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Mini Refineries(НПЗ)

Design of mini-refineries (including projects for the construction of mini-refineries, reconstruction of mini-refineries and modernization of mini-refineries) - is one of the main activities of our Design Institute of Oil and Gas Industry.
The project on mini-refineries referred to construction projects, reconstruction and modernization of small-capacity plants (mini-refinery) of crude oil or recycled oil products (fuel oil, bitumen, gas oil), with little capacity to 500 000 tonnes / year.
Design of mini-refineries (mini-refinery) runs the institute, LLC "PrivolzhskNIPIneft" taking into account customer requirements and conditions on the object.
Mini-refinery project consists of the design documentation (Stage II) - which runs the state or non-state examination of project documentation, as well as working documents (RD stage) and the special sections:

  • Occupational safety and production management
  • Estimates of construction and organization
  • ITM civil defense measures to prevent emergencies
  • Environmental protection (EP), environmental impact assessment (EIA) of planned and existing facilities
  • Performance of calculations and the development of maximum permissible norms of emissions (discharges) of pollutants into the environment, waste disposal
  • Design Institute of Oil and Gas Industry Company "PrivodskNIPIneft" also provides:
  • Automation equipment tonnage refineries (mini-refineries)
  • Functions of the general designer mini-refineries
  • Supervision of construction of mini-refineries
  • Engineering services in the field of oil refining.
  • Project malotonnazhnogo mini-refineries or mini refinery complex includes:
    UPN - installation of oil refining (standard equipment UPN: reactor furnace heating materials, a recuperative heat exchanger, distillation column, gas-liquid separator, heat exchanger, air cooler, condenser pump working (raw, pumping products), pump a reserve capacity of raw materials, container for the bottoms, the capacity of reflux, the receiver cracking gases, circulating compressor) and other infrastructural facilities: a drain rack for receiving crude oil by railway transport, tank farm storage of crude oil tank farm storage of finished products (storage tanks of gasoline storage tanks of diesel fuel storage tanks of fuel oil and bitumen and other by-products), car loading dock and rail loading dock for loading processed on a mini-refinery oil.
    Biorekc Ltd. for its customers offers a variety of processing plants, allowing the fuel to produce according to GOST or regulations EURO 3,4,5.
    To comply with the current regulations in the Russian fuel (it should be the quality of not less than EURO-4) our Institute in designing a mini refinery uses crude oil processing plant (OTP) with recycling.
    Introducing a standard number of mini refinery productivity thousand. Tonnes per year:
  • Mini Refinery 15 thousand. Tonnes / year
  • Mini Refinery 30 thousand. Tonnes / year
  • Mini Refinery 50 thousand. Tonnes / year
  • Mini Refinery 70 thousand. Tonnes / year
  • Mini Refinery 100 thousand. Tonnes / year
  • Mini Refinery 150 thousand. Tonnes / year
  • Mini Refinery 200 thousand. Tonnes / year
  • Mini Refinery 250 thousand. Tonnes / year
  • Mini Refinery 300 thousand. Tonnes / year
  • Mini Refinery 500 thousand. Tonnes / year
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    MINI НПЗ

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    Mini-refinery (small plants) for the production of motor fuel The solution for remote areas and oil fields Obtaining commercial motor fuel conforming to any standards
    Mini-refinery for production of motor fuels (oil) are fully equipped modular units (factories) suitable for immediate installation on site and designed to be fully operable within three weeks after the arrival of the equipment to the prepared construction site.

