1. Strategies, Technologies, Innovations of Antipinsky Oil Refinery

Strategies, Technologies, Innovations of Antipinsky Oil Refinery

14.12.2012

Most of Russian oil (72%) and natural gas (91%) reserves are concentrated in the south-east of Russia in the Tyumen Region. However, despite the fact that the Tyumen Region is one of the largest oil producing areas it has to acquire light-oil products in the volume of some 1.2 million tons from other regions, in particular, from Omsk Oil Refinery (550 kilometers far from Tyumen), Ufa Oil Refinery (800 kilometers far), and Permnefteorgsintez (600 kilometers far). For the purposes of taking counter measures against mini-refineries producing improper fuel the issue of building an up-to-date oil refinery with new technological equipment making it possible to supply quality products to the market in required volumes is especially topical. That is why the construction on the territory of the region of its own oil refinery is absolutely logical.

History Of Refinery
Antipinsky Oil Refinery was founded in July 2004 on the territory of one of the largest oil-and-gas constituent entities of the Russian Federation, the Tyumen Region. The refinery is situated in the industrial area of the city of Tyumen in its south-eastern part not far from Antipino rural settlement.

Due to the fact that any construction of a refinery with the maximum possible oil processing depth producing the complete range of high-quality engine fuels requires significant capital investments, refineries are constructed in several workflow phases. That is, each phase implies the organization of a complete production cycle making it possible to refine oil and ship a certain range of oil products of agreed quality to consumers. This is the development mode chosen by Antipinsky Oil Refinery CJSC.

Work flow phase I with the estimated capacity of 400 thousand tons p.a. was already put into operation at the end of 2006 (November). Due to technical modernization its actual capacity as of 2008 made up 740 thousand tons p.a. In May 2010 work the refinery’s flow phase II with the capacity of 2.75 million tons p.a. was commissioned. Therefore, after the commissioning of phase II the total capacity of the refinery amounted to 3.5 million tons p.a.

However, it is expected that in the course of the second phase modernization its capacity will grow to 3.3 million tons p.a. by the end of 2012 what will make it possible to achieve the overall refining capacity at the enterprise of 4.1 million tons.

Environment

Special attention was paid to the application of high technological standards in the course of building Antipinsky Oil Refinery. Of late against the background of growing oil production and refining volumes the issues of environmental protection and industrial security are of top priority for both, governmental structures and oil refining companies. Acute necessity for introducing no other but comprehensive measures at modern refineries aimed at minimizing the harmful effect on the environment due to industrial exploitation of oil refining facilities is noticed.

The ecology department of the Refinery’s accredited chemical analytical laboratory keeps regular monitoring of the environment, surface and waste water condition. To reduce impact on the environment a number of technological solutions were developed as the Refinery was designed in order to minimize water consumption and, consequently, waste water discharge and pollutant emissions to the atmosphere, as well as to avoid contamination of the soil and ground waters with oil and oil products.

Such solutions include as follows: - equip process furnaces with burner units which comply with the most stringent environmental requirements; - use a sealed system within the entire process flow;- control, computerize, and telemeter processes to prevent accidents, as well as minimize pollutant emissions to the atmosphere by strict adherence to the established; - provide for leak-proof filling of tanks with light oil products via gas equalizing lines with gas removal; - use air-cooling systems for process flows; - implement a water drainage system to avoid waste water discharge to surface waters; - construct concrete platforms for processing equipment and oil loading racks with guard rails and ladders.

Implementation of these solutions minimizes any eventual environmental damage. In addition to that Antipinsky Oil Refinery is building sewage treatment facilities which will provide for the treatment of technical, storm, service and household waste waters to the required extent making it possible to use purified waste waters repeatedly, or discharge them to a fishery water body.

Wastewater treatment facilities consist of three main blocks: 1. The physical-chemical wastewater treatment block (impeller flotation using Separation Specialists equipment). 2. The biological wastewater treatment block (the membrane bioreactor of GE Water and Process Technologies). 3. The wastewater post-treatment block (the process of dual filtration using FSU sorption carbon filters with subsequent UV disinfection of wastewaters as required by Sanitary Rules and Standards (SanPin) 2.1.5.980-00 “Hygienic Regulations For Surface Water Protection”).

