Precommissioning of the Delayed Coking Unit, the second section of the Atmospheric Residue Deep Conversion Unit, started Antipinsky Oil Refinery on June 1, 2016. The first coke, a final product used in the metallurgy, was produced during the active phase of precommissioning of the Delayed Coking Unit, on June 26, 2016.
The commissioning of the Atmospheric Residue Deep Conversion Unit meant the completion of construction of the 3 stage of the III start-up complex as a result of which Antipinsky Oil Refinery, the only commercial oil refinery in Tyumen region and Ural Federal District, will attain the record refining depth of 97-98% in Russia and increase the share of diesel oil in its production output up to 50% of the total refining capacity. Thanks to the introduction of new processes, Antipinsky Oil Refinery enters the new quality level and expands its presence and influence not only on the oil refining market of Ural and West-Siberian, but also among the largest participants of the oil refining industry of Russia.
For the purpose of implementation of the project, the management and specialists of Antipinsky Oil Refinery selected the leading companies for the design and construction of oil facilities. The model front end engineering design of the Atmospheric Residue Deep Conversion Unit with the annual capacity of 3.3 million tons of fuel oil (after modernization – 4.4 million tons) in 2012 was developed by Foster Wheeler, a US company and one of the world leaders in the design and operation of similar units. The working documentation was developed by JSC Neftechimproject that had significant experience in this area; Yunix, a Limited Liability Company, which has implemented a number of large construction projects was selected as the General Contractor.
When selecting the design, the top specialists of Antipinsky Oil Refinery and developer proceeded, first of all, from the total production capacity of the company. In accordance with the general schedule with the master oil refining plan, this figure made 8 million tons upon approving of the design; that is why the Atmospheric Residue Deep Conversion Unit was divided into two sections: Vacuum Section and Delayed Coking Section. According to Murzin Sergey Vladimirovich, Chief Engineer of Antipinsky Oil Refinery, “this was a good compromise allowing, on the one part, to optimize the cost of the final design and, on the other side, to consider the refining opportunities of Antipinsky Oil Refinery.” The solution also included the automation of the vacuum section in the principal communication and heat balance: in particular, the commissioning of the vacuum station that could be done before completion of construction of the Delayed Coking Section with its test operation in different modes.
Equipment of both foreign manufacturers: Gould Pumps (South Korea), KSB (Germany), Zimmermann&Jansen (Germany), RuhrPumpen (Germany), Koerting Honnover AG (Germany), Foster Wheeler Italiana, Koch-Glitsch (Italy), GARO (Italy), Brembana&Rolle (Italy), FELGUERA CALDERERIA PESADA, S.A. (Spain), Taim Weser (Spain), Velan (Canada), Elliot (USA), etc. and domestic manufacturers: Uraltechnostroy-Tuymazychimmash, Glazovsky Zavod Chimmash, Company Tapflo, Tambovsky Zavod Komsomolets, Hydrogas, etc. was used for the construction of the Atmospheric Residue Deep Conversion Unit.
To operate the Atmospheric Residue Deep Conversion Unit at Antipinsky Oil Refinery, a special shop was established with 60 operators all of which, before being permitted to operate the Atmospheric Residue Deep Conversion Unit, were trained by the representatives of the front end engineering designer and supplier of compressors.
The main target products at the Delayed Coking Section are light coking gasoil, and coking naphta which are supplied as feedstock to the diesel oil hydro treating unit and add the value. The bulk-coke yield makes about 30% of the crude oil (acid residue); the remaining portion consists of the target light products. Another target product is coking liquefied hydrocarbon gas which will be commercially produced after commissioning of the naphtha hydro treatment and liquefied hydrocarbon gases.
The current primary tasks are to preserve the production capacities of Antipinsky Oil Refinery at the level of more than 8 million tons and complete atop of production of atmospheric residue. For this purpose, the management of Antipinsky Oil Refinery studies two modes of operation of the Delayed Coking Unit: with the production both of electrode coke and coking additive. After the section is put into operation in the design mode, the data will be analyzed to reach maximum balanced output of hydrocarbon oils and coke.
It should be noted that the cost of the Atmospheric Residue Deep Conversion Unit that consists of the Delayed Coking Unit and Atmospheric Residue Vacuum Unit which are operated jointly with the hydrogen refining facility as part of the Diesel Oil Hydrotreating Unit, Hydrogen Unit and Elemental Sulfur Unit made 1.5 billion US Dollars.
While the unit is at the stage of precommissioning and preparation for the full-cycle operation, Antipinsky Oil Refinery has already started the project of modernization of the unit to increase the production capacity of the Delayed Coking Section. The project has been completed with the purchase of equipment; it only remains to approve the ultimate manifold solutions. As a result of modernization of the Delayed Coking Unit, the annual Atmospheric Residue refining capacity will increase from 3.3 million tons of fuel oil up to 4.2 million tons.
After the Atmospheric Residue Deep Conversion Unit is commissioned, Antipinsky Oil Refinery will halt the production of all previously produced types of Atmospheric Residue and attain the industry record in the refining depth (97-98%). According to the Chief Engineer, Sergey Vladimirovich Murzine, “we have dropped out of the niche of a small-tonnage facility. We have very good perspectives. The operation of the Atmospheric Residue Deep Conversion Unit means the deeper and deeper refining up to 97-98%.”Dmitry Petrovich Mazurov, Chairman of the Board of Directors of JSC Antipinsky Oil Refinery, points out that "the Refinery has passed the important milestone on the way of introduction of advanced oil refining and set a firm course for production of the bigger quantity of light oil products, including Euro-5 high octane gasoline".