Business - plan
The title of the project:
« Construction of small capacity Refinery in Altai krai »
The author of the project:
The Limited Liability Company «Geodesic and Engineering Centre »
THE CONTENT
1. Introduction … … … … … … … … … … … … … … … ….3
2. Technological features of oil refining processes in unit … .... 4
3. Configuration of the unit and placement … … … … … … 7
4. Automation, power supply, analytical supervisory control… 7
5. Ecological aspects of unit operation … … … … …........ …. . 8
6. Basic characteristics of the Refiner and products of raw material
processing … … … … … … … … … … … … … ….. … … … 9
7. Economic indexes of small capacity refinery
… … … … … … … … … … … … … … … … … … … … … … 11
8. Financial plan … … … … … … … … … … … … … … … …12
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1. Introduction
The problem of provision to remote regions of Russia by high-quality petrol up to real time is
deciding basically by expensive seasonal delivery. Even if this areas have petrol, the oil refining on
regional Refinery does not find wide application and is carried out in limited quantity on the units
which as a rule not provide necessary quality of marketable products, depth of a thorough revision,
and also ecological and technological safety.
The energy strategy of Russia for the period up to 2020 years, affirmed by the order of
Government of the Russian Federation from 28.08.2003г. № 1234-р (section VI-2), implies the
construction of new high performance Refinery of an average power in areas of concentrated
consumption of oil, and in remote northern and eastern areas - small plants with a complete cycle of
oil refining.
For small Refinery the traditional schemas of oil refining used at the large oil refining
enterprises are unacceptable because of the high cost price of processes. That’s why the majority
existing units power up only an atmospheric petrol distillation at which 40-60 % of final - products
are made with fuel oil. Thus receiving of documentary benzenes and diesels is based on
compounding of distillate fractions.
In a base of the unit offered by us is incorporate advanced achievements of the Russian
scientists in sphere of refining hydrocarbon raw material, permitting to finish depth of refining with
90-93 %.
The base of the process consists of atmospheric distillation and combining a viscosity breaking
with cavitation - acoustic influence (the developer is the Limited Liability Company
SCIENTIFIC AND PRODUCTION CENTER " THERMAKAT ", Ufa).
The technology offered by “THERMAKAT" allows to bring up process of refining
hydrocarbon raw material on Refinery up to high-quality products, and also increases output of
refined oils by 20-25 % to compare it with classical methods.
The high performance schema of refining raw material ensures also high profitability of
manufacture, and low payback time of investments. For a unit by productivity 100 thousand tons
per year on raw material payback time is less than 1 year.
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2. Technological features of oil refining processes in unit.
The process of transformation of hydrocarbonic raw material (oil) to the final-products can be
presented in two stages (blocks):
- Atmospheric distillation of raw material with reception of once-run benzene, diesel fuel and
black oil;
- Processing black oil using "THERMOKAT" technology and receiving additional quantity
of light fractions (once-run benzene, diesel fuel) and bitumen or boiler fuel.
In the considered unit atmospheric distillation of raw material is carried out according to the
traditional, classical technology. Thus there is a possibility of various design columns, furnaces,
heat exchangers, separators and other units depending on production potentialities, used materials,
etc.
The difference from the classical variant is that the rectification column should "process"
gaseous products not only of its own block, but also block "THERMOKAT". Using it in separate
columns their number in installation unfairly increases.
The following block (stage) of processing realizes "VISBRAKING-THERMOKAT"
technology.
"VISBRAKING-THERMOKAT" technology is based on the traditional thermolysis of
hydrocarbons which is combined with several stages of destructive - polycondensation
transformation of hydrocarbons adjustable in time with step changing of pressure and temperatures
under the influence of supersonic fields raised by cavitation devices.
This influence allows providing a special-purpose designation of process (increase yield of
refined oils) by realization of rational decomposition temperatures and exceptions of coke
production, resulting, at the same time, to necessary condensation of heavy hydrocarbons up to the
stage of the asphaltenes which is necessary for recieving oxidated asphalts of adjustable quality.
