The Gazprom Neft Omsk Refinery has completed installation of key production equipment for its future delayed-coking unit (DCU) — this project being part of developing a delayed-coking complex at the Omsk Refinery, involving the construction of new (and the modernisation of existing) facilities. These works will lead to a two-fold reduction in environmental impacts, while increasing refining efficiency. The company’s investments in building this facility stand at RUB50 billion — this being one of the most important projects in developing the Omsk Refinery, something Gazprom Neft has been implementing since 2008.
Thanks to the launch of the new two-million-tonne-capacity DCU the Omsk Refinery will cease production of fuel oil, instead increasing production of motor fuels and a high-quality raw-material for the aluminium industry — petroleum coke. The coking-oven installed will heat heavy oil residues to the temperatures needed for full processing, fuelled by environmentally-friendly natural gas. A further environmental benefit is being achieved by using systems to prevent industrial dust from getting into the atmosphere.
Construction is on schedule, and consistent with all operational and industrial safety requirements. Together with the other projects involved in the second phase of the Omsk Refinery’s modernisation, conversion rate is expected to increase to 97%, and the light-product yield to 80%.
The delayed coking unit (DCU) currently under construction is designed to process heavy petroleum feedstock, predominantly tar. Pre-heated tar is fed into the fractionation column, where it is separated into light fractions and ultra-heavy tar. Light hydrocarbons are sent to be processed into commercial oil products, while the ultra-heavy tar is sent to a coking chamber to be turned, under high temperatures, into coke. Coking chambers operate cyclically, with the coking process going on in one chamber, while the other is unloaded and prepared for the next cycle. The produced coke is in considerable demand by the aluminium and electrical engineering industries.
The modernised DCU is expected to produce 38,700 tonnes of needle coke every year, once renovation is complete in 2021. Investment in the project stands at RUB5.2 billion. Installation of three major coking ovens, each 28.5 metres long and weighing 197 tonnes, is already complete. Process heaters and secondary refining columns will also be replaced as part of this reconstruction, an additional tank farm built, and an automated control system deployed.
Gazprom Neft is currently involved in a full-scale modernisation programme at its Omsk and Moscow refineries, involving cumulative investment of more than RUB550 billion. The first stage of this programme has allowed the enterprise to transfer to the exclusive production of modern, environmentally-friendly Euro-5 fuels. The implementation of the second phase of this modernisation programme is now ongoing, as a result of which refining depth and light product yield are expected to increase to match the highest international standards.