The project of oil refinery

ЭнергопроминжинирингЭнергопроминжиниринг

Limited Liability Company

Energopromengineering The project of oil refinery

with the capacity of 500 thousand/tons a year

Modern innovative technologies – the basis of effective economy

2011


General information

Company’s objectiveCompany’s objective – continuous development, competitiveness, success and being number one partner for our customers and partners.

SpecialistsSpecialists – high qualification and considerable experience in completing special, challenging and unconventional tasks, a lot of specialists have academic degrees of Ph.D. in Economics and Cand.Sc. (Engineering).

Major competencies Major competencies – design, engineering, management of investment and innovation-based projects of power engineering and infrastructure, OR (oil refinery) designing and construction.

The Company’s MissionThe Company’s Mission is an effective technical support of preparation and implementation of the projects in the sphere of electric power industry, FEC (fuel - energy complex), infrastructure, complex decisions concerning the city waste management, working with hazardous wastes, land recultivation.


Company’s profile

Energopromengineering is a modern company which provides a wide complex of services on design and construction of energy and infrastructure facilities.all the stages of project management: from the idea and designing to the facilities construction on turnkey terms.

exercise of the General Designer’s and Prime Contractor’s functions

accomplishment of designing, construction, installation and commissioning works.

service maintenance and routine maintenance of different facilities.

considerable and successful cooperation experience with business corporations, financial institutions and administrative agencies

company employees’ professional experience when implementing Russian and international projects in the sphere of electric power engineering and wastes reclamation.


Types of activity

Electric power plants

Power transmission lines

Transformer substations Water supply:

Water conditioning and water drain

Routine maintenance

Repair operations

Design and construction Operation

Power engineering facilities

Highway construction

Gas supply

Heat supply

Infrastructure projects

Wastes reclamation: garbage recycling plants, garbage

sorting lines, hazardous wastes

reclamation

FEC (fuel - energy complex)

OR (oil refinery)

Oil and gas pipeline

OPS, GPS (oil and gas pumping stations)


Technical Proposal for Oil Refinery construction

• A planned for the construction OR is meant at the first stage for the capacity of 500 thousand tons of raw stock per year. As a raw stock the project presupposes the oil with average output of light oils up to 63% (at the boiling temperature up to 3700С), with paraffin content up to 2.0% and mass fraction of sulphur up to 3.5%.

Our company has possibility to optimize the project construction and operation oil refinery on the block-modular delivery of the process equipment, with capacity of each module on primary processing to 1 million tons per year. Consecutive input in a system of necessary quantity of modules with possibility of processing of a various kind of raw (light, heavy oil from different fields, gas condensates and their mixes) allows to diversify source of raw material. The planned for application processing equipment will provide high economic indicators and reasonable term of the project payback. The products manufactured at OR will meet all the requirements imposed to these products by the customer.Design, production of all the process equipment and personnel training is performed in Russia, by forces the Russian companies and specialists. The expendables necessary for functioning OR are produced and supplied from Russia.


Since 2005 a new method of oil stock refining and oil-refining plants on its basis was put into practice and used successfully.

The given method is called “Vortex rectification”. Non-traditional method is noted for high environmental friendliness (in contrast to the traditional arrangement there is no need to collect liquid wastes – oil slimes – they are absent), atmospheric emissions do not differ from internal-combustion engines exhausts.

The method of raw hydrocarbon rectification is based on flashing evaporation and step-by-step cooling at each stage of rectification.

The new thing is that the separation into vapor and liquid phase at all the stages of rectification is made in cyclone evaporators – separators, the structure of which provides not only effective separation of vapor and liquid phases in the process of vortex movement, but also effectively restricts the outlet of sinking fractions vapor together with the vapor of light fractions to the next stage of rectification. In such a manner, the realized approach is based on gasdynamic task solution of the hydrocarbon separation into fractions.

The advantages of the process is that it enables to refine successfully at one and the same processing plant using the “vortex rectification” method both light and heavy oil, gas-condensates and raw hydrocarbon mixtures.

The experience of such a method practical usage has revealed its additional advantages in the process of raw hydrocarbon refining, new spheres of usage and new effective opportunities of oil refining.

