The complex of deep crude oil processing KT-1 starts secondary processes of oil distillation at the refinery. KT-1 was the first complex in USSR on deep vacuum processing of oil residue which has been into operation in 1983. The designed capacity of the complex for vacuum distillation of oil residue is 2,0 million t/year.
The design of the first complex KT-1 in the USSR was developed by "Grozgiproneftekhim" Institute (Grozny city) especially for the Pavlodar oil refinery.
ODCOP allows producing additional valuable oil products from oil residue: high-octane component of gasolines of grades AI-92-K4, AI-95-K4, and component of hydrotreated diesel fuel, propane-propylene and butane-butylene fraction (