Pavlodar Oil Chemistry Refinery Upgrading Project and gas fractionation 1,25 ... • UOP (England)...
Transcript of Pavlodar Oil Chemistry Refinery Upgrading Project and gas fractionation 1,25 ... • UOP (England)...
Pavlodar Oil Chemistry Refinery
Upgrading Project
1971 – start of construction;
1978 – start-up and commissioning;
Since August 2009 – POCR LLP entered the Group of Companies of
“NC KazMunayGas” JSC.
General designer:
• 1971 – 1986 – “Giprogrozneft” (City of Grozny);
• since 1986 – Omskneftehimproekt OJSC (Omsk).
Design capacity – 6 mln.tons per annum;
Processing depth – 85%
Structure of the Refinery:
Name of products
• Motor gasoline, grades
RON 80, RON 92, RON 95, RON (K2);
• Jet fuel (ТС-1);
• Diesel fuel (K2 winter type, summer type);
• Fuel oil. Mazut;
• Petroleum Bitumen (structural, roofing, paving);
• Hydrocarbon liquefied fuel gas;
• Technical sulfur;
• Petroleum coke, not calcined;
• Vacuum gasoil.
History and Structure of the Refinery
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Name of units Capacity mln.tons per year
Complex LK-6U (1978)
CDU (ELOU-AT) 6
Gasoline hydrotreating 1,2
Catalytic reforming 1
Diesel fuel hydrotreating 2
Gas fractionation 0,45
Complex KT-1 (1983)
Vacuum distillation of mazut 4
Vacuum gasoil hydrotreating 2,4
Catalytic cracking 2
Absorption and gas fractionation 1,25
Waste-heat recovery -
Bitumen Production unit 0,5
Sulfur Production unit 25 th. tons/year
Delayed Coking Unit 1
Hydrogen Production Unit 31 th. Tons Nm/h
Scheme of main crude oil pipelines Russia-Kazakhstan-China
Atasu
supply from RussiaSupply of the Kazakh crude
Yurgamysh
Pavlodar
Atyrau
Samara
Omsk
Kenkiyak
KarakoinKumkol
Shymkent
5 mln.tons
• Agreement for transit of 7 mln. tons of crude oil.
• The Kazakh section of TON-2 (Tuimazy – Omsk – Novosibirsk-2) -185,6 km
• Increase in carrying capacity from 7 up to 10 mln. tons per year
(replacement of TON-2 pipeline section). The project cost - 32 billion of
Tenge
UfaTuimazy Crude oil quality
deterioration:
Sulfur- 1,6-1,8 %
• Kumkol
Kuatamlonmunay, Kazgermunay, Turgay Petroleum,
KazPetrolGroup, NC KOR, Souths-Oil.
• Kenkiyak
СНПС-Aktobemunaygas, Kazakhoil-Aktobe, Ada Oil
company, Alties Petroleum Ent. B.V.
The Kazakh section TON-2
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Crude oil extraction, export and processing over 2012-2016 (plan) (mln.tons)
79.2 81.7 80.8 79.4 77.472.9 72
62.2 60.9 60
14.2 14.2 14.9 14.1 13.6
0
10
20
30
40
50
60
70
80
90
2012 year 2013 year 2014 year 2015 year 2016 year
Extraction
Export
Processing
5.03 5.01
4.84.7
4.8 4.8
5.06
4.5 4.34.4 4.4
4.9
4.6
3.8
4
4.2
4.4
4.6
4.8
5
5.2
2012 year 2013 year 2014 year 2015 year 2016 year
POCR
PKOP
Atyrau Ref.
