Up-to-date Technologies for Environment

21.06.2013

Significant growth of oil production and refining volumes which is evident in Russia of late has once again made the issues of environmental protection and industrial security topical for oil refining enterprises. As of today Antipinsky Oil Refinery CJSC which is the only industrial refinery in the Urals Federal District cannot but meet the current challenges of modern reality and is actively taking comprehensive measures aimed at enhancing the work efficiency in the area of industrial security and environmental safety, as well as labor protection.

Resources are of paramount importance

Antipinsky Oil Refinery CJSC was founded in July 2004 on the territory of one of the major oil and gas constituent entities of the Russian Federation, the Tyumen Region, where the most part of Russian oil (72%) and natural gas (91%) reserves is concentrated.
The 1st workflow phase of the refinery with the capacity of 400 thousand tons per year was commissioned at the end of 2006. Due to technological modernization in 2008 its actual capacity reached 740 thousand tons per year. Over the year 2012 Antipinsky Oil Refinery processed more than 2.9 tons of oil. Some 345 thousand tons were produced and refined at Tarkhovskoe oilfield by its corporate partner Tarkhovskoe LLC.
In two years, in May 2010, workflow phase II with the capacity of 2.75 million tons per year was commissioned. Thus, after workflow phase II commissioning the total capacity of the refinery made up 3.5 million tons per year. As a result of phase II modernization in late 2012 its capacity reached 3.5 million tons per year. So, the aggregate capacity of the refinery (ELOU-AT-1 + ELOU-AT-2) amounts to 4.2 million tons per year since November 2012.
As of today the workflow phase III construction is in full swing.
The availability of the finished products sector (FPS) with the area of 15 hectares located nearby Antipino Railway Station which is also owned by the Antipinsky Oil Refinery enables the latter to ship light oil products (gasoline, diesel fuel) by rail quickly and in workmanlike manner. Either-direction tank filling racks make it possible to load 71 rail tankers at a time. The volume of the indirect tank farm situated between the racks is 20 thousand cu.m. Owing to FPS it has become possible for the refinery to facilitate operation of functioning loading/discharge racks. Empty tanks will be used as indirect what will make it possible in perspective to enhance the reliability of processing facilities’ operation, as well as improve the production efficiency of the enterprise engaged in refining oil which, in part, is delivered by railway. The total volume of the refinery’s tank farms amounts to 315 thousand tons. The total area of the refinery’s territories exceeds 150 hectares.
The location of Antipinsky Oil Refinery is favorable: the enterprise is situated nearby a developed logistic network with railway and motorway infrastructure.
Antipinsky Oil Refinery is connected to oil trunk pipelines of Transneft JSC with the total capacity of six million tons per year considering the development of the enterprise including phase III.
Nowadays Antipinsky Oil Refinery is actively engaged in the development of its material and technical base. Environmental compound is taken as a basis for the majority of applied solutions.

Expanding capacities

For the purpose of the work efficiency enhancement at Antipinsky Oil Refinery CJSC a decision has been taken on the construction of workflow phase III. Its objectives are: to reach the oil refining capacity of up to 7.5 million tons per year, to increase the processing depth up to 94%, and to produce Euro-5 standard fuels.
The construction of the new workflow phase (General Contractor is Velesstroy LLC) will be carried out in several stages.
ELOU-AT-3 unit with the capacity of 3.7 million tons p.a. will be commissioned at the 1st stage of workflow phase III, 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 IVth 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.

No enterprise of similar capacity has been commissioned on Russian territory over the past 30 years, but for “TANEKO” oil refining and petrochemical complex, however, it is a state-run but not a private enterprise unlike Antipinsky Oil Refinery.
The oil processing depth will reach up to 94% at the third stage of workflow phase III construction due to the commissioning in the IVth 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. American company Foster Wheeler is the licenser of the process and the developer of the basic project. Coke which is received as a result of tar carbonization and constitutes the end product is in great demand in metallurgy.
In 2016 (the Ist and IInd 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 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 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 II hydrogen production unit and off-site facilities will be built.
The volume of investments in the project within the period between 2010 and 2015 is planned at the level of USD two billion. One the steps forward to the implementation of the 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. The agreement in question 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 (London).
The credit with repayment period in March 2017 consists of three tranches denominated in US dollars and Russian rubles with security in the form of pre-export and project financing components.

A new word in the wastewater treatment system

Due to the aggravated ecological situation oil and gas companies, especially modern refineries, have realized an acute need to apply the full range of efficient measures in their activity focused on minimizing the harmful impact of industrial exploitation of oil refining facilities on the environment.
In this connection professionals of Antipinsky Oil Refinery pay special attention the selection of modern technological equipment which must comply with requirements of strict environmental standards when constructing new facilities and carrying out technical modernization of the entire enterprise.
Water is needed for refining oil and oil products at the units of Antipinsky Oil Refinery, that is why the construction of the IIIrd workflow phase began with the building of water intake, water conditioning, and treatment structures.
High-technology equipment will be used at the treatment facilities of Antipinsky Oil Refinery the suppliers of which are such Russian companies as “Komsomolets” Tambov Plant OJSC, LIT Research and Production Association, EKO-Umvelt CJSC, TEKO-FILTR Production Enterprise LLC, as well as such foreign companies as Zickert (Sweden), Separation Specialist (USA), GE Water & Process Technologies (Hungary), and other enterprises well-known all over the world.
To lessen pressure on the environment a number of technological solutions were taken into account by the refinery making it possible to reduce the area needed for treatment facilities twice as compared with traditional technologies; minimize the amount of emissions of harmful (pollutant) substances in the atmospheric air and the formation of waste; as well as considerably reduce water consumption at the refinery and decrease wastewater discharge, accordingly. In addition to that, the application of these solutions makes it possible to prevent spillage of oil and oil products in the soil, surface and underground waters, to cut operational costs.
Up-to-date methods applied to the treatment of industrial and rainfall as well as 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.
Quality control of wastewaters will be exercised at all stages of their treatment using advanced technology of the accredited ecological and analytical laboratory of Antipinsky Oil Refinery CJSC.
“The building of sewage treatment facilities of a new type at Antipinsky Oil Refinery will make it possible to significantly minimize the harmful impact resultant from the operation of oil refining facilities on the environment,- explains General Director of the enterprise Gennady LISOVICHENKO, - as well as make the refinery’s work better and more efficient.”

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