Projects
Pioneer in Oil Refining and Petrochemistry
Amina Jalilova
Atyrau refinery is always ahead in all major undertakings in our country. Firstly, it is the firstborn of Kazakhstan oil refining- this year it celebrated its seventieth anniversary. Secondly, this is the first plant, where the modernization was started: very soon it will result in production of environmentally friendly fuels, in compliance with K-5 standard. Thirdly, theAtyrau refinery became the first enterprise in the country, producing the petrochemical products: this year it started producing the benzene and paraxylene
Petrochemistry as a priority
The development of the petrochemical cluster is the trump card, a cornerstone for success of Kazakhstan’s industrialization. President Nursultan Nazarbayev instructed to pay special attention to the development of the petrochemical industry, which can provide higher value added in the conditions of low commodity prices. Atyrau oil refinery perform this task. This year the refinery started the production of petrochemical products-benzene and paraxylene at the complex for the production of aromatic hydrocarbons for the first time in Kazakhstan.
This complex was built as part of the strategy of industrial-innovative development of the Republic of Kazakhstan and the programme for the development of petrochemical industry in Kazakhstan. The Government approved an action plan for the development of the petrochemical industry in 2006 with a view to establishing a petrochemical complexes for deep processing of hydrocarbonic raw materials with the release of the export petrochemical products with high added value, according to which the Ministry of Energy and KazMunayGas were instructed to ensure timely implementation of the project of the aromatic hydrocarbons production at the Atyrau refinery.
Construction of the complex was carried out by the China’s Sinopec Engineering company (People’s Republic of China). The technology supplier is Axens (France), one of the leaders in the global petrochemical industry.
Construction of the complex was completed last year. Today the complex can be operated under two options: to produce the fuel to obtain high-octane components for gasoline production that is necessary for the production of environmentally friendly types of fuel and to produce the petrochemicals-for benzene production (in a volume of 133 thousand tons annually) and paraxylene (496 thousand tons annually).
The first batch of benzene was received on July 3 of this year and paraxylene-on October 2. Now the refinery is ready to produce both products in the commercial volumes. Benzene and paraxylene are highly- demanded petroleum products, being the raw materials for a huge range of petrochemical products, i.e. for production of caprons, plastics and plastic fibers. The dyes, solvents, pesticides for agricultural production, phenol formaldehyde resins for the construction business, furniture and components of medicines are produced in their basis.
Three stages of modernization
Successful modernization and transition to fuels, corresponding to the highest world standards is the main objective of the Atyrau oil refinery at this stage. It should be noted that the plant didn’t stop its production: construction and ongoing works of the plant are ensured at the same time. Of course, it requires a precise management. Security is a must at such a big production facility, where the hydrocarbons are processed and, at the same time, the construction is going on: it is not an easy task and the workers are coping with it brilliantly.
However, let us return to the modernization. The first stage of modernization was successfully implemented in 2003-2006. It was marked by the construction of new process units, producing ecologically pure brands of diesel fuels and gasoline and complying with environmental standards. As a result of the reconstruction, hydroprocessing and gasoline isomerization units appeared, as well as hydrotreating and dewaxing units, hydrogen purification and generation units, sulphur regeneration units with soldification units.
The first stage focused on solving the issue of improving environmental properties of motor fuels, reducing their content of sulphur, nitrogenous and other harmful substances. Upon implementation of this project, the oil production of the Atyrau oil refinery today is compliant with the effective technical regulations. This stage also included modernization of off-site objects, a biological wastewater treatment unit was also built. New tank fleets, loading rack for the dark petroleum products, flaring system with modern security control systems were also implemented. The modernization, carried out with participation of Japanese companies, has improved the quality of products and reduced adverse environmental impact to a minimum.
During this period the technological units that had been built earlier also underwent reconstruction, basic equipment was replaced, process control system based on microprocessor technology was launched, the conditions for subsequent transfer of plant control to a single operation unit were created.
This year the second stage was completed- the complex for production of aromatic hydrocarbons was built at the Atyrau refinery. It is the largest complex of benzene and paraxylene production in the territory of the former Soviet Union. Its application to obtain high-octane components of motor gasoline catalytic reforming process with continuous regeneration of catalyst is also unique.
The project stipulates a number of actions to reduce the aromatics plant’s negative impact on the environment. The integrated automation of technological processes was ensured with providing the operator’s room with all parameters, characterizing the safe operation of the equipment. Process management is organized on the basis of microprocessor technologies and electronic media monitoring and automation. Material selection for the equipment, pipelines and their elements was successfully carried out in accordance with the aggressive environments, process parameters and operating conditions. The obtained aromatics products(heavy and light refined petroleum, reformate mixture of xylenes, aromatic hydrocarbons, C9 +, para-benzodiazole and toluene, benzene and paraxylene, gasoline components) in the tanks, equipped with floating aluminum pontoons Ultrafloat with the sealing bolt Ultraseal and the nitric cushion. The process of paraxylene filling is automated and provides automatic regulation of loading and off at emergency situations at a special loading facility with drawing-off the vapor recovery at the paraxylene vapor filling at the hydrocarbon recovery block.
The ultimate goal of modernization is the creation of a modern, secure and competitive enterprise, production of ecologically clean petroleum products compliant with grade K-5 and world standards, productivity improvement.
Due to the commissioning of the aromatic hydrocarbons production complex, additional 277 workplaces were created, and the deep conversion refinery will create 400 more jobs.
Successful transformation
For many years the Atyrau refinery remains an enterprise with no staff reductions. Due to careful preparation and competently work, the transformation was completed in a way to avoid the employee redundancy and to keep their current salary level.
We would like to remind that the transformation is now ensured for all the companies- members of the NWF Samruk-Kazyna. It implies rejection from non-core activities and privatization of non-core assets. Several units, including the electrical, instrumentation and automation, IT Department, Transport Department, mechanical repair shop are already outsourced by the Atyrau refinery. In addition, a part of the press service, group of standardization, metrology service and other support structures are removed from the Atyrau refinery LLP. Now they have the opportunity to serve not only the Atyrau refinery, but also the other customers-they now work for themselves. As a result of the transformation, which is not yet completed, the refinery staff was already reduced almost by half.
In the new year...
The main task of the refinery for 2016 is this is a long-awaited completion of modernization: to complete the construction of deep oil refining (DOR), followed by the production of high-octane gasoline and diesel fuel types, corresponding to the K-5 class. This is achieved due to introduction of modern world-class technological processes. One of the key criteria for K-5 class is the ecological safety.
In addition, the DOR introduction will reduce the burndown of dark product petroleum products and it will increase the production of light oil products at the Atyrau refinery. Gasoline production will triple:it will be a good help for Kazakhstan, which still imports one-third of all the fuels and lubricants, consumed in the country. Moreover, there are more and more cars every year in the country.
In 2017, it is planned that the DOR will reach its full capacity and the Atyrau refinery will have a maximum production of motor fuels, complying with the requirements of K-5 standard.
Published full article