New Solution for Environmental Safety

30.08.2013
The ecological component of production is one of priority areas of activity for the majority of enterprises today, including for the companies operating in the oil refining industry, the resultant quality of the finished products of which is directly related with the impact on the environment. That is why the main objective of modern oil refineries is to make their production process as environmentally friendly as possible and to minimize the harmful impact of their activity on the ambience. For this purpose companies energetically apply new methods and technologies in their work, improve production processes, methods and equipment. As of today Antipinsky Oil Refinery CJSC is the only industrial oil refinery in the Urals Federal District which perfectly exemplifies a successful combination of scientific-technical approach and innovative technologies regarding the issues of the environmental safety of its production process.

Powerful Resources Guarantee Efficient Operation

Antipinsky Oil Refinery CJSC was founded in July 2004 on the territory of one of the largest oil refining entities of the Russian Federation - the Tyumen Region.
The refinery’s location is favorable since it is situated not far from a developed logistic network: railway and motorway infrastructures are available. Antipinsky Oil Refinery is connected to oil trunk pipelines of Transneft JSC with the total capacity of six million tons p.a. taking into account the development of the enterprise including the third phase.
Antipinsky Oil Refinery can sell fuel to enterprises directly from the refinery by loading it to small tank trucks of 5-30 tons. Therefore, it becomes economically advantageous due to the method of product shipment in small volumes.
Such leading international companies as VITOL, GLENCORE, MERCURIA, LITASCO are strategic partners of Antipinsky Oil Refinery CJSC.
Powerful technological potential of the enterprise enables it not only to manufacture high-quality products in required volumes, but also to develop constantly by improving production facilities.
Workflow phase I with the estimated capacity of 400 thousand tons p.a. was put into operation at the end of 2006. In 2008 its actual capacity amounted to 740 thousand tons p.a. as a result of technical modernization.
In May 2010 workflow phase II of the refinery with the capacity of 2.75 million tons p.a. was commissioned. Therefore, after commissioning of workflow phase II the total capacity of the refinery made up 3.5 million tons p.a. In the course of phase II modernization at the end of 2012 its capacity reached 3.5 million tons p.a. Thus, the overall capacity of the refinery (ELOU-AT-1 + ELOU-AT-2) amounts to 4.2 million tons p.a. since November 2012.
Antipinsky Oil Refinery CJSC acquired and repaired Antipino railway station in the vicinity of which the finished products sector (FPS) was built for the purpose of the transportation of light oil products (gasoline, diesel fuel) by rail.
The FPS is a detached facility connected with the main area of the refinery by means of industrial pipelines with the total length of about 2.9 km. The area of the sector occupies 15 hectares. On the territory of the sector there are two either-direction tank filling racks making it possible to load 71 rail tankers with an indirect tank farm of 20 thousand cu. m.
The FPS commissioning has increased the total estimated oil-product loading capacity of the refinery up to eight million tons p.a. (three million tons account for the basic capacity and 5 million tons of the FPS), it also lessened the load of functioning fill/discharge racks situated in the main area of the refinery. Empty tanks, in their turn, 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 in refining oil, including that delivered by railway transport. Today the total volume of tank farms makes up 315 thousand tons.

Augmenting Potential

Antipinsky Oil Refinery is rapidly developing its material and technical base by implementing new projects its territory.
Currently workflow phase III is being built actively (Velesstroy LLC is the General Contractor) to be completed in several stages.
Thus, ELOU-AT-3 unit with the capacity of 3.7 million tons p.a. will be commissioned at the 1st 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 of workflow phase III 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 (Danish company Haldor Topsoe is the licenser of the process and the developer of the basic project). 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 IVth quarter of 2014.

The oil processing depth is planned to reach up to 94% at the third stage due to the commissioning in the fourth quarter of 2015 of a combined deferred tar carbonization unit with a fuel-oil vacuum distillation block (American company Foster Wheeler is the licenser of the process and the developer of the basic project). The output of diesel fuel, as a result, will grow up to 50% of the total refining volume.
In 2016 (the first and second quarters) it is planned to transfer to the production of high-octane gasoline of Euro-5 standard with the octane number of no lower than 95 points under research method. These results are to be achieved due to the commissioning of the gasoline reforming unit with the catalyst permanent regeneration and isomerization block. (UOP is the licenser of the processes.)
In 2017-2018 it is planned to build 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.
The volume of investments in the project in question within the period between 2010 and 2015 is planned at the level of USD two billion. One of the steps forward to implementation of planned enterprise development strategy is the signature in March 2012 of 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. That agreement was signed by OAO Gazprombank (OJSC), Raiffeisen Bank International AG and ZAO Raiffeisenbank (CJSC) jointly with Glencore International AG, Vitol S.A., Globexbank CJSC, and WestLB AG.
The credit with repayment period in March 2017 consists of three tranches denominated in US dollars and Russian rubles secured with a collateral in the form of pre-export and project financing components.
Antipinsky Oil Refinery CJSC reports that its 2012 revenues exclusive of the VAT grew by 27% and made up 55.7 billion rubles.
The net profit of the refinery over the year 2012 grew by 10% as compared with the previous year and amounted to 1.25 billion rubles.
EBITDA index for the year 2012 made up USD 190 million taking into account other companies of the group.

On Guard of Environmental Safety

Being a sustainable and dynamically developing enterprise Antipinsky Oil Refinery cannot stay aside from current challenges of today’s reality. The enterprise is 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.
Today Antipinsky Oil Refinery is busy with the design and construction of workflow phase III which will enable it to provide the region with Euro-5 motor gasoline and diesel fuel after commissioning of new units, and, as a consequence, to reduce environmental pressure of vehicles on the ambiance of the south of the Tyumen Region.
Since water is needed for refining oil and oil products at the units the construction of a new 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. The use of treatment facilities will enable the refinery to purify all industrial, rainfall, and domestic waters by means of preliminary, 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 relevant equipment will make it possible to prevent 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.
It should be specially noted that 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), GEWater & Process Technologies (Hungary), and other firms well known all over the world, will be used at the new facility of the refinery.
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 technical purposes of the enterprise, 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.

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