    PRODUCT YIELT WITH A MINI REFINERY

    NAFTA (straight-run gasoline mini refineries) - A typical final boiling point naphtha - from 110 ° C to 185 ° C. This hydrocarbon fraction UMT is divided into two components - naphtha and Nefras. Naphtha is then used as the basic component in the production of high-octane gasoline. Diesel fractions (distillate MINI refinery) - Typical boiling temperature range of the product is in the range from about 185 ° C to 340 ° C. The product was further subjected to distillation to separate the kerosene (naphtha) and diesel fuel. Depending on the customer's requirements can be produced arctic, winter or summer diesel fuel.
    Residual fraction (straight-run fuel oil from refineries MINI) - a fraction of the primary distillation after which heavy distillates, with an initial boiling point of about 320 ° C. This product is commonly used in the production of various grades of naval fuel and fuel oil.
    During the processing of the conventional crude oil refinery with a small specific gravity to 0.865 unit will operate at rated power, and there will be approximately 20% by volume. light naphtha and gasoline (Nefras), 30% by volume. middle distillate (kerosene and diesel fraction) and 50% of the residual fraction (virgin oil). The actual production capacity of mini refinery product yields as a percentage and their boiling points vary depending on the specific characteristics of the crude oil used is supplied on a mini refinery. After receiving the data on the composition of crude oil is necessary to provide the yields of products that can be produced on the mini refineries and carry out a mini refinery modifications to meet the specific needs and requirements of the design.
    Design BIOREKC OOO is ready to provide the design of any additional equipment for further processing of the product streams, such as middle distillate hydrotreater, catalytic reforming, vacuum distillation and stabilization of naphtha.

    INSTALLATION FOR THE PRODUCTION OF MOTOR FUEL (mini refineries) OPTIONS AND SERVICES:

  • Delivery of spare parts designed for two (2) years of the plant
  • Technical supervision during construction - 1 person for 30 days
  • Technical supervision during start-up and technical training - 1 person for 30 days
  • Installing oil desalting in modular design
  • The dispensing system in a modular design for two (2) additives
  • Loading rack
  • Tanks for raw materials
  • Containers for food
  • Protective transport packaging
  • Delivery to the port or to a construction site
  • PERFORMANCE MINI REFINERY

    Mini refinery designed customized to meet the specific requirements of a particular customer. Yield motor fuel varies according to the specific characteristics of processed crude oil. Typically, the installation can be operated with a minimum capacity of 70% of maximum performance.
    Standard elements MINI Refinery
    Mini refinery comes from the process modules fully assembled with all necessary equipment, piping, electrical and instrumentation equipment, including:
  • Heat exchangers
  • Pumps
  • Atmospheric distillation column
  • Separator light gasoline
  • The column side stream - diesel fraction
  • Cooling Devices

  • Apart from modules supplied raw materials for the installation of the oven near the module mini refinery.
    On request, the main control panel and electrical panel are located in a separate building - the operator of mini refineries. The panels come with a finished internal wiring, the wires and cables are arranged so that they provide easy connection to the place.
    Separately mount the mini refinery on the site are available the following items:
  • Piping between the modules of a mini refinery
  • Ladders, platforms and isolation of the atmospheric column and strippers mini refinery

  • Additionally, elements can be combined:
  • Fire protection systems on the modules a mini refinery
  • All the technological scheme with piping and instrumentation, single-line wiring diagrams, sample circuits loads on foundations and installation instructions needed to implement the complete assembly (assembly) Mini refineries.
  • Manuals
  • LIST OF EQUIPMENT MODEL MINI Refinery

    Name of equipment
  • A column of atmospheric distillation mini refinery
  • Column diesel fraction mini refinery
  • A furnace for heating of raw material fed into the atmospheric distillation column of small refineries
  • Heat exchangers (raw material / product) mini refinery
  • Coolers naphtha diz. fractions, kerosene, fuel oil
  • Raw pumps
  • Pumps Irrigation atmospheric distillation column
  • Coolant pumps (or air coolers)

