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 and petrochemical products requires enormous capital investments, refineries are constructed in several workflow stages. Each workflow stage implies the organization of a complete production cycle and shipment of a certain range of oil products of agreed quality to consumers. This is the development mode chosen by JSC Antipinsky Refinery.
I workflow stage (2006):
- Unit: Crude Unit - 1;
-Initial nameplate capacity: 0,4 MTPA.
-After re-equipment in 2008 nameplate capacity amounted to 0,74 MTPA.
-Processing depth: 55%.
-Storage tanks: 52,000 cum.
-2 either-direction railway tank filling racks
-2 road tanker filling rack.
Capacity of crude oil transportation through oil trunk pipelines of Transneft – 0,5 MTPA.
II workflow stage (2010):
- Units: Crude Unit - 2 with gasoline stabilizer
- Initial nameplate capacity: 2.5 MTPA
- After re-equipment in 2012 nameplate capacity amounted to 3.3 MTPA. Total capacity of the refinery (Crude Unit-1 + Crude Unit-2) made up to 4.0 MTPA
- Processing depth: 55%
- Storage tanks for 120,000 cum (the total volume amounts to 172 000 cum)
- Finished Products Sector with 2 either-direction railway tank filling racks for 71 rail tankers
- Capacity of crude oil transportation through oil trunk pipelines of Transneft – 1,7 MTPA
III workflow stage:
Taking into consideration the scale of the III workflow stage objectives its construction is being carried out in several start-up complexes, first of which has been completed in January 2014 and second – in October 2015.
1st start-up complex of the III workflow stage (completed in January 2014)
- Unit: Crude Unit - 3
- Initial nameplate capacity: 3.7 MTPA Total capacity of the refinery: 7,74 MTPA Processing depth: 55%.
- Storage tanks: 140 000 cum (diesel storage tanks – 80 000 cum; crude oil storage tanks – 60 000 cum; total volume including relay storage tanks volume of FPS – 332 000 cum).
- Five staged water intake, treatment and effluent facilities
- Capacity of crude oil transportation through oil trunk pipelines of Transneft – 7,2 MTPA
2nd start-up complex of the III workflow stage (completed in October 2015)
A diesel fuel hydro treating unit (the licensor and developer of the basic design is the Danish company, Haldor Topsoe) was built at the 2nd start-up complex of the III workflow stage in order to make the diesel quality comply with Euro-5 standard (with the sulfur content of no more than 10 ppm), to provide for the required freezing temperature with a possibility to produce winter and arctic diesel. Hydrogen generation unit with a gas treatment module and elementary sulfur recovery unit (with a granulation module) were built for the purpose of supporting operations of the hydro treating unit.
- First diesel hydro treating unit with the nameplate capacity up to 3.0 MTPA;
- Hydrogen generation unit with gas amine treatment module, capacity - 25 thousand TPA;
- Licensor and developer of the basic design is the Danish company, Haldor Topsoe;
- Sulfur recovery unit with a granulation module, capacity – 30 thousand TPA.
- Crude unite -3 reconstruction for the purpose of total capacity increase up to 5 MTPA. Refinery’s total nameplate capacity reached 9,0 MTPA
- LPG depot for transportation of commercial liquid motor gas Grade PA (Motor Propane) and PBA (motor propane-butane), produced at Crude unite -3. The LPG depot capacity makes 25,000 tons per year.
- Receipt and dispatch of dark oil products base with 6 km of extended lines
3rd start-up complex of the III workflow stage (2016)
The oil processing depth will reach 97% at the 3rd start-up complex of the III workflow stage due to the commissioning in the 2nd quarter of 2016 of the combined delayed coking unit with a fuel oil vacuum distillation module. As a result diesel yield will increase up to 50% from the total refining output. The licensor and developer of the basic design is the American company, Foster Wheeler. The coke resulting from tar carbonization and constituting one of the end products is in great demand with iron and steel industry.
Combined delayed coking unit together with a fuel oil vacuum distillation module consists of:
- Delayed coking module (with the nameplate capacity of 1.3 MTPA; after revamp in 2016 the total capacity will exceed 1,7 MTPA)
- Fuel oil vacuum distillation module (with the nameplate capacity of approximately 3.5 MTPA);
- Licensor and developer of the basic design is the American company, Foster Wheeler;
- Second diesel hydro treating unit (with the capacity of 1,0 MTPA; total maximum capacity is up to 4,0 MTPA).
- Processing depth: 97%
- Commissioning: 2Q 2016 Construction of a new automotive product-loading (auto-loading) facility at the Final Products Site and two 5,000 m3 automobile gasoline tanks.
Currently, the foundation works have been completed; the cocking drums have been supplied and installed; piping works for the delayed coking unit are carried out; the fuel oil vacuum distillation unit has been installed and under commissioning.
4th start-up complex of the III workflow stage (2016)
In the 3rd quarter of 2016 at the 4th start-up complex it is planned to start production of high octane Euro-5 gasoline with the octane number of 92, 95 points using a research method due to the commissioning of the gasoline catalytic reforming unit with a continuous catalyst recovery and the isomerization module.
Combined high octane gasoline reforming unit consists of: Gasoline fraction and coking naphtha hydro treating module «Unionfining» (with the nameplate capacity of 850 thousand tons per annum);
Catalytic reforming module with a continuous catalyst recovery (with the nameplate capacity of 300 thousand tons per annum);
Light gasoline fraction isomerization unit (with the nameplate capacity of 240 thousand tons per annum)
Licensor and developer of the basic design is “UOP” - Commissioning: 4Q2016
Currently, the foundation works and underground pipelines at the ñombined high octane gasoline reforming unit have been completed; the metal structures have been manufactured, continius catalyst regeneration, reactors and column facilities have been installed. The production and process facilities have been ordered and are expected to be delivered to the site in February.
IV workflow stage
The Refinery’s development in 2017-2018 includes construction of vacuum gasoil hydrocracking unit with the nameplate capacity of 2,7 MTPA which will use the refinery’s own gasoil as the raw material from the vacuum module of the complex fuel oil processing unit .