The use of control energy of cavitation at this or that stage of the process expands the
opportunity of regulation of depth and speed of pass of splitting and condensation reactions,
processes of evaporation and polyfunctional condensation and, hence, a yield and quality of
products.
The process is made for recieving hydrocarbonaceous distillates and residual products (fuel
oils and bitumens) from heavy oil residue, including black oils, petroslimes, gas condensate
oddments, by soft controll thermal cracking in conditions of cavitation - acoustic influence on
reactionary environments.
Hydrocarbonaceous gas in quantity 2-5 % is used for technological needs, from 65-88 % of
distillate fractions components produce the engine fuels or furnace fuel (light) are manufactured, and
6-30 % of residual products are qualified as road or structural bitumens.
Finishing of received once-run benzine (octane value 50-60) up to a commodity output is
possible in various ways.
1. Processing from low-octane benzine to high-octane.
2. Mixing in necessary proportions of once-run benzine with high-octane, not ethylated
additives (WATERS and etc) This way allows to raise octane value of once-run benzine to 10-15
units.
From the existing processes the most efficient is the process of once-run benzine in highoctane method "ZEOFORMING", developed by Scientific Researching Centre "ZEOSIT" by
Russian Academy Of Sciences (Novosibirsk city). It is allows to produce benzines from AI-80 up to
AI-95, and also European such as "EUROSUPER-95" without addings and compoundition. As
against traditional processes of top bracket gasolines reception - reforming - process ZEOFORMING
does not demand application of hydrogen, hydroclearing of raw material, expensive platinum
catalysts.
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The basis of technology consists of catalytic conversion of low-octan liquid hydrocarbons in
high-octane components of benzines on zeolite-content catalysts such as IK-30-1.
According to the licenses and baseline designs Scientific Researching Centre "ZEOSIT"
plants "ZEOFORMING" with capacity from 5 up to 40 thousand tons a year are constructed: Russia
(Nizhnevartovsk Gas Plant, 1992 - 5 thousand ton/year), Poland (Oil Plant "GLIMAR", 1997 - 40
thousand ton/year about the design of firm " Lurgi "), Kirghizia (Bishkek, 1998 - 40 thousand
ton/year), Georgia (Rustavi, 2002 - 40 thousand ton/year), South Korea ( DAYJOHN, 2001,
demonstration unit, together with company "Samsung"). Industrial production of catalysts is created
on «Novosibirsk factory chimkonzentratov».
The diagram of oil refining on "THERMOKAT" technology is submitted on
pic. 1.
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Pic. 1 Basic circuit of oil refining
desalinized oil, dry oil,
100 %
Atmospheric
distillation
Gas, 1 %
Benzine fraction -180С,
10 %
Diesel fraction.
180-360С, 33,0%
Black oil, 56%
Process
Secondary gas, 2%
Secondary benzine,
180, 9%
viscosity breaking -
«THERMOKAT»
Secondary diesel
fraction, 32%
Bitumen, 13%
Hydrocarbon gas, 3%
Benzine (180С), 19 %
Bitumen, 13 %
Process
ZEOFORMING
Liquefied gas
High-octane benzine, 65-85%
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Diesel fuel
(180-340С), 65%
3. Configuration of the unit and placement.
Refinery settles down in the place with necessary engineer infrastructure, including
tank battery, security systems, household rooms. The process equipment can be executed
from separate technological blocks of factory manufacture in forms of modules which
are convenient for transportation. The modules are placed in an open area with a canopy
and easy protect designs.
The rough area occupied with technological blocks for the unit with productivity of
100 thousand ton/year makes ~ 20х60 m. The sizes of a platform for an oil refining
complex as a whole with infrastructure depend on rhythm of supply raw material and
shipment of production (volume of tank battery), presence and such as the access roads,
approved schema of automation, power supply, conditions of life for the personnel, etc.
