanks. All processing equipment and oil loading racks are installed on concrete platforms with guard rails preventing spillage of hydrocarbons to soil. All processes are computerized what makes it possible to abide by established technological parameters and, therefore, use feedstock as fully as possible. Sensors which will warn of emergencies keep all processes under surveillance. Besides, the chemical and analytical laboratory of the refinery exercises continuous control over the state of environment.
According to Antipinsky Oil Refinery CJSC the company revenues over the year 2012 grew by 27% making up 55.7 billion rubles exclusive of the VAT. The net profit exceeded 1.25 billion rubles, what is 10% up as against the year 2011.
• The volume of investment between 2010 and 2015 is planned at the level of USD 2 billion.
• In March 2012 OAO Gazprombank (OJSC), Raiffeisen Bank International AG and ZAO Raiffeisenbank (CJSC) jointly with Glencore International AG, Vitol S.A., Globexbank CJSC, and WestLB AG (London) signed a multi-currency credit agreement on extending term and revolving credit facilities for the total amount of up to USD 750 million to Antipinsky Oil Refinery CJSC.
• Such world leading companies as VITOL, GLENCORE, MERCURIA, LITASCO are strategic partners of the company.