Crude Oil Processing in refineries of Kazakhstan over 2012 -2016 (plan) mln.tons
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Crude oil balance over 2010-2015 years (mln. tons)
Crude oil balance 2010 2011 2012 2013 2014 2015
Opening balance (changing) 3 498 4 776 5 121 3 228 4 706 6 876
1. Extraction of oil and gas condensate79 686 80 060 79 215 81 789 80 826 79 457
1. Import 7 047 7 751 6 094 7 037 0 0
2. Export 71 085 71 845 72 989 72 077 62 273 60 950
via pipeline 53 900 55 618 54 575 56 771 54 460 56 965
incl. Atyrau-Samara 15 100 15 427 15 432 15 375 13 885 13 490
incl. Caspian Pipeline Consortium 28 700 28 085 27 903 28 712 35 026 38 015
incl. Atasu - Alashankou 10 100 10 893 10 400 11 828 4 831 4 794
incl. Karachaganak Petroleum Operating-
Orenburg0 1 211 838 856 718 666
across marine port of Aktau 8 785 7 982 7 064 6 269 5 487 3 171
by railway 8 400 8 244 11 349 9 034 2 325 814
3. Transit of the Russian crude oil
(Rosneft) 6 985 6 900
4. Processed at refineries of
Kazakhstan13 682 13 725 14 213 14 296 14 911 14 171
The Kazakh crude oil processed 7 349 7 313 8 229 7 340 9 985 9 361
The Russian crude oil processed 7 021 7 155 5 983 6 956 4 926 4 810
5. Balance of crude oil 4 776 5 121 3 228 4 706 6 876 10 754
6. Processed by mini-refineries 688 1 321 881 975 1 472 833
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• Eni S.p.a, APS Engineering – FS development
• Technip S.p.a, Kazgiproneftetrans, VNIPIneft JSC – front end engineering
design development
• Omskneftehimproekt PJSC – development of detail documentation
• UOP (England) – Vacuum Gasoil Hydrotreating, Catalytic Cracking,
Isomerization and Naphtha Splitter.
• Siirtec Nigi (Italy) – sulfur recovery and tail gas treatment
• Rominserv S.R.L. (Romania) / Vladimirteplomontazh – ЕРС-contractor for
Isomerization and Naphtha Splitter
• NFC (China) – ЕРС contractor of Sulfur Recovery Complex
• Haldor Topsoe (Denmark) – hydrotreating of naphtha, hydrotreating of diesel
fuel and kerosene
Project mission:
Production of motor fuels of environmental class К4, К5
according to requirements of the Technical Regulation of the
Customs Union.
Main financing figures of the
Project:
Total cost of the Project -
616 mln. US dollars
PBР – 10 years;
IRR – 4,12%
Pavlodar Refinery Upgrading Project
Start of commissioning works – May 2017.
Completion of commissioning works – July/August 2017.
Completion of reconstruction and production of diesel fuel К5 – end of 2017.
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Companies - partners
Rominserv S.R.L/ Vladimirteplomontazh/NFC
Cost of scope of work - $ 616 million
Feed – West-Siberian crude oil
New units:
Isomerization unit (571 th. t/ year);
Naphtha Splitter (1961 th. t/ year)
Sulfur recovery unit and tail gas treatment
Amine regeneration unit
Sulfur granulation unit
Sour water stripper (2 lines)
Automated gasoline blending station
2 isomerate tanks
Utilities and Offsites
Reconstruction of the existing units
− CDU (ELOU-AT) (capacity – 6 mln. t / year);
− Catalytic Reforming (capacity – 1 mln. t / year);
Licensor UOP
− Vacuum Gasoil Hydrotreating (capacity – 2,4
mln. t / year);
- Catalytic cracking*
*capacity increase from1 200 up to 1 900 th.t/year. 2003 reconstruction was made with capacity
decrease from 1925 to 1200 th. t /year.
Licensor Haldor Topsоe
− Naphtha Hydrotreating
− DHT and KHT (capacity – 2 mln. t/ year/ 364
th. t/year).