All these parameters are defined at the project stage on the starting data of the
Customer and the chosen platform.
4. Automation, power supply, the analytical control.
In the project of the unit automation the following is stipulated:
- Measurement, the remote control and registration of technological process
parameters;
- Automatic control of technological parameters;
- The preventive signal system of dangerous parameters;
- Automatic protection of pumps and devices by achieving the process of
permissible values for this equipment of the parameters ;
For control and process monitoring are chosen the modern electronic gauges
working with transducers and receiver recorders. In the system are applied only singlepoint devices.
The regulating accessory is used with air-operate transforming the electric signal in
pneumonic with the help of electrical air-operated transducers of hardened execution.
All means of the control and automatics of a domestic production have certificates
of conformity and the sanction to application in explosive installations.
Management of the unit is conducted from operational office, located outside of an
explosive zone with two tambour entrances. In the operational office constant ventilate
air with air-condition is created.
In basic technology three-phase electric power is consumed. It can be taken over
from existing systems of electro delivery. For heating raw material fuel developed on the
unit is used. For start-up of the unit you need starting volume of fuel for start and work
within 2 days, heating and reactionary technological furnaces. The necessary stock of
liquid fuel makes ~ 10 m3.
Refinery is provided with emergency system of power supply - diesel generator as
the oil refining enterprises should have two independent sources of power supply.
The analytical control of the process is carried out by standard methods of analyses
in accordance with GOST, on the routine lab ware with routine methods of selection of
mineral oil and designs of samplers. At the self-contain schema of the unit the laboratory
is equipped in mobile wagon.
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5. Ecological aspects of unit operation.
At the full-time work of the enterprise flue gases of technological furnaces P-1,2
and the furnaces of heat-transfer medium P-3 are sources of pollution liable to clearing.
These gases are formed at the combustion of fuel and they contain dioxide of sulfur in
concentration up to 0,05 % of weights, nitric oxides in concentration up to 0,00005 % of
weights.
The project of the unit does not suppose using water for cooling production lines.
There are cooling devices purpose use in this unit.
At any contingencies temporary passages of mineral oil are possible while
performing technological operations or repair equipment. In this case procast mineral oil
is covered by sorbent. The fulfill sorbent goes to a metal pressure-tight container and
puncheons and is manufactured further together with Mechanic admixings, collected
from filters of pumps. A surface is washed out by industrial water, containing
PEAHENS, the outwashes go to the system of industrial sanitary piping.
The Solid waste products from Zeoforming unit are fulfilled zeolite - catalyst IK30-1.
Before the unloading, the catalyst is subjected to annealing at temperature 450 С
by feeding reclaiming gas that provides complete removal from the catalyst of
hydrocarbons and the coke deposited on the catalyst.
The fulfilled and cleared catalyst has no toxicological properties and goes to the
dump. The work is underway on possible usage of dead-catalyst in road building as filler
for concrete coverings which don’t stand heavy traffic (concrete paths, platforms, etc.)
Operating the enterprise the periodic control of the contents of harmful substances,
starting, intermediate and termination products in air of the industrial rooms, the occupied
places, in water of reservoirs and ground by meothods of the tool control over techniques,
fixed Federal Hydrometereology and Environmental Monitoring Service is manufactured.
The platform for placement Oil Refiner should be on distance not less than 1000 m
from habitable area. Other requirements are defined at the project stage and are similar to
the requirements showed to warehouses of the PETROL PRODUCTS.
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6. Basic characteristics of the Refiner and products of raw
material processing.
Oil refining in blocks of atmospheric distillation and "THERMOKAT" it is
possible to receive the following products .
The basic nomenclature:
- component of benzine A-76 according to GOST 2084-77 (on fractional
composition);
- component of summer, winter and Arctic solar oil according to GOST
305-82 (on fractional composition);
Or
- furnace household fuel according to technical specifications 38.101656-87;
- fuel oil according to GOST 10585-75;
Or
- bitumens road not oxidated according to technical specifications 025609600151807-97.
