The Bitumen Production Unit (BPU) is designed for processing crude oil residues and producing high-quality petroleum bitumen. It has been put into operation in 1979.
Design of the unit was made by Grozgiproneftekhim Institute jointly with Rostgiproneftekhim Institute based on recommendations of the Bashkir Research & Scientific Institute for crude oil processing, Ufa.
Design capacity of the BPU is 500 thousand tons/year. The unit is intended for processing of oil tar (mazut) and production of high quality bitumen of different grades: road bitumen, construction bitumen, insulation bitumen, and roofing bitumen.
As a base of technological process of the BPU there is the method of continuous direct oxidation of oil tar (cut>500 °С) in vertical vessels (columns) to the required grade of bitumen.
The unit consists of mazut vacuum distillation section and bitumen section.
The vacuum distillation section is designed for processing of mazut by means of rectification under the vacuum to produce oil tar – feed of bitumen section.
The bitumen section is intended for production of bitumen by means of oxidation of oil tar by oxygen in oxidizing towers.
The Delayed Coking Unit (DCU) has been started-up in 1986. The design of DCU of type 21-10/9M with capacity of oil tar processing of 600 thousand tons a year and output of total coke of 120 thousand tons a year has been done by the «Bashkirproneftekhim» Institue of Ufa city.
The unit has been revamped in 2015. The design capacity on feedstock after revamping has been increased up to 925 thousand tons a year.
The delayed coking unit is designed for production of petroleum coke, besides coke the unit produces the following:
The feedstock of the unit is oil tar (fraction > 500 °С) from section C-001 of KT-1 complex or vaccum block of BPU.
As a basis of coke production process is method of thermal cracking of oil tar in coke chambers at temperature of 460-490 °С with further rectification of coker gas in column К-1.
In steam generation section of DCU and SG there is a boiler used of БМ-35РФ type, intended for generation of water vapor with pressure of 1,4 MPa and temperature of 300ºС. Capacity is 50t/h.
Emergency Gas Station (EGS) together with flare pipelines is serving for collection, short-time storage, compression and recycle of gas and gas condensate for further utilization or combustion on flares. From process units and O&U the gas comes to emergency gas station via flare headers. The discharged flare gas coming from headers goes through condensate KO drums, where gas condensate is getting separated, afterwards off-gas goes to gas holders, gas accumulators to compressors inlet, or through hydraulic to the flare.
Within the limits of refinery’s modernization there has been launched Flare System E911, designed for collection of emergency discharges of hydrocarbon and acid gases from the operation units, scavenging of liquid hydrocarbons and safe combustion of gases discharged on the flare.
Flare system consists of the following sections:
- common flare system for collection of hydrocarbon emissions from process and auxiliary units, consisting of one flare header (further common flare header), flare separators and two flare stacks;
- special flare system for collection of all hydrogen sulfide gas emissions, consisting of one flare header, flare separators and two special flare stacks;- LP flare system for collection of hydrocarbon emissions with pressure less than pressure in common flare header and consisting of one flare header, one flare separator. Flare stacks of this system are the stacks of common flare system.