Modernization of Afipsky Refinery. The Russia and CIS Project & Equipment Forum RPEF 2015 April 21-22, 2015, Moscow
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1 Modernization of Afipsky Refinery The Russia and CIS Project & Equipment Forum RPEF 2015 April 21-22, 2015, Moscow
2 Contents Current Status of Afipsky Refinery Approved Modernization Program: Completed Projects Current Projects Logistics Project Implementation Management and Monitoring Financing Program Results Conclusions
3 Current Status Afipsky Refinery (ANPZ) is located 18 km to south-east from Krasnodar and 130 km from Novorossiysk. Afipsky Refinery is a city-forming enterprise and represents within Krasnodar Territory: One of the largest tax payers; Largest employment center (Refinery employs over 900 people); Production providing jobs for Krasnodar Territory infrastructure companies; Service Provider (water and heat supply, waste water treatment, etc.) for industrial and residential area of Seversky District.
4 Current Status Two Crude Distillation Units, with capacity of 3 MMTA each, commissioned in 1964 and Afipsky Refinery processes Siberian Light crude. In 2014, Afipsky Refinery produced 5.8 MMTA of products. 46% 17% 37% Export Naphtha Gas oil Fuel Oil
5 Approved Modernization Program Objectives: Capacity Increase; Feed Processing Flexibility Transition from Siberian Light to Urals; Higher Conversion Rate; Improvement of Product Quality. Growth of competitiveness and social significance of Afipsky Refinery
6 Completed Projects From 2010 to 2014 Afipsky Refinery has successfully implemented following modernization projects: Capacity increase from 2.6 MMTA to 6 MMTA; Expansion of main pipelines, feed introduction and oil product shipping systems; Railway facilities, utility systems and off-site facilities revamping; Implementation of modern automated control and safety systems.
7 Current Projects Phase 1 Construction of Fuel Oil PM- 3 Processing Unit. Commissioning in I quarter of Phase 2 Construction of Crude Distillation Unit with capacity 3 MMTA. Commissioning in I quarter of Phase 3 Construction of VGO Hydrocracking and Diesel Hydrotreating Complex. Commissioning in III quarter of 2017.
8 Current Projects Phase 1 Construction of Fuel Oil PM-3 Processing Unit: Purpose: higher profitability due to production of VGO and residual fuel oil М-100; Unit Configuration: Section 100 Vacuum Distillation of straight-run fuel oil (3.3 MMTA); Section 200 Vacuum Residue Visbreaking (1.65 MMTA); Section 300 Hydrogen Sulfide Disposal; Status: Completion of detailed design, construction is under way.
9 Current Projects Phase 2 Construction of Crude Distillation Unit with capacity 3 MMTA Purpose: Crude distillation capacity and feed flexibility increase; Focus on minimization of capital costs and energy efficiency; during design engineering Status: Process layout engineering study.
10 Current Projects Phase 3 Construction of VGO Hydrocracking Complex: Purpose: VGO processing with maximum Euro-5 diesel fuel yield; Configuration: VGO Hydrocracking Unit (licensor CLG); Hydrogen Production Unit; Sulfur Recovery Plant; Sour Water Stripping Unit; Amine Regeneration Unit. Status: Project submittal in June, 2015.
11 Current Projects Phase 3 Construction of VGO Hydrocracking Complex: Project Implementation Strategy: FEED and project documentation development and long-lead equipment procurement at early stage; FEED Contractor CB&I also provides coordination of Licensors activities;
12 Key Objectives within FEED: Development of basic design for all units of the Complex; Completion of all engineering studies and interpretation; Current Projects Phase 3 Construction of VGO Hydrocracking Complex: Development of preliminary 3D-model; Cost definition using open-book method; Issue of enquiry specifications and data sheets for long-lead equipment.
13 Current Projects Phase 3 Construction of Diesel Hydrotreating Unit: Purpose: Processing of straight-run diesel and visbreaking naphtha; Unit capacity: 3 MMTA; Licensor: Haldor Topsoe; Status: basic design complete, project documentation is under way, project submittal in August, 2015.
14 Current Projects New Off-site Facilities within Modernization Program: Main step-down substation; Central control room; Main transfer pumping station; Startup boiler room; Offsite fuel gas supply system; Water and condensate treatment unit; Recycling water supply systems; Local treatment facilities; Flare gas disposal unit; Nitrogen, utility air and instrument air supply unit; Expansion of main pipeline system.
15 Logistics From Sea of Azov via Protoka and Kuban rivers to Afipsky township: Transshipment from sea barges to river barges using floating crane; No river bridge revamp is required; Construction of temporary berth close to Afipsky; From Afipsky township to construction site: Construction of temporary roads from berth to regional road; Investigation and dam reinforcement close to the township; Construction of temporary passage and crossing. Successful transportation of vacuum column (35х10Х10, 279 t)
16 Logistics
17 Project Implementation Management and Monitoring Development of multi-level construction management system; Primavera is used for management, monitoring, resource, materials and equipment tracking; Visualization is provided for activities on construction site using video surveillance; Laser 3D-scanning is used for accuracy of construction works.
18 Financing Project financing; Sberbank of Russia is the Creditor; Euro Petroleum Consultants (EPC) is Creditor s technical consultant: Technical support in project implementation best practices; Supervision and construction site inspection; Key contracts negotiation; Councelling prior to credit line opening and funds drawing.
19 Program Results Crude processing capacity increase up to 9 MMTA; Production of Euro-5 diesel: 5.2 MMTA; EBITDA (Brent crude oil price $60 per barrel forecast): 730 $MM/year. Product Balance after Modernization Program Implementation, MMTA 6,0 5,0 4,0 3,0 2,0 1,0 0,0 5,2 1,9 1,6 бензин Export экспортный Naphtha технологический дизельное топливо Diesel мазут М-100 Fuel Oil M-100
20 Conclusions Modernization Program will enable significant increase of Afipsky Refinery competitiveness; Afipsky Refinery will prove its regional social significance; Implementation of advanced complex approach, with all engineering design, equipment logistics and control aspects been considered, is a primary condition for success.
21 Thank you for your attention!
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