ЕРС Rominserv S.R.L
Cost of scope of work - $ 1072 million
Feed – West-Siberian crude oil/ the Kazakhstani crude oil
New units:
Licensor UOP
Hydrotreating and dewaxing of diesel fuel, kerosene
fraction;
LPG teratment (Merox) ;
Isomerization unit (571 th. t/ year);
Naphtha Splitter (1961 th. t/ year);
Licensor Siirtec Nigi
Sulfur recovery unit and tail gas treatment
Not licensed units
Amine regeneration unit
Sulfur granulation unit
Sour water stripper (2 lines)
Automated gasoline blending station
Automated fuel oil blending station
Utilities and Offsites
18 new tanks
Reconstruction of existing units
− CDU (ELOU-AT) ( capacity – 6 mln. t/year);
Licensor UOP
− Catalytic Reforming (capacity – 1 mln. t/ year);
− Conversion of the existing DHT to Coker Naphtha
Hydrotreating;
− Hydrotreating of vacuum gasoil (capacity – 2,4 mln.
t/year);
− С-200 – Catalytic cracking (capacity – 1,9 mln. t/ year);
- 456 mln.$
Reasons for
optimization
Prolongation of the
Agreement between
Russia and Kazakhstan
for crude oil supply
SWAP-operations not less
than 7 mln. t/ year
Guaranteed supplies of the
Russian crude oil
Project Optimization
No need to process the
Kazakhstani crude oil
Worldwide deterioration
in economic situation
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Pavlodar Refinery Upgrading Project
Pavlodar Oil Chemistry Refinery LLP
Cost of scope of work - $ 284 millionRominservS.R.L / Vladimirteplomontazh JSC
Cost of scope of work - $ 332 million
Sulfur Recovery Complex:
Sulfur recovery unit and tail gas treatment
Amine regeneration unit
Sulfur granulation unit
Sour water stripper (2 lines)
Isomerization Complex:
Isomerization Unit (571 thousand t/year);
Naphtha Splitter (1961 thousand t/year);
Reconstruction of the existing units
Utilities and Offsites
Utilities and Offsites
Total cost of project implementation - 616 mln. USD
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Licensor and Basic Design Developer -
UOP (England)
Project development – Technip (Italy)
EPC contractor –
Rominserv S.R.L. (Romania) / Vladimirteplomontazh JSC
Isomerization Unit - 571 000 t/ year
Naphtha Splitter Unit - 1,961 mln. t/ year
Product – component of motor gasoline (isomerate)
Commissioning – 2017
Complex of Isomerization and Naphtha Splitter Units
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May 2015 April 2016 November 2016
Chronology of construction. Isomerization Complex
October 2015 November 2016April 2016
Start of construction – May 201510
Concrete works- 95%, installation of metal structures - 98%, installation of equipment- 97%
March 2016 July 2016
Chronology of Utilities and Offsites Construction
June 2016 November 2016 June 2016
Start of construction – March 2016.
November 2016
Main Control Room
Implemented U/O objects:
Cooling water system and water towers, plant air and instrument air unit, caustic supply and removal system, fire-fighting
system, nitrogen distribution system, flare system, interconnecting racks, system of demineralized water and condensate return.
Plant Air and Instrument Air Unit
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POCR – Client
NFC (China) – ЕРС Contractor
Siirtec Nigi (Italy) – Licensor and Basic Design
Developer
Capacity - 60 000 tons/year
Commissioning – 2017
Complex of Sulfur Recovery Units
Composition of complex:
Sulfur recovery unit and tail gas treatment
Sour water stripper (2 lines)
Amine regeneration unit
Sulfur granulation unit
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August 2015 January 2016
Chronology of construction. Complex of Sulfur Recovery Unit.
March 2016 November 2016 July 2016
Start of construction – August 2015
November 2016
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Concrete works - 96%, installation of metal structures - 99%, installation of equipment - 97%
Reconstruction of LK and KT complexes
Column К-301 (LK-6U)
Replacement of 23 sets of valve trays.
Producer: KOCH GLITCH
Column К-102 (LK-6U)
Replacement of 23 sets of valve trays.
Producer: KOCH GLITCH
Reactors of Vacuum Gasoil Hydrotreating
Replacement of 2 reactors.