In the aggregate wastewater treatment facilities occupy the area of 10.73 ha. The overall area of the enterprise’s territory exceeds 150 ha.

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 site is 15 ha. There are two either-direction tank filling racks making it possible to load 71 rail tankers at a time (what amounts to the RZhD rate) with a relay tank terminal of 20 thousand cu. m.

The FPS commissioning has increased the total estimated oil-product loading capacity of the refinery up to 8 million tons per year (the basic capacity is 3 million tons + 5 million tons of the FPS), it also lessened the load of functioning fill/discharge racks situated on the main area of the refinery. Empty tanks of the main area of the refinery will be used as relay both, now and in the future, what will make it possible to enhance the performance reliability of processing facilities and raise the enterprise’s productivity in the course of refining oil which, in part, is delivered by railway transport. The total volume of tank farms makes up 315 thousand tons.

Oil Reserves And Production
Over the year 2011 Antipinsky Oil Refinery CJSC yielded more than 2.6 million tons of products including diesel fuel of three kinds (winter, winter with additives, and winter compliant with GOST), directly distilled gasoline, residual oil. Besides, some 340 thousand tons were extracted and refined from Tarkhovskoe oil field. The corporate partner, Tarkhovskoe LLC, holds licenses for oil exploration, prospecting, and extraction within six licensed territories within which six developing oil fields are located (Yershovoe, Sorominskoe, Severo-Sorominskoe, Severo-Tarkhovskoe, Nikolskoe, Tul-Yoganskoe), plus one oil field is on the stage of prospecting. So, the 2011 turnover amounted to 2.94 million tons what is tantamount to more than USD 2 billion in money terms. Total current reserves of ABC1+C2 categories are as follows: geological reserves make up 75.1 million tons, extractable reserves - 8.45 million.

The Progress Of The Project Implementation On Increasing Capacities, Processing Depth, And Producing Euro-5 Fuel.
As of today the company refines crude oil subsequently producing technological fuel oil, bunker fuel, directly distilled gasoline, and diesel fuel according to both, GOST and Euro-2 standards.

The processing depth amounts to 60%, but Antipinsky Oil Refinery being an enterprise of efficient and sustainable development, builds plans on swelling volumes and increasing the oil processing depth .

Development Strategy Of Refinery Until 2016.

  1. To increase the refining capacity up to 7.5 million tons p.a. for which purpose the delivery-and-acceptance section will be reconstructed by December 1, 2012 in order to increase the oil pumping up to 6.0 million tons of oil through the trunk pipeline of JSC Transneft. Reconstruction of ELOU-AT-2 unit for the purpose of increasing its capacity from 2.5 to 3.3 million tons of crude p.a. will be completed by the end of October 2012. The commissioning of the new ELOU-AT-3 unit with the capacity of 3.5 million tons p.a. is scheduled for December 2013. A number of technical measures will be taken in order to integrate the facilities of the third work flow phase of construction in the current process of production. These are only the issues which refer to the increase of the refinery’s capacity. Within the framework of the 3rd phase of construction it is planned to commission treatment facilities for the purpose of purifying industrial sewage water. Presently construction works are carried out by general contractor Velesstroy, whereas the commencement of commissioning and adjustment works is scheduled for August- September 2013, so that the complete cycle of commissioning and adjustment works at the waste treatment facilities will have terminated prior to the commissioning of ELOU-AT-3 unit. In connection with increasing the refinery’s capacity it is required to build commodity and crude parks, what is now being done at two sites of the refinery: the diesel fuel park with the total storage capacity of 80 thousand tons is being mounted in the finished product sector and the crude oil park with the total storage capacity of 60 thousand tons is being constructed on the main site of the refinery. Naturally, to provide for the normal operation of production facilities off-sites are being built, including a boiler house, gas distribution substations, distribution substations, recycling water supply block, etc. This is, in general, the description of the 1st stage of the 3rd phase of construction and its completion is scheduled for the end of 2013.

  2. The second stage includes the construction of facilities making it possible to refine the components of commercial oil products obtained at units ELOU-AT-1, 2, 3, and subsequently achieve the quality of fuels compliant with EURO-5 European standards. The second stage will include diesel fuel hydrotreating units with the total capacity of 3.6 million tons of crude and a hydrogen production unit, Haldor Topsoe Danish company is the licensor. An elementary sulfur production unit with a granulation block of Canadian company ENERSUL and with the big-bag packaging line will also be constructed. Technological processes will be controlled from the central operator’s room from which control over the first and second phase facilities will be exercised, too. This solution has been applied for a long time and successfully at both, foreign and domestic oil refineries. This stage is to be commissioned at the end of 2014.

