The oil and gas processing complex is the key driving element of the Tatarstanís economy. The Kama Innovative Regional and Production Cluster industrially specialized in auto industry, oil refining and petrochemicals, has been determined as the republicís economic growth point. TAIF-NK PSC (TAIF Group) is called one of the key members of Innokama, the basic development center of the Kama agglomeration.
TAIF-NKís Heavy Residue Conversion Complex, which is now under construction, is one of the priority national projects, and even today experts qualify it as a future model of the global oil refining industry. Albert Karimov, Deputy Prime Minister of the Republic of Tatarstan, Minister of Industry and Trade, who made a working visit to the HRCC construction site, defined a new enterprise as one of the Tatarstanís key economic projects, and expressed confidence that the company would timely complete the entire construction-related works.
Social Stability Is a Cornerstone of Sustainable Development
While familiarizing himself with the work of the largest industrial enterprises in Nizhnekamsk, Albert Karimov, Deputy Prime Minister of the Republic of Tatarstan, Minister of Industry and Trade visited the refinery, the gasoline plant, TAIF-NKís Heavy Residue Conversion Complex site under construction, and participated in the labor collective conference.
TAIF-NK PSC is one of the major national refining companies, whose development strategy is aligned with the main directions of the presidential program of the petrochemical complex development in Tatarstan. Basic components of the social partnership adopted in the company are the prerequisite for the successful implementation of the companyís tasks. The labor collective conference, where past year operating results and performance of the employment contract were summed up, only confirmed this formula.
In 2015, 8,430,315.378 tons of feedstock were refined including 7,522,125.000 tons of oil, and 908,190.378 tons of gas condensate. The commodity output totaled RUB 143 billion. Over 57% of the products manufactured were exported. Basic production capacities utilization rate was 101.14%.
Expanding production capacities and optimizing the labor in the company, TAIF-NK PSC complies with the fundamental principles and rights in the area of labor by paying decent, continuously indexed wages to the employees, stimulates the work of its employees by implementing a wide range of social benefits, guarantees and compensations ensured based on the financial status of the company. Health care, rehabilitation, sports, physical training and recreation of the employees and their families are the main components of this program. In addition to the Social Mortgage and Development of Industrial Complexes housing programs already existing at the enterprise, a special Additional Housing Program was developed and implemented in 2015 that allowed improving living conditions of all the companyís employees interested.
The social security system established and being developed helps attract qualified specialists, reduces employee turnover, strengthens corporate spirit and makes basis for successful production activities. The indicator of the companyís economic stability is an additional competitive advantage, and, as a result, the number of employees in 2015 increased by 325 people.
When characterizing the performance of the labor collective of TAIF-NK PSC, Albert Karimov gave high rating to the social and industrial strategy of the company, and expressed a hope that the vector of development will keep the direction towards innovations, scientific and technological achievements.
New Generation Technologies
Since 2012, TAIF-NK has been implementing a large-scale investment project of the Heavy Residue Conversion Complex (HRCC) construction. This is a grassroots production site being built within a very short time if compared to the industrial standards and using innovative technologies. The starting point of the project may be considered the conclusion of the EP Contract and the License Agreement for the VCC unit (Veba Combi Cracking) with Kellogg Brown & Root LTD (KBR) in 2011.
The new plant is based on a cutting-edge innovative VCC technology that meets all up-to-date safety, environmental performance and production scale standards. TAIF-NK selected VCC process for the HRCC project based on technological and technical and economic performance of the plant, which will allow TAIF-NK to reach a new level of quality in the oil feedstock refining; the production will be almost waste-free, and the oil conversion depth will reach 98.5%. Whereas currently the company produces more than 20% of fuel oil having much less value than the feedstock purchased (oil and gas condensate), after launching the Complex built based on the unique VCC process, the abovementioned quantity of fuel oil and the surplus vacuum gas oil produced to date by TAIF-NK, will be converted into light and high-quality oil products, in particular:
- diesel fuel with quality not lower than required as per Euro 5 standards;
- naphtha as high-quality feedstock for petrochemical industry development;
- liquefied petroleum gases (LPG) as propane and butane cuts.
Increased oil conversion depth will allow boosting the production volume that results ultimately in significant improvement of the enterpriseís economic performance. The entire product slate of the HRCC will have advanced environmental properties.
To assure the operability of the VCC unit operating based on hydrocatalytic processes, a significant amount of hydrogen will be required. For this purpose, TAIF-NK will build its own 160 kta-capacity hydrogen production plant. A distinguishing feature of this plant is high energy efficiency that implies the use of the heat generated in the process for preparation of high-pressure steam which is further used in the VCC unit pumps and compressors drive.
TAIF-NK refines oil with high sulfur content. The essential share of sulfur is concentrated in heavy oil residues. During hydroconversion of residues at the VCC unit a significant amount of hydrogen sulfide is generated. To remove the hydrogen sulfide from the product stream and further process it at HRCC, TAIF-NK is building a combined 130 kta sulfur production plant. Elemental sulfur recovery process in based on the Claus technology. In addition, the sulfur plant includes methyldiethanolamine (MDEA) solution recovery unit and sour water stripping unit that can significantly reduce the costs of consuming fresh reagents and water in the process. The own air separation unit is built at the HRCC site to supply the Complex with plant air and nitrogen.
Focus on European Standard
Building the HRCC, TAIF-NK focuses strongly on the introduction of advanced resource-saving technologies as well as implementation of measures allowing reduction of an adverse environmental impact from both the planned sites and the company's existing facilities.
The power supply systems of the new Complex involve cutting-edge technologies, state-of-the-art materials and equipment, supervisory control and information systems. Power will be supplied to the HRCC from three independent sources, each having a 110 kV capacity, that will significantly improve reliability, during maintenance, too, that is the most important factor for this production plant. The main step-down substation (SDS) at the HRCC is equipped with S=100 MVA power transformers.
The equipment produced by such global leading manufacturers as Siemens, Schneider Electric, and ABB is used for the construction of power plants of the Complex. State-of-the-art lighting equipment, energy-saving and LED technologies are used in the lightning systems. Within the framework of the energy saving program, modern methods of heat insulation of the equipment and pipelines are applied in the construction; almost the entire Complex has LED lighting. The design of all the HRCC facilities envisages the use the medium 10 kV voltage instead of the standard 6 kV therefore allowing significant reduction of the electrical equipment size and cutting losses during power energy transmission. Using steam to drive turbines also allowed reducing power consumption.
Buildings and structures of the Complex are also built using advanced building materials to optimize costs for creation of the climatic conditions necessary to ensure the reliable operation of the equipment, and comply with sanitary regulations at the workplace of the production staff. Maximum utilization of internal resources generated in the process of the HRCC operation allows significant reduction of the natural resources consumption, and lowering the negative impact on the environment. Due to the launch of the Heavy Residue Conversion Complex, the oil refining process at TAIF-NK will become highly efficient.
High-quality oil products manufactured by the complex will be able to meet the demand from the chemical and petrochemical industry of the Republic of Tatarstan, and the Russian Federation and will be exported.
Innovations in Biological Treatment Systems
Safe operation of the technological process, cooling of equipment, and other needs of the Complex require significant amount of cooling water, which is approximately 128 million cubic meters of water per year or ca. 5% of the entire Nizhnekamsk Reservoir. To materially reduce water consumption by the HRCC, a Water Recycling Section is being developed. This Water Recycling Section is unique because it has film fill cooling towers equipped with special nozzles that allow reducing windage water loss significantly.
Chemically treated water is used for HRCCís technological processes. To reduce the consumption of the chemically treated water for HRCCís operation, condensate treatment unit is being build that allows condensate recycling due to the closed-loop condensate circulation system thus materially decreasing water consumption from outer sources. To collect industrial wastewater and storm water, the reconstruction of local treatment facilities at the refinery has been completed.
The main purpose of this project is to create a closed-loop water circulation cycle with a 99.99% treatment degree that would allow water recycling for technological processes and therefore full elimination of water withdrawal from Kama. Biological treatment facilities (BTF) will be able to process 500 m/h of various wastes including those containing residual oily contaminants. Loading/unloading racks were built with application of the most advanced hydrocarbon evaporation recovery and recuperation systems thus significantly minimizing air pollution.
The start-up of the new production facility is scheduled for 2016. The implementation of TAIF-NKís strategic project is almost on the homestretch and even today it adds value to the Republicís strategy of the future. After the HRCCís start-up Tatarstan will have one of the most efficient production enterprises where a new generation oil refining will be a powerful driver for the expansion of new capacities, social stability strengthening and new prospects for the development of the republic and the entire nation.
Russian Newspaperís reference
TAIF-NK has been implementing the large-scale investment project of the construction of the Heavy Residue Conversion Complex (HRCC) since 2012. HRCC is a strategic project in the field of oil refining. The feedstock conversion capacity of the new Complex will be 3.7 million tons per year. Once the project is implemented, the oil conversion depth at TAIF-NK will increase up to 98%. The companyís profit will almost double.
About the company
TAIF-NK PSC (TAIF Group, Nizhnekamsk, Republic of Tatarstan) is one of the biggest oil refining sector players of the national oil and gas industry. The company embraces a refinery, a gasoline plant, a gas condensate processing plant, and the Heavy Residue Conversion Complex under construction. The companyís product slate includes 22 items: various grades of gasoline, jet, marine, and diesel fuel, road bitumen, liquefied and hydrocarbon gases, etc. The enterprise develops its own petrol filling station. In 2012, the company fully switched to the production of Euro-5 diesel fuel and in 2015 Ė to Euro-5 gasoline.
High quality and environmentally friendly properties of the companyís products were acknowledged with the Prize of the Russian Government in the field of quality, and the victories in local and state contests. For active participation in the project Cultural Heritage of Tatarstan: an ancient city of Bulgar and Sviyazhsk Island-Town, TAIF-NK is listed in the VI volume of the Book of Philanthropists. By the decision of the Ministry of Industry and Trade of the Republic of Tatarstan, the company is listed in the All-Russia Register of the organizations, enterprises and institutions actively participating in the social and economic development of a region and municipalities The Book of Honor 2015.