The Yaya Oil Refinery North Kuzbass is the largest industrial enterprise built in the Kemerovo Region in recent years. It is designed to reduce the acute shortage of fuel and lubricants in the Altai-Sayan region. The design capacity of the first stage processing is 3 million tons, the introduction of the second stage will double the output.
History
Kemerovo region is a large industrial cluster in the south of Siberia. Demands for gasoline, diesel and other fuels and lubricants are constantly increasing. Given the prospect of further growth in the manufacturing sector, in 2008 a fundamental decision was made to build a new oil refining complex in the north of the region.
The main investor was NefteKhimServis LLC, which invested 63 billion rubles in the construction of a unique plant. The work was personally supervised by the governor Aman Tuleyev. In the summer of 2013, the first stage of the refinery started operating, and work is underway on the construction of the second stage. The total capacity of the Yaya refinery will be 6 million tons of refined oil annually. It is planned to bring the processing depth to 93%, which is an excellent indicator. In the future, it is planned to build the third stage.
Description
The Yaya oil refinery was built from scratch from scratch, away from industrial centers. He was dubbed the "Industrial Miracle of Southern Siberia." On a vast territory of 60 hectares, production workshops, commodity parks, multi-kilometer discharge and loading racks, treatment facilities, a circulating water supply unit, transport hubs and other facilities are dispersed.
Industrial buildings and infrastructure of the second stage will occupy another 7 hectares. Foundations have already been laid for flyovers, buildings and structures. In the near future, it is planned to introduce a vacuum distillation unit for fuel oil with a capacity of 1,600,000 tons. It will increase the refining depth to 75% and increase the production of medium distillates of oil (gas oil and others) with high added value.
Production
Kemerovo region - Kuzbass - is the leading coal mining region of Russia. There was no oil refining experience or suitable specialists. The regional administration and investors faced a number of intractable tasks: personnel, production, technological, and logistics. All of them were promptly resolved.
Initially, questions arose regarding the purchase of raw materials, but thanks to new government regulations, the plant can receive petroleum products from all fields in Siberia both via the main pipeline and by rail. The Yaya Oil Refinery has its own loading and unloading station.
The production base includes:
- ELOU-1 installation for primary oil refining;
- diesel hydrotreatment unit;
- hydrocracking;
- delayed coking unit;
- amine hydrogen sulfide purification system;
- reforming with an isomerization unit;
- sulfur producing plant;
- household objects;
- point of reception and delivery of oil;
- a full-cycle railway station, including flyovers for the shipment of petroleum products and the reception of crude oil;
- a 7.5 km long pipeline system connecting the Anzhero-Sudzhensk oil pumping station to the Yaya oil refinery.
The installed equipment allows you to receive gasoline grades AI-92 and AI-95, corresponding to the European quality standard. Yaya Oil Refinery produces:
- diesel fuel (grade A);
- diesel fuel (grade B);
- stable gasoline (brand BL);
- heating oil, low-ash.
Innovation
Designers tried to minimize the “human factor” by entrusting the production cycle to “artificial intelligence”. The entire oil refining process is displayed on the large screen of the centralized control room. Operators monitor in real time all the parameters of the plant. Any non-staff changes in the technological mode are monitored by a special program that alerts specialists with an alarm about possible problems.
In the future, an increase in processing depth of up to 93% will make it possible to abandon the production of heating oil, which has low added value. In addition to fuel distillation, high-tech products will be produced instead: lump sulfur, low-sulfur petroleum coke, vacuum gas oil and other items. Subsequently, YaNPZ plans to bring the quality of diesel fuel to Euro-5 standards.
Frames
The Yaya refinery is an example of enterprises of the future. High-tech automated technologies have been introduced here, as a result, sophisticated equipment serves a surprisingly small number of employees. The optimization of personnel was achieved due to the wide specialization of workers and engineers: in addition to the main, they master related specialties.
The plant allowed to significantly reduce unemployment in the region, providing employment for about 2000 people. Most of the employees come from the neighboring city of Anzhero-Sudzhensk. Near the plant is the village of Yaya. The village, which arose in 1897, has more than 10,000 inhabitants.
In order to work at the Yaya refinery, it is necessary to undergo retraining and advanced training. A number of educational institutions of the region are engaged in this: the Achinsk College of Oil and Gas, Anzhero-Sudzhensky Polytechnic College and others.
Prospects
Further development of the YaNPZ is scheduled until 2025. A new vacuum unit worth 5 billion rubles is being commissioned. The next in line are isomerization and reforming systems (25 billion rubles). The launch of these units will improve the quality of gasoline to “honest” AI-92 and AI-95.
Until 2020, it is planned to install a delayed coking unit worth 18 billion rubles. It is necessary for the production of coke and sulfur. By 2025, management expects to double the volume of refined crude oil by increasing the range of finished products, installing new systems, and increasing the depth of processing. Also, by 2015, a new hydrotreating unit will be built. However, the development of the enterprise does not end there. Already, expansion projects are being developed: the introduction of the third and fourth stages.
Economic importance
The Yaya oil refinery is a solution to global problems with providing the southern regions of Siberia with fuel. Kemerovo region consumes about 3.5 million tons of oil products. After entering the 2nd stage, the plant will cover the needs of both Kuzbass and its neighbors. Accordingly, the budget will receive a significant increase.
Today, the plant sells most of the fuel and lubricants in the Kemerovo region. Thus, the region gains independence from external suppliers of gasoline and diesel, dictating unfavorable business conditions. The sale of low-grade fuel from semi-legal “mini-refineries” has also decreased, and the market for oil products is normalizing.