  3. The third stage is to be completed at the end of 2015. Provided that we achieve the processing depth of 75% at the first two stages, the construction of the fuel-oil vacuum distillation block with the capacity of 3.5 million tons and the deferred tar carbonization block will make it possible to increase the oil processing depth up to 92-95%. The licensor of the SYDECcm process is American company Foster Wheeler. In addition to that in 2016 high-octane gasoline production unit will be constructed which will consist of the reforming block with the catalyst permanent regeneration and isomerization block, what will enable us to produce high-octane Euro-5 gasoline with the basic octane number of at least 95 points. These kinds of gasoline are to be supplied to the domestic market in the volume of 0.5 million tons per year. The licensor of the technological process is UOP company, one of the world’s leaders in such processes.

  4. In 2017-2018 the gasoil hydrocracking unit is supposed to be commissioned.

We can speak about the technological constituent of the refinery’s development for a long time. Only main production facilities have been mentioned, and auxiliary facilities will occupy almost 1/3 of the refinery’s site. The road-tanker loading sector will be reconstructed, the storage facility for liquefied hydrocarbon gas, the refinery’s own mechanical repair shop, administration and utility complex, etc. will be built.

In addition to high quality kinds of gasoline the refinery is planning to produce coke which is in great demand in metallurgy, and the elementary sulfur (granulate) production unit is also to be installed.

The amount of investments in the project within the period between 2010 and 2015 is estimated at the level of USD 2 billion. One of the steps forward on the way of attaining the intended objective has become the signature in March 2012 of the multicurrency facility agreement on lending term and revolving credit lines to Antipinsky Oil Refinery for an overall amount of USD 750 million. This multicurrency facility agreement was signed by Gazprombank OJSC, Raiffeisen Bank International AG and Raiffeisenbank CJSC jointly with Glencore International AG, Vitol S.A., Globexbank, and WestLB AG (London).

The credit to be repaid in March 2017 consists of three tranches denominated in US dollars and Russian rubles with a security in the form of pre-export and project financing.

Antipinsky Oil Refinery CJSC occupies a worthy place on the Russian oil product market. Much attention is paid here to the recruitment policy which is aimed at quality selection of personnel with higher and specialized secondary education, as well as to social programs, such as the creation of healthy and safe labor environment.

The management team of the enterprise is sure that business will develop profitably only if people are trained efficiently, favorable conditions are provided to the company employees for their work and creativity when labor makes any employee happy both, morally and materially. That is why everything necessary is here for each employee to count on remuneration and career growth depending on his/her professional and personal contribution to the activity of the company.

As far as social programs are concerned the management team of the enterprise takes care of high quality medical service, supports its staffers through the system of different kinds of benefits and compensations, and, what is especially important, it strives to improve their living conditions.

Thus, by resolution of the Chairman of the Board of Directors, Mazurov D.P., a multi-family house with 152 flats is being built for the company’s professionals and foremost workers to be delivered by 2013.

One of the main spheres of social policy pursued by Antipinsky Oil Refinery CJSC is charity. For the entire period of its existence the enterprise has developed key areas of charitable assistance: it doesn’t use charitable organizations and foundations, but renders support directly to orphanages, boarding schools, clubs, cultural institutions, the Tyumen regional organization of the Russian national society of the. The efficiency of such approach to social policy is proved by friendly relations established between the enterprise and Orphanage No. 66, Municipal Educational Establishment, intended for orphans and children deprived of parental care.

The enterprise pays no less attention to sports by providing finance to one of the junior judo clubs in Tyumen. Besides, charitable assistance was rendered not so long ago for the purposes of preparation and hosting in the Tyumen Region of the XIIth Tourist Forum for disabled persons, “Robinsonada 2012.”

Strategic partners of Antipinsky Oil Refinery CJSC are the leading international companies among which there are «VITOL», «GLENCORE», «MERCURIA», «LITASCO».

Exposition Oil Gas
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