The plants with the capacity of charge stock from 10 tons a day up to 600 thousand tons of oil per year (Russia, Ukraine, Kazakhstan) have been developed and constructed.

Vortex rectification

Refinery procedure


Qualitative measure Vortex rectification Traditional

arrangement

Simplicity and reliability of servicing. + -

High level of safety – the pressure in processing line is close to the atmospheric one. +with additional safety

measures

Insensitivity to the variations of the refined charge stock percentage composition when the plant has to operate with different types of charge stock (in practice, this allows to refine at one and the same plant both light and heavy oil, clear and dark gas-condensate, as well as to re-refine faulty oil products).

+ -

High percentage output of clear fractions with maintenance of the fuel qualitative indicators. +Is achieved for the

plants of high productive capacity

During the plant operation with the majority of oil grades the octane number of the directly distilled gasoline according to motor method is by 5-6 units higher than the analogous coefficient for traditional plants of column type.

+ -

Low materials consumption of the equipment. + -

Just in 40 – 50 minutes after start-up the plant reaches the qualitative operation mode. + -

The possibility to refine raw hydrocarbon with an in creased water content (up to 8%) + -

Vortex rectification The process advantagesThe mentioned advantages of the plants enable to use them in the following spheres:

universal, effective and trouble-free oil-refining equipment for motor and power-plant fuels receipt. general-purpose equipment for oil slimes refining. oil-refining plants based on the principals of “Vortex rectification” are successfully operated under climatic conditions

from +450С to –450С.


Oil Refinery Process Flow Scheme

hydrocarbon gases

Gas fractionation

unit

hydrocarbon gases

hydrocarbon gases

hydrocarbon gases

hydrocarbon gases

Clean HCGM

Hydrogen

Reforming

Hydrogen

Hydrogen

HCGM for sweeteningHydrogen

production

Sulphides

Gas to fuel system

Gases sweetening

Gasoline to farm

Gasoline to farm

Gasoline to farm

Diesel fuel to farm

Sulfur production

Sulphides

Sulphides

Gasoline to farmResidue

TarBitumen

production Bitumen to farm

Sulphur to farm

Diesel Fraction

Light vacuum gasoil

Heavy gasoil Thermal cracking

DF hydrotreater

Gasoline fraction

hydrotreater

Gasoline fractionFeed stock

Atmospheric distillation


OR plants

Ц 44/500 – primary oil processing unit, fractionation of oil.

Hydrotreater – unit for fuel fractions hydrotreatment from sulphides.

Thermal cracking – unit for advanced refining of black oil with the purpose of light hydrocarbons production.

Reforming –high-octane petrol production unit.

Bitumen production – tar oxidation unit for bitumen production.

Sulphur production – Klaus unit for granulated sulphur production.

GFU – gas-fractionation unit.

Hydrogen production unit

DF – diesel fuel

HCGM – hydrocarbon gases mixture

HG – hydrocarbon gas

OR process flow scheme list of plantsInterpretation of the accepted abbreviations


Atmospheric distillation

on the basis on the cyclone type unit with the unit of the production raw stock topping with the capacity of 500 thousand tons of raw stock a year.

ensures stable indicators of the production quality at the refining capacity from 25% to 110% from rating value.

enables to refine light and heavy oil, gas-condensate and their mixtures, as well as oil-slimes without loss of quality.

enables to get up to 5 oil fractions: light and heavy gasoline fractions (for secondary processes usability), illuminating oil, diesel fuel and black oil.

the received directly distilled gasoline possesses an increased octane number compared with traditional atmospheric distillation (minimum 5-6 units more according to motor method): so, for the oil – up to 72 units according to motor method, and for gas-condensate – up to 75 units according to motor method.

the unit maintenance personnel – 2 operators per shift

Atmospheric distillation unit


Thermal cracking

Black oil thermal cracking plant

the plant with the capacity of 200 thousand tons of raw stock a year ensures stable indicators of the production quality with the refining capacity from 25% to

120% from rating value. the possibility of operation in the mode of direct atmospheric oil distillation with the

capacity up to 250 thousand tons of crude oil a year. increasing of oil refining depth (output of light oils) up to 73-84% the possibility of refining with the help of thermal cracking method both black oil and

vacuum gas-oil with cracking-gasoline production, as well as furnace oil and hydrocarbon gases

the plant maintenance personnel – 2 operators per shift


Black oil vacuum distillation plant

with the capacity up to 200 thousand tons of black oil a year.

vacuum gas-oil production (for its refining with thermal cracking and cracking gasoline production, furnace oil and hydrocarbon gases), and tar – raw stock for paving and construction bitumen.

the plant maintenance personnel – 2 operators a shift.

