March 25, 2014
Antipinsky Oil Refinery: Tyumen Potential In Oil Refining
Antipinsky Oil Refinery is unique because it is a private but not a state-run project the capacity of which will reach 7.5 million tons p.a. (in 2013) and the quality of its oil-product output will comply with Euro-5 standard (diesel in 2014, gasoline in 2016), whereas the processing depth [refining efficiency] will increase up to 94% (in 2015). More than 2.9 million tons of crude were refined at Antipinsky over the year 2012. It should be noted that some 345 thousand tons were produced and refined using the oilfield of our corporate partner Tarkhovskoe LLC.
Phase by phase
Antipinsky Oil Refinery CJSC was founded in July 2004 on the territory of one of the largest oil-and-gas constituents 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 with the estimated capacity of 400 thousand tons p.a. was commissioned already in November 2006. Due to technological modernization as of 2008 its actual capacity amounted to 740 thousand tons p.a..
In May 2010, the II workflow phase of the refinery with the capacity of 2.75 million tons per year was commissioned. Thus, due to the commissioning of the II phase the overall capacity of the refinery made up 3.5 million tons p.a.. After the II phase modernization in 2012 the aggregate capacity of the enterprise (the first and second workflow phases) amounted to 4.2 million tons p.a..
Antipinsky Oil Refinery CJSC has acquired and repaired Antipino Railway Station for its own industrial purposes in the vicinity of which it has built a finished products sector (FPS) intended for 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 sector occupies 15 hectares. On the territory of the sector there are two either-direction tank filling racks making it possible to load 71 rail tankers (in compliance with the Russian Railways Rules) with an indirect tank farm of the volume of 20 thousand cu.m.
The FPS commissioning has increased the aggregate oil-product loading capacity of the refinery up to 8 million tons p.a. (thee million tons of the basic capacity plus five million tons of the FPS) and lessened the load on filling/discharge racks in the main area of the refinery. The empty tanks of the main site of the refinery will be used as intermediate. In the perspective it will make it possible to enhance the reliability of operation of process facilities and raise the refining efficiency of crude, including that delivered by rail. The total volume of the refinery’s tank farms exceeds 315 thousand tons.
Increasing oil refining efficiency
The construction of the III workflow phase ((Velesstroy LLC is the General Contractor) is to be completed at the enterprise in several stages. ALOU-AT-3 unit with the capacity of 3.7 million tons p.a. will be commissioned at the first stage, which will swell the enterprise’s crude oil refining capacity 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-grade 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 meeting the strictest environmental standards. This stage will be completed in the fourth quarter of 2013.
The second stage of the III workflow phase is aimed at improving the quality of produced diesel fuel as required by Euro-5 standards (with the sulfur content not exceeding 10 ppm) and at ensuring the necessary freezing temperature so that winter and arctic diesel fuels can be produced. For this purpose the diesel-fuel hydrotreating unit will be built at the enterprise (Danish company Haldor Topsoe is the licenser of the process and the developer of the basic project). Its operation will be ensured by hydrogen production units and elemental sulfur production units with the granulation block. The second stage will be completed in the fourth quarter of 2014.
No enterprise of similar capacity has been commissioned on the territory of the Russian Federation over the past 30 years, except Taneko, but it is a state-run company whereas Antipinsky Oil Refinery is private. The leading international companies VITOL, GLENCORE, MERCURIA, LITASC0 are among strategic partners of Antipinsky Oil Refinery CJSC.
On January 29, 2013 at nine o’clock a.m. the ten-millionth ton of crude oil was refined at the enterprise.
At the third stage of the III workflow phase the oil processing depth [refining efficiency] will increase up to 94% due to the commissioning in the fourth 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 refining output. American company FosterWheeler 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 the first and second quarters of 2016 the enterprise plans 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. It will be achieved due to the commissioning of the gasoline reforming unit with the catalyst permanent regeneration and isomerization block. UOP is the licenser of the processes.
And, finally, in 2017-2018 it is planned to build 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 second hydrogen production unit and off-site facilities will be built.
Financial performance of Antipinsky Oil Refinery CJSC over the year 2012:
- the 2012 company revenues grew by 27% making up 55.1 billion rubles, exclusive of the VAT;
- the refinery’s net profit in 2012 grew by 10% as compared with the previous year 2011 making up over 1.25 billion rubles;
- the 2012 EBITDA index amounted to USD 190 million taking into account other companies of the Group.
The volume of investments in the project within the period between 2010 and 2015 is planned at the level of USD two billion. One of the steps forward to implementation of 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. That agreement 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 its repayment period in March 2017 consists of three tranches denominated in US dollars and Russian rubles secured with a collateral in the form of pre-export and project financing components.
Serious social assistancePromyshlennost Rossii
Social policy pursued by the Antipinsky Oil Refinery CJSC includes programs and measures aimed at social protection of employees, creation of healthy and safe labor environment. The company’s management team not only takes care of quality medical service to be provided to the employees and renders assistance to them through the system of various kinds of material aid and compensations, but also, what is especially important, tries to improve their living conditions. Thus, by resolution of the Chairman of the Board of Directors an apartment house with 152 flats is being built for the enterprise’s professionals and foremost workers. The house is to be delivered in 2014.
