Project for the manufacture and delivery of hydrocracking reactors for Tuapse Refinery (OJSC Rosneft)

As part of a contract concluded in 2010 between Izhorskiye Zavody and Tuapse Refinery (part of OJSC Rosneft), in 2012 OMZ Group completed the manufacture and delivery of six heavyweight vessels intended for the deep conversion of oil and the production of high-quality Euro 5-compliant fuel. The total weight of the equipment amounted to more than 5 thousand tons, and two vessels have the following unique weight and dimensions: height – over 40 meters, diameter – more than 5 meters, weight – about 1,400 tons. This was the first time that these types of petrochemical reactors had been produced in the Russian Federation.

The manufacture of vessels is performed in accordance with the requirements of the ASME Code and Russian regulatory documents for petrochemical production equipment. The licensor of the project was Chevron Lummus Global (USA), which is one of the world's largest companies engaged in the development of state-of-the-art technologies for deep conversion of hydrocarbons.

Shipment of the hydrocracking reactors to Tuapse Refinery was a unique transport operation, as this was the first time in the history of Izhorskiye Zavody that products were shipped to the customer in batches of three petrochemical vessels at a time, with a total weight of over 2,600 tons. All vessels were shipped to the customer by waterway from the Izhorskiye Zavody loading dock on the Neva River in the village of Ust-Slavyanka.

The Customer

Rosneft is the leader of Russia's oil industry and one of the world's largest publically traded oil and gas companies. Rosneft's core activities include exploration and production of oil and gas, production of petroleum products and petrochemicals, and the sale of such products. The company is included in the list of strategic enterprises of Russia.

Rosneft's geographic coverage for exploration and production includes all main hydrocarbon provinces of Russia: Western Siberia, Southern and Central Russia, Timan-Pechora, Eastern Siberia, the Far East, and the Arctic sea shelf. The Company also has active projects in Kazakhstan, Algeria, Venezuela, and the United Arab Emirates.

The main competitive advantage of Rosneft is the size and quality of its resource base. The company has 22.8 billion BOE of proven reserves, which is one of the highest among publically traded oil and gas companies of the world.

The cumulative oil refinement volume of the company's refineries for 2010 set a record for the Russian refinement sector at 50.5 million tons (369 million barrels). Rosneft plants have an advantageous geographic distribution that enables significantly higher efficiency in delivery of produced petroleum products. Rosneft is currently implementing projects to expand and modernize its refineries in order to improve the balance between production and refinement, as well as to increase the output of high-quality products with high added value that also comply with the latest environmental standards.

One especially notable project in the company's development program for the refinement sector is the expansion of capacities at Tuapse Refinery from 5 to 12 million tons (from 37 to 88 million barrels) per year. This project involves using the territory of the existing refinery to build a new state-of-the-art plant with a Nelson complexity index of approximately 8 and a light product output of 90%. In addition, the vehicle motor fuel produced at the refinery will comply with classes 4 and 5 (Euro 4 and Euro 5 equivalent). The Tuapse plant is distinguished by its more advantageous geographic location among Rosneft's refinement assets, which determines the high economic effectiveness of its capacity expansion project.

The project is being implemented in two stages. The first stage, which is planned for completion in 2012, includes construction of a crude oil distillation plant ELOU-AVT-12 with a naphtha hydrotreatment section, as well as general plant utilities. The second stage, which is planned for completion in 2014, includes construction of a unit for vacuum gas-oil hydrocracking and diesel fuel hydrotreatment, a unit for hydrogen production, isomerization and hydrotreatment of naphtha, a unit for catalytic reforming, sulphur production, and a flexicoking unit.

For more than ten years, Izhorskiye Zavody has been Russia's largest machine-building facility producing unique reactor equipment for hydrocracking units, hydrotreatment units, catalytic cracking units, and others. In recent years, it has designed and manufactured more than 150 vessels, including vessels with customized weights and dimensions.

Technical capabilities

Izhora industrial facilities have developed and implemented an integrated (end-to-end) technology for producing heavy petrochemical reactors constructed from large-sized forged shells made of chromium-molybdenum-vanadium steel, which is the primary material used by global leaders manufacturing similar equipment.

Izhorskiye Zavody has the technical capabilities to manufacture petrochemical equipment in accordance with ASME codes and Russian standards, and with the following parameters:

  • Outside diameter, mm; from 500 to 9,000
  • Length, mm: from 300 to 80,000
  • Wall thickness, mm: from 4 to 450
  • Weight, tons: from 0.05 to 1,450
  • Operating pressure, MPa: up to 250
  • Operating temperature, 0C: from -70 to +600

An important competitive advantage of Izhorskiye Zavody is the fact that a single production site contains its own high-quality metallurgy (OMZ-Special Steels), a scientific research center (TK OMZ-Izhora) providing metallurgical support of all production stages, and a design bureau capable of using modern software systems to design equipment that meets the requirements of global licensors.

To ensure high strength of reactors used for oil refinement, Izhorskiye Zavody developed and successfully employ a large number of unique welding and overlaying technologies. The technology of welding chromium-molybdenum-vanadium steel with a large thickness (more than 200 mm) has been mastered by only a few companies in the world, and Izhorskiye Zavody is the only Russian company employing this technology. Another unique technology that it developed and implemented in the production of reactors for oil refinement is homogeneous one-layer corrosion-resistant electroslag strip cladding with a width of 90 mm.