Vacuum distillation


Bitumen production

Tar oxidation plant

with the capacity up to 100 thousand tons of bitumen a year.

paving and construction bitumen production using tar oxidation method.



Gasoline hydrotreater

with the capacity up to 150 thousand tons of raw stock a year.

gasoline sweetening up to European standards .


Hydrotreating


Diesel hydrotreater

with the capacity up to 200 thousand tons of raw stock a year.

diesel sweetening up to European standards.


Hydrotreating


Catalytic reforming and hydrogenation plant

petrol fractions hydrocarbons reforming.

two-reactors scheme implementation enables the receiving of the petrol high-octane component with a decreased content of aromatics – conformance to the requirements of the European standards gasoline.


Reforming


Motor fuel components blending unit

mixed high-octane gasoline production, corresponding to European standards.

received gasoline fractional analysis optimization.


Compounding


Gas-fractionation plant

enables the separation and division of oil

refining residual gases for their further

utilization in the process flow.

the plant maintenance personnel – 2

operators a shift.

Gase separation

Hydrogen sulphide removal unit

enables the utilization of hydrogen sulphide

and production of technological sulphur,

sulphuric acid.

the plant maintenance personnel – 2

operators a shift.


Discharge, loading

the plant infrastructure with the capacity of 500 thousand tons/year should include the

railroad overpass that enables the discharge/loading of raw stock and finished product,

or terminals of pipeline and/or water transport.

the shipping of short-run batches of products into road tankers is also possible.


Summary

As a result of the suggested effective technological solutions realization the minimum

processing depth will be 72,5%, and maximum – 87,5% (depending upon the season and

the product line defined by the sponsor).

Production output corresponding to norms of European standards.

The suggested scheme involves the autonomous electrical energy consumption and

low water consumption during the compact location of plants, as well as minimum impact

on the environment.

High degree of automation provides a small number of personnel.

The possibility of electric power supply to the nearest inhabited localities is provided.


Marketable products

The oil refinement (products for sale) in such oil refineries under the condition of the refinement of all the black oil at vacuum distillation plant, with production of maximum amount of bitumen and with thermal cracking of all the received vacuum gas-oil will be presented in the following way (in terms of charge stock in mass fractions):

Petrol Аi95, Аi96 30.0 – 34.0%

Diesel fuel 35.0 – 38.0%

Black oil

Fuel oil

15.0 – 20.0%4.0 – 6.0%

Bitumen 8.5 – 9%

In-plant fuel

process fuel 1,0 – 1,5%

gases 6,0 – 6,5%


The list of output products

Petrol of the European standards

Diesel of the European standards fuel

Black oil

Paving bitumen

Construction bitumen

Sulphur


Automated Process Control System

Indicators of the available Process Control System

Automation system SCADA provides the centralized control of the facilities condition,

the alarm system of the parameters deviation from the norm, process parameters

regulation, facilities operation remote control, protection (stop action) of processing

equipment, journal of emergency and process events composition, database maintenance.

Automation system provides the operation of the automation object around-the-clock

with all the necessary parameters output at the operator’s automation equipped working

place .


Laboratory

the laboratory uses standardized and licensed equipment at which the analysis

according to the standard GOST, API, ASTM are made.

each lot of the production output receives a passport.

continuous quality control of the production output is carried out.

the laboratory maintenance personnel – 1 laboratory assistant a shift.

Certified laboratory


Resources

Resources requirement

Land resource. for the construction of complex Oil Refinery 30 ha of land with the area of 370х800 meters is required.

Water needs.to meet the water needs of the plant the water volume up to 100 m3/day will be enough.

Electric powerto meet the electric power needs of the plant the power equal to 800 kV will be enough.