Charity is one of important areas of social policy pursued by Antipinsky Oil Refinery CJSC. Over the entire period of its existence the enterprise has developed key directions of such assistance: support is rendered not through charitable organizations and foundations but directly to kindergartens, boarding schools, clubs, cultural institutions, the Tyumen regional organization of the Russian national society of the disabled. Friendly relations established between the enterprise and Orphanage No. 66, Municipal Educational Establishment, intended for orphans and children deprived of parental care prove it. The enterprise pays no less attention to the area of sports subsidizing one of junior judo clubs in Tyumen.
Up-to-date industry relying on environmental safety
Of late the issues of environmental protection and industrial safety are among those which are of top priority for both, governmental structures and oil companies, against the background of the growing volumes of oil production and refining. Noteworthy is the acute need of applying comprehensive measures at modern oil refineries for the purpose of reducing the harmful impact of operating oil refining facilities on the environment.
Being a sustainable and dynamically developing enterprise Antipinsky Oil Refinery cannot stay aside from current challenges of today’s reality carrying out efficient activity in the area of industrial and environmental safety. The enterprise is trying to comply with international quality standards and fulfills requirements of the Russian Federation’s legislation, as well as of its own regulatory documents and standards forming the basis for prevention of breakdowns, accidents, and incidents at a hazardous industrial facility.
That was why special attention was paid to the choice of up-to-date technological equipment complying with the strictest ecological standards in the course of construction and modernization of Antipinsky Oil Refinery. To lessen the pressure on the environment a number of technological solutions were taken into account at the design stage making it possible to minimize the negative impact on the environment, and, among other things, significantly reduce water consumption what means to considerably decrease sewage discharge, pollutant emissions into the atmosphere, and prevent oil and oil-product spillage in the soil, surface and underground waters.
Such technological solutions include:
- the use of burner units in process furnaces which comply with the most stringent environmental requirements;
- the application of a sealed system within the entire process flow;
- the control, computerization, and telemetry of technological processes to prevent accidents, as well as to minimize pollutant emissions to the atmosphere by strict adherence to established technological parameters;
- the provision of a leak-proof filling of light oil products with gas removal to tanks via gas equalizing lines;
- the use of air-cooling systems in process flows;
- the implementation of water removal systems which prevent wastewater discharge to surface waters;
- the construction of concrete platforms for processing equipment and oil loading racks with guard rails and ladders.
Purify and use
Today Antipinsky Oil Refinery CJSC is busy with the design and construction of the third workflow phase which will enable it to provide the region with Euro-5 motor gasoline and diesel fuel, and, as a consequence, to reduce environmental pressure of vehicles on the ambiance of the south of the Tyumen Region. Since water is needed for refining oil and oil products at the units the construction of the third workflow phase of the enterprise began with the building of water intake, water conditioning, and sewage treatment facilities.
Treatment facilities occupy the area of 10.73 hectares. Wastewater treatment process consists of five stages. The equipment of treatment facilities will enable the refinery to purify all industrial, rainfall, and domestic waters by means of preliminary, physical and chemical (separators and impeller floatation), biological (membrane bioreactor) treatment, advanced post-treatment and disinfection (dual filtration using sorption carbon filters and UV disinfection), and, finally, dehydration of trapped oil products, residues, and excess sludge.
The equipment in question will make it possible to:
- to prevent changes of the Tura River bottom and any limitations of water traffic when using water intake structures;
- provide the refinery with water of required quality complying with regulations imposed on equipment installed in the basic and auxiliary technological units;
- reduce the area of construction four times as compared with traditional treatment technology at primary and secondary sludge basins (biological wastewater treatment technology);
- minimize operational costs (low power consumption equipment, use of advanced chemical agents, etc.);
- reduce the impact of harmful factors (such as noise, vibration, emissions, and discharges, etc.) on the environment and employees.
Competitive advantages of Antipinsky Oil Refinery:
- Antipinsky Oil Refinery is the only industrial refinery in the Tyumen Region and the Urals Federal District;
- Antipinsky Oil Refinery is favorably located in the vicinity of a ramified logistic network, the railway and motorway infrastructure;
- Antipinsky Oil Refinery is connected to oil trunk pipelines of Transneft JSC with the overall capacity of six million tons p.a. taking into account the enterprise’s development, including the third phase;
- Antipinsky Oil Refinery can sell fuel to companies directly from the enterprise by loading it to small 5-30-ton tank trucks. Thus, economic effect is achieved on account of using the method of loading products in small volumes.
It should be specially noted that only high-technology equipment of such most advanced Russian enterprises as “Komsomolets” Tambov Plant OJSC, LIT Research and Production Association, EKO-Umvelt CJSC, TEKO-FILTR Production Enterprise LLC, as well as of such foreign companies as Zickert (Sweden), Separation Specialist (USA), GE Water & Process Technologies (Hungary), and other firms well known all over the world, will be used at the new facility of the refinery. Up-to-date methods applied to the treatment of industrial, rainfall and domestic sewage waters will enable the refinery to reuse up to 60% of treated wastewaters for technical purposes of the enterprise, and improve the remaining 40% of water as required by hygienic standards applicable to surface water protection subsequently discharging them to the Tura River. The accredited ecological and analytical laboratory of Antipinsky Oil Refinery CJSC will exercise quality control over wastewaters at all stages.