- To bring obtained products of oil refining up to a commodity output it is
necessary to apply corresponding additives and reagents including:
The name of
Materials
The charge, kg /
Comment
tons of Commodity
output
Soda caustic liquid (caustic soda), 38
3,1
Alkalining benzine
% water solution
Methyltrebutyl ether,
37,5*
Component of benzine
Or its analogue
Agidol
0,7
Antioxidizing dopant to engine
fuels
Lime calcium unslake
10
Component of a mineral filler
asphaltconcrete
Iron (III) sulphate
0,08
Component of absorbent of
hydrogen sulphide
Trilon-B
0,1
Component of absorbent of
hydrogen sulphide
Nitrogen technical
0,04
Noble gas for blow-down of
the equipment
9
* Depending on type of raw material.
As a result of such compounding it is possible to receive the following basic
nomenclature:
- Benzines A-76 - A-93 in accordance with GOST 2084-77;
- Solar oil with improved ecological properties (summer, winter) under
technical specifications 38.401-58-170-96.
Reception of high-octane commodity benzines only by compounding is rather
problematic and, as a rule, can be provided by processing very "good" petrol. Traditional
compositions do not allow to increase octane value by introduction of dopants more than
76.
There are opportunities for padding nomenclature of production obtained by
updating of regime parameters: nefracs on OST 3801199-80, mobile ship fuel on
technical specifications 38.101567-87, black oil naval in accordance with GOST
10585-75, residual fuel SVT, SVL, CDC on technical specifications 38.1011314-90,
bitumens structural{building} in accordance with GOST 6617-76, bitumens
insulation in accordance with GOST 9812-74; bitumens roofing in accordance with
GOST 9548-74; bitumens friable in accordance with GOST 21822-87.
For production of commodity output on blocks AT and "THERMOKAT"
following rough resources are required:
The charge on 1 ton raw material
The name
1. Solar oil, or fuel gas (at the moment of start-
33
up), kg
2. Air KIA, nm3
2,6
3. Nitrogen, periodically, nm3
At start-up and stop
4. The electric power, kw. / hour
15
By production of top bracket benzines on "ZEOFORMING" block the following
rough charges of by-products are required:
The charge on 1 ton raw material
The name
1. Catalyst, kg
0,1/0,2 *
2. Solar oil, or fuel gas (at the moment of start-
37,4
up), kg
3. Air KIA, nm3
19,2
4. Nitrogen, periodically, nm3
3,9 / 8,6 *
5. The electric power, kw / hour
37,2
*By production of benzines AI-76 and AI-95 accordingly.
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7. Economic indexes of small capacity refinery.
Quantitative value of fuel production, developed on unit, is defined, basically, by
the composition of the feed stock (oil), and also the chosen type of end product.
For one of the Tyumen origin Oils the following ratio between termination products
are obtained:
Oil crude
- 100 %
Benzine AI-92
- 25 %
Solar oil (summer)
- 58 %
Bitumen not oxidated
- 12 %
Losses, expenses on
preheating of raw material and work of aggregates
-5%
For installation with productivity of 100 thousand ton/year on raw material the
commodity output will make :
Benzine AI-92
- 25 thousand тons/year
Diesel Fuel
- 58 thousand тons/year
Bitumen not oxidated - 12 thousand тons/year
The total cost of the unit (without "Zeoforming" block) with a building part and
infrastructure will make ~ 10 million euro, including the process equipment - 6 million
euro . The specified cost will be specified at the stage of concrete Refenery design with
its concrete location and raw material.
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8. Financial plan
Economic efficiency of realization of any investment project directly depends on
existing economic conditions for the business, the existing price level and tax policy that
works in the market of Altai krai.