Resources

Main technical and engineering personnel of the oil refinery

ItemFacility Profession, qualification Total

1. Discharge/loading railroad overpass Operator (worker) 16

2. Discharge/loading auto overpass Operator (worker) 8

3. Product/raw stock farm Operator (worker) 8

4. Plant Ц44/500 Operator (engineer) 8

5. Thermal cracking plant Ц42/200TK Operator (engineer) 8

6. Black oil vacuumization plant Operator (engineer) 8

7. Bitumen preparation and oxidation plant Operator (engineer) 8

8. Diesel hydrotreater Operator (engineer) 8

9. Gasoline hydrotreater Operator (engineer) 8

10. Hydrogen sulphide removal unit Operator (engineer) 8

11. Reforming Operator (engineer) 8

12. OR (oil refinery) Technologist 4

13. Instrumentation and automation service Instrument tender on duty 8

14. Electrician service Electrician on duty 4

15. Laboratory Shift supervisorLaboratory assistant

48

16. Mechanical engineer service Shift fitter 8

TOTAL: 132


Qualification

Personnel training

during the equipment installation the Oil Refinery personnel training will take place.

training will take place in real time.

required professionalism: minimum secondary technical education.

the training of plant operators, discharge/loading overpass operators, technologists will

take place.


Products-Raw stock farm

Raw stock tank farm consists of:for oil – of 3 pieces of vertical tanks with a total capacity of 15000 m3, including: 5000 m3- 3 pcs.

Products tank farm consists of:for petrol – of 5 pieces of vertical tanks with a total capacity of 15000 m3, including: 3000m3- 5 pcs;

for diesel fuel – of 3 pieces of vertical tanks with a total capacity of 9000 m3, including: 3000m3 – 3 pcs;

for black oil – of 3 pieces of vertical tanks with a total capacity of 15000m3, including: 5000m3 – 3 pcs;

for kerosene – of 2 pieces of vertical tanks with a total capacity of 400m3, including: 200m3 – 2 pcs;

for cracking residues – of 3 pieces of vertical tanks with a total capacity of 9000 m3, including: 3000m3 – 3 pcs;

for paving and construction bitumen: of 6 pieces of vertical tanks with a total capacity of 4800 m3, including:

800m3 – 6 pcs;


Period for delivery and installation

the equipment delivery will start in 7 months after the beginning of financing.

to get through procedures of customs the delivery of full- complete equipment is

considered to be the optimal one according to the time period.

installation and commissioning works for different plants are from 3 to 5 months.


Commissioning schedule

Item Equipment Commissioning period (months from the beginning of general financing)

1 Plant Ц44/500 14

2 Gas fractionation plant 14

3 Plant Ц42/200TK 16

4 Reforming 18

5 Black oil vacuumization plant 19

6 Bitumen oxidation plant 20

7 Diesel hydrotreater 22

8 Gasoline hydrotreater 22


Partners

Institute of Hydrocarbons Processing of the Siberian Branch of the RAS of the Russian Academy

of sciences

Research and Development Enterprise

The fund “National Environmental Management and Cleaner Production Center for Oil and Gas

Industries”

Tomskneftegasproekt LLCdesign and engineering

Geological surveys and geophysical activitiesgeodesic and cartographic activities


Russian licenses and certifications

The Company possesses all authorizations and certificates required to conduct its activities connected with design, preparation and organization of construction, reconstruction, overhaul, engineering and technical operations (including specially dangerous units) within the RF, as well as engineering-geodesic, engineering-geological, engineering-ecological survey, the activities in the sphere of energy survey.

The Company implements the Quality Management System (GOST R ISO 9001-2008/ISO 9001:2008)) and the Occupational Health and Safety Management System (GOST 12.0.230-2007/OHSAS 18001:2007).

The Company is completing the certificates receiving for energy audit of municipal housing economy units.


Contact us

Address: 107076, Russia, Moscow City, Elektrozavodskaya Street, b.33, constr. 4

Telephone/fax : +7 495 643-18-79

Website: www.en-prom.ru

Zaurbek Khuchiyev

Chief Project Engineer

mob.: +7 968 865 88 34

E-mail: [email protected]

The project of oil refinery

Business

Transcript of The project of oil refinery