  • Special designs IN DESIGN MINI Refinery

    Design work using steam - This version is designed for cases where the owner prefers to use steam for the operation of the plant. It can be used for a project to provide special order processing system, which requires steam for stripping or heating.
    Execution to work in cold climates - This design is intended for systems operating in harsh winter conditions. Specially designed installation can be used in areas with a temperature below -39 ° C. For such installations are subject to special metals, electrical equipment in the arctic, recirculating air-cooling, heating and electric heat tracing system flushing. Process Modules run closed with thermal insulation, heating and ventilation is provided. Made removable to work in the summer, the walls of the module during transportation to the site provide additional protection for the installation.
    Design with additional cooling of the product - for cooling of the product before it is fed to the storage unit uses water cooling. If you need additional cooling in the summer and in hot climates, the scheme after the end refrigerators with water cooling can be added air coolers that operate during peak periods of high temperatures.
    Design for use as a distillate fuel in the furnace - is used where the fuel gas is not available. Raw furnace can be modified to allow for burning it as fuel oil from the UMT.
    Execution using constructional materials designed for high feed sulfur - Standard installation is designed for the processing of crude oil with sulfur content of 1.5% by weight. and higher. If the feedstock has a higher sulfur content, furnace, pipes, string and some other equipment made of alloyed steel.
    Execution of crude oil with high content of salt - in the event that crude oil contains large amounts of salt in the draft process unit can be used in electrostatic desalting unit and special materials of construction equipment

    DESIGN Modular mini refinery

    Mini Refinery (Refinery) is intended for the production of high-quality commercial fuel. Installation is constructed to ensure compliance with rules and regulations of the Russian Federation GOST and SNIP. Mini refinery equipment is equipped with the necessary equipment, so that during operation of the required minimum supervision by the operator. When proektirvoanie modular equipment is installed at the refinery so as to provide easy and convenient access to the nodes and components during the installation of those. service. Mini refinery is designed with a view to ensuring maximum energy efficiency. All products are produced at the facility are cooled to the temperature required for storage.

    MECHANICAL

    All pumps and heat exchangers of the "tube in tube" set at a modular design. Column atmospheric distillation of crude oil and the column d / fractions delivered mounted on modules according to their transport position. On the job site the customer will be required to expand the column crude oil atmospheric distillation column and diesel fraction in their upright position.
    Structural materials used to manufacture the plant designed for processing low-sulfur oil, and are generally made of carbon steel. The exceptions are control valves, having a coating of an alloy steel and the furnace tube made from an alloy with a chromium content of 5%. At manufacturing plants for processing of raw materials with high sulfur content are used more high-quality construction materials.
    The equipment can be delivered in the winter or arctic regions with cold climates and tropical version for countries with hot climates.
    PIPELINES AND piping
    Designs, manufactures and installs modular basis all the piping between the heat exchangers and pumps.
    All tubing, fittings and valves made of carbon steel or, optionally doped alloys.
    All pipes are modular installation hydraulic test before shipment installation.
    ELECTRICAL
    To control the operation of electric pumps and cooling units as part of the process module is supplied shield electric starter.
    The lighting system installed on the process module, atmospheric distillation column and module capacity / cooling unit.
    Equipment
    The equipment provides all the hardware equipment, the circuits in the pipeline with the devices.
    Equipment supplied equipment pneumatic or electric type of the customer's choice.
    The set also provided the raw panel burners oven to ensure the safe and efficient operation of the furnace.

    PROTECTIVE COATING

    All piping and equipment modules are covered with primer and provided with a layer of thermal insulation in accordance with the schemes of pipelines with strapping equipment.
    All piping and equipment within the module that does not require installation of a thermal insulation layer, covered with soil and paint.

    INSTALLATION

    Mini plant for the production of petroleum products is designed in such a way that ensures fast and easy installation. Mini refinery for the production of motor fuel typically can be fully installed and commissioned with the production of the technical specifications of motor fuel during the three weeks after the arrival of the equipment to the prepared construction site.
    Three modules, which include the manufacturing equipment, the column the atmospheric crude distillation column and the diesel fraction, are designed so that they are adjacent to each other and connected by bolts. All the connecting lines between the modules prefabricated and provided with flanges for easy assembly.

    Design documentation

  • Two (2) sets of data suppliers of components, including original drawings, technical data, parts lists and operating manuals.
  • Two (2) sets of documentation (manuals) on the operation of the plant. These guidelines set out in detail the procedure for transactions carried out during start-up and operation of the plant.
  • Two (2) sets of drawings flowsheet installation drawings of pipelines with strapping equipment, single-line circuit diagrams, layout drawings, and all construction drawings, layout piping, mechanical, instrumentation and electrical drawings required for maintenance and operation of the plant.