Volume of necessary investments:
1. Investments (cost of the unit and infrastructure) 8.500.000 EUR or
293,250,000.00 roubles (the Central Bank of the Russian Federation
rate on 01.04.2007 34.50 roubles / EUR), including VAT of 18 %;
2. Necessary initial turnaround means for maintenance of 30-days
need of raw material of 51.750.000 roubles, including VAT of 18 %
(or 1.500.000 EUR);
Total: 345,000,000.00 roubles, including VAT of 18 %.
(or 10.000.000 EUR)
Calculation is made in real terms (as of 01.04.2007) and taking into account the
following accepted essential starting parameters:
1. Internal parameters
1.1. The charge of raw material on total output of 100 thousand tons of oil in one year
1.2. The production program of output is determined by technological process and
assumes the following ratio of a feed stock and termination products of processing:
- Oil crude
- 100 %
- Benzine A-80
- 25 %,
-Solar oil (summer)
- 58 %,
-Bitumen
- 12 %,
-Losses, expenses of production on
Preheating of raw material - 5 %.
1.3. The given variant of calculation gives full realization of the manufactured products,
thus sales volume is defined by level of industrial loading and on total output makes 47,5
thousand tons of mineral oil a year.
plan of sales
Quarter plan
In tons
1. Benzine A-80
Year plan
In tons
Quarter plan
In roubles
Year plan
In roubles
6 250
25 000
105 386 808
421 547 232
2. Diesel oil
14 500
58 000
265 891 886
1 063 567 540
3. Bitumen
3 000
12 000
19 918 234
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Total
23 750
95 000
391 196 928
79 672 936
1 564 787 710
2. External parameters
2.1. A wholesale price for oil and mineral oil from the factory on the
average on Ural-Siberian Region (the Internet source www.riccom.ru):
- Oil crude
- Benzine A-80
- Solar oil (summer)
- Bitumen
- 7000 roubles/ton
- 16000 roubles/ton,
- 17400 roubles/ton,
- 6300 roubles/ton
2.2. Expenses for processing of 1 ton of oil at total output make 1300 roubles and
include the salary of the personnel with deductions, expenses for certification,
municipal services, the electric power and other working costs
2.3. Norms of deductions and the rates of taxes established by the Government of Russia
2.3.1. The norm of depreciation charges on oil refining installations according to
Classification of the basic means, authorized by the Government of Russian
Federation from 01.01.02, makes 9 % (group 6, from above 10 and till 15 years
inclusive)
2.3.2. Value Additional Tax (VAT) of-18 %
2.3.3. Property Tax
- 2,2 %
2.3.4. Profits Tax
- 24 %.
2.3.4. Excises: A-80 - 2700 roubles / ton; Solar oil - 1080 roubles / ton.
In total:
Expenses for processing – 130 000 000 roubles.
Excises A-80
- 67 000 000 roubles.
Diesel fuel
- 62 640 000 roubles.
Taxes
- 166 000 000 roubles.
In total payments
- 462 140 000 roubles.
Raw material
- 751 712 362 roubles.
As a result we have for 1 year:
1 564 787 710 roubles of receipt from sale
-1 213 852 362 roubles - expenses
________________________
350 935 348 roubles or 10 172 039 EUR .
It is necessary to notice, that reduction of the price on 3 %, plus reduction
of charges on delivery, plus an opportunity of buying by gasoline tank trucks, make
our production quite competitive. All given calculations are given with stress on
Tyumen oil, we shall present the standard data in the elementary diagram of
processing.
The high performance schema of raw material processing provides either high
profitability of production or fast term of recovery of outlay investments. For the unit
with productivity of 100 thousand tons/year on raw material the term of outlay recovery
takes 1 year.
The term of the Refinery building takes 8-10 months.
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Such factories are supposed to be replaced in Altai krai, as a minimum ten of them with
volume of 1000000 tons one year that makes 45 % from all consumer market of mineral
oil in the region. The sum of expenses accordingly will increase up 100.000.000 EUR.
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