Producer: Volgogradneftemash
In accordance with UOP Basic Design reactors of vacuum gasoil
hydrotreating were replaced
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FCC Reconstruction based on UOP Technology
Works within shutdown period of 2016:
• Replacement of internals of the main FCC
rectification column
• Assembly of domes with cyclones
• Works on lining
Plan of works within shutdown period of
2017:
• Replacement of dome with cyclones in
reactor-regenerator section
• Replacement of feed injection to reactor
UOP – licensor of the process, developer of Basic Design
NEFTEHIMPROEKT CJSC – detail documentation designer
Grif management – supplier of the main equipment for reactor-regenerator section
HASON – authorized manufacturer of UOP
EMTROL-BUELL – technical support of equipment manufacturing
OMUS-1 – Executor of construction and assembly works
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Production of internal devices for reconstruction of reactor-regenerator section
of catalytic cracking at HASON plant
Hason – authorized manufacturing plant according to UOP recommendation
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Hason plant manufactured:
8 two-stage cyclones of regenerator
6 one-stage cyclones of reactor
Segments of dome parts and receivers of reactor and regenerator
Regenerator air distributor
Replacement of heads of reactor and regenerator with collection chambers
and groups of cyclones
Replacement of ballistic separator of reactor R-201 with vortex
separation system, replacement of riser section Replacement of cascade trays of stripper section of reactor R-201 with AF
packing systemReplacement of reactor steam distributorsReplacement of Y-shaped section of reactor, reactor feed distributor
Replacement of remaining part of lining
Replacement of overhead line №201 of reactor R-201
Replacement of gate valves and hydraulic drives of transport lines
Replacement of air distributor of regenerator
Mechanical works
Application of lining to new domes and
collection chambers of reactor R-201
and regenerator R-202
Planned scope of lining replacement
Additional scope of lining replacement
Lining replaced in 2015
Replacement of lining in 2016 :
Replacement of the remaining lining in 2017
Works on replacement of lining
Reconstruction of Catalytic Cracking based on UOP technology
Work on replacement of lining is performed
by Aliter Axi
Reconstruction of reactor-regenerator section. Internal devices are going to be replaced with application of lining without
replacement of apparatus casing
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Production of jet fuel with
sulfur content less than 10
ppm
Reconstruction of Hydrotreating Units based on Haldor Topsoe technology
New equipment 25 units
Vessel 4
Heat-exchanging
equipment4
Heat-exchanging
equipment7
Heaters 2
Rectification column 1
Filters and internals 7
Increase in productivity up to 1,2 mln.
tons per year;
Preparation of feed for isomerization
unit and catalytic reforming):
New equipment 7 units
Vessel 1
Pumping equipment 2
Heat-exchanging
equipment2
Feed filters 2
Guarantee of diesel fuel
production (summer type) of K5
ecological class
New equipment 13 units
Reactor 2
Vessel 4
Pumping equipment 4
Heat-exchanging
equipment1
Feed filters 2
Naphtha Hydrotreating Diesel fuel Hydrotreating Kerosene Hydrotreating
Rectification column K-202 of Naphtha
Hydrotreating Unit18
Transportation Route of DHT Reactors
Mipo Port
Novyy Port
4 000 km
10 000 km(5,500 miles)
POCR jetty
jetty
POCR
Total length is 14 000 km
19 km
17th of July
25th of August
2nd of October
Manufacturer –HYUNDAI HEAVY INDUSTRIES 19
Delivery of diesel fuel hydrotreating reactors
17th of July shipping of reactors, Mipo port, South Korea
19th of September completion of foundations assembling
25th of August transshipment of reactors to river barges
2nd of October delivery of reactors to temporary jetty
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Conclusion
Completion date and quality of products
Implementation of POCR Upgrading project shall be finished in 2017 with production of motor fuels of К4
and К5 ecological classes (analogue of Euro 4 and Euro 5).
Technologies
In the process of Pavlodar Refinery Upgrading the advanced technologies and experience of leading
worldwide companies were applied.
Project optimization
Optimization allowed reducing of capital expenses by 456 mln. US dollars.
Training and experience exchange
To maintain new units there was 161 new workplaces created. The personnel was trained and had
extension courses in the refinery (Atyrau), in Yokogawa offices, on simulating equipment of NFC (China)
and T-soft (St.-Petersburg).
The refinery staff has got the experience in upgrading project management for crude oil processing.
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Thank you for your attention!