  • Spare parts for mini refinery

  • Land, buildings and foundations installation, including site preparation;
  • Systems providing energy required to operate a mini refinery
  • Reservoirs, tanks, boilers and other equipment that is not included in the description of a standard refinery
  • All pipe and cable bridge between the standard setting and the above equipment
  • Firefighting equipment
  • Treatment facilities mini refineries, which must be supplemented by a mini refinery to meet the requirements of federal, republican and local laws and regulations or other administrative permissions to protect the environment
  • DESIGN OTHER MINI Refinery

  • Vacuum distillation
  • Settings hydrotreating and catalytic reforming of gasoline

  • Oil refining

    The purpose of refining (refining) - production of petroleum products, especially various types of fuel (automotive, aviation, boiler and so on. D.) And raw materials for further chemical processing.
    Primary Processes
    Primary treatment processes do not involve changes in chemical and oil are its physical separation into fractions. First, fishing oil passes the primary cleaning process oil produced from the gas, water and solids - this process is called primary oil separation [1].
    Oil treatment
    Oil is supplied to the refinery in the form prepared for transport. At the plant it is subjected to further purification from mechanical impurities, removal of dissolved light hydrocarbons (C1-C4) and dehydration electric desalting plant (CDU).
    Atmospheric distillation
    Oil enters the distillation column for atmospheric distillation (distillation under atmospheric pressure), where it is separated into several fractions: the light and heavy gasoline fractions, kerosene fraction, a diesel fraction and an atmospheric distillation residue - oil. The quality of the fractions does not meet the requirements of commercial oil, so the fraction is further (secondary) processing.
    Material balance of atmospheric distillation of West Siberian oil
  • Gas
  • Gasoline fraction
  • Kerosene
  • Diesel fuel
  • Mazut
  • Losses
    Vacuum distillation
    Vacuum distillation - the process of distillation of oil (atmospheric distillation residue) fractions suitable for processing into motor fuel, oils, waxes and ceresins and other refined products and petrochemical synthesis. The remaining residue was then called the heavy tar. It can serve as raw material for production of bitumen.
    Secondary processes
    The purpose of the secondary process is to increase the amount of produced motor fuels, they are associated with the chemical modification of hydrocarbon molecules that make up the oil, usually to their conversion to more convenient forms for oxidation.
    According to its directions, all secondary processes can be divided into 3 types:
  • Deepens: catalytic cracking, thermal cracking, visbreaking, delayed coking, hydrocracking, the production of bitumen, etc.
  • Ennobling: reforming, hydrotreating, isomerization, etc.
  • Other: Processes for the production of oils, MTBE, alkylation, aromatic hydrocarbons production, etc.
  • Reforming

    Catalytic reforming - catalytic aromatization of petroleum products (increase in the content arena as a result of the reaction of formation of aromatic hydrocarbons). Reformed gasoline fraction are subjected to boiling range 85-180 ° C [2]. As a result, the reforming gasoline fraction enriched with aromatic compounds and the octane number is increased to about 85. The resulting product (reformate) is used as a component for the production of gasoline and as raw material for extracting aromatics.
  • Hydrotreating
  • Catalytic Cracking
  • Catalytic cracking - catalytic thermal refining process of petroleum fractions to produce high octane gasoline component and unsaturated fatty gases. The raw material for catalytic cracking unit are atmospheric and light vacuum gas oil, an object of the process is the splitting of heavy hydrocarbon molecules, which would use them for the production of fuel.
    During cracking, a large amount of fatty (propane-butane) gases are separated into individual fractions, and are mostly used in tertiary processes at the refinery. The main cracking products are pentane-hexane fraction (ie. N. Natural gasoline) and naphtha cracking which are used as components of gasoline. The residue cracking unit is a component of fuel oil.
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    Mini МПЗ

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