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One of priority directions of company work in sphere of protection of environment is reduction of emissions of harmful substances into the atmosphere. Up-to-date design concepts of the front end engineering design (FEED) and stages "Project" have allowed to reach reductions of emissions up to annual 9 700 tons. At the first stage of operation the emissions amount will make 2900 t/year.

Blowout Prevention during the Process Operation

For achievement of considerable reductions of blowout into the atmosphere during the process operation the following design decisions have been made:

• the Plot Plan and configurations of units, a relative positioning of utilities and blocks, their reference to engineering networks are executed so as to take into account a wind rose, and in accordance to existing rules and regulations, SNiP;

• Flow charts, mechanical arrangement of oil refining and petrochemical process units are developed in consideration of the rational use of oil raw materials and fuel and energy resources;

• Natural gas of own make and hydrocarbon gas which is desulphurized are used as fuel in the process furnaces;

• Oil refining processes are carried out in tight vessels under gage pressure and high temperatures;

· For flange gaskets and stuffing box packing effective modern materials are used which provide extended operation;

· Blowout of polluting substances from technological furnaces are reduced at the expense of gaseous fuel use;

· Burners with extra-low formation of nitrogen oxides are applied in furnaces;

· All basic process equipment is located on the open concrete covered platforms;

· Compressors and separate kinds of pumps are located on production premises on the pedestals;

· Decrease of liquid additives, catalysts, dehumidifiers, adsorbents emissions during loading and unloading operations is achieved due to the use of means of mechanization of auxiliary operations of cargo handling works and equipment of vessels containing toxic and light flammable liquids with "nitrogen breathing ";

· Decrease of gaseous and liquefied hydrocarbons emissions from the equipment is achieved due to use of flange connections with packing of highly effective modern materials, valve of A-class and tight pumps with double mechanical seals;

· Process units are equipped with the automated distributed control system and system emergency safe automatic protection on the basis of electronic control devices and automatics, including computer aids that allow to considerably reduce a chance of occurrence of emergencies and to raise stability of process conditions, reliability of control;

· Supply of raw materials from installation tank farms is made by pumps with double mechanical seals;

· Minimum quantity of flange connections is used on pipelines;

· Swapping of process media is made by pumps with unary and double mechanical seals which provide high tightness;

· Viscous products are pumped over by pumps with stuffing box packing;

· Closed system of vessel drain is accepted;

· The units are equipped with fire announcers and HVAC transmitters;

· Highly efficient flue gas treatment systems are used — min. 99 % in processes during regeneration of catalysts;

· Catalytic treatment of flue gases of nitrogen oxides is applied by using ammonia efficient to 80 %, the developer is Haldor-Topse;

· Absorption of hydrogen sulfide (ÌDEA treatment), its segregation (ÌDEA regeneration) are provided;

· Produced of hydrocarbon gases and gasoline hydrogen, sulfide is directed for processing;

· Aspiration systems sleeve filters prevent blowout of dust during loading and unloading of catalysts and dehumidifiers into the equipment;

· Prevention of release of process mediums into the environment during production emergency shutdowns (power, cooling water, etc. cutoff.) emptying of vessels is made into closed drain tanks.

Blowout Prevention during the Storage and Shipment

· Characteristics of tanks, their relative positioning, vessel equipment for filling and emptying, gauging of oil products level ventilation, treatment, sampling, dump of commercial water, maintenance of pressure and foam fire fighting meet the requirements of environment protection and Rules of Industrial Safety for oil refining facilities;

· Tanks are located by groups on the open areas in dikes;

· The tank pipeline hook-up provides a possibility to pump the products from one tank to another at an emergency case;

· On pipelines the minimum quantity flange connections is used;

· Tanks with oil are equipped by floating pontoons of the type "Ultraflout", representing the internal floating design established in tanks which covers an oil surface to prevent its evaporation. It forms impenetrable for steams condensing shutter which keeps a layer of sated steams over a liquid surface. Pontoons, in comparison with other means and devices, provide the greatest effect in reduction of losses of oil from evaporation to 99 %;

· Minimum quantity of flange connections is used on pipelines;

· Tanks with oil are equipped with floating pontoons "Ultraflout" type, representing the internal floating design which will be installed in tanks, and which covers oil surface to prevent its evaporation. It forms impenetrable for vapours condensing shutter which keeps a layer of saturated vapours above the liquid surface. Buoyant pontoons in comparison with other devices and facilities provide the greatest effect in reduction of oil losses during evaporation up to 99 %;

· The oil feed tank farm is equipped for 100 % with gas compensation lines;

· The tanks with gasoline are equipped with floating pontoons of "ConTEK" reducing evaporation up to 99,97 %;

· Tanks with dark oil products (vacuum gasoil) are equipped with hydroseals having nitrogen breathing;

· Dumps from safety valves of vessels go to the closed flare systems that excludes release of gas into atmosphere;

· Railway oil products loading platforms meet the requirements of VUP SNE 87;

· To decrease the blowout into atmosphere, the loading of the products is performed into the bottom part of the tank under the liquid layer;

· The loading of light oil products into railway tanks is carried out at the installation with the block recovery vapours of "John-Zink" with catching efficiency of over 99 %.

Flare Facility

The Complex flare system is worthy to be described separately. The flare system unit is designated for reception and burning of waste gases coming from process units of the Oil Refining and Petrochemical Complex. The detailed design which was executed at the initial stage by Fluor, and then finished by State Unitary Enterprise, Design Institute "BashGyproNafteKhim" provides a possibility of reception and burning of emergency emissions at the three separate flare systems. The package unit for recycling of gases of GÀRÎ (Italy) allows to return after amine treatment about 4700 nm3/hour of purge gases into a fuel network of the Complex. For combustion of gases, a redundant mast flare system (the supplier is OOO "Generation") is used which is equipped with lifting/lowering of stacks system using stationary system of hoists unique for height and design. The mast flare system includes four flare stacks, 140 meters high, for flares of high and low pressure, for sour gases, and the reserve flare stack installed on one base plate and attached to a uniform basic tower 120 meters height.

All four flare stacks are equipped with flare tips which have jet shutters, power saving up pilot burners with a system of remote firing of NAO (USA) who is the leader on designing and manufacturing of the equipment of flare systems. To reduce soot blowout during combustion of hydrocarbons, water steam is supplied to the flare burners. This mast flare system with completely lowering down stacks of 140 m high is the only one in the world. The project of a basic tower and lifting/lowering system is executed by STUDIO TECHNICO (Italy) and redeveloped by Joint Stock Company “Institute Project Steel Construction”. Hoists are made by “Italgru s.r.l” (Italy), the manufacturer of elements of a basic tower is OOO “Nizhni Tagil Factory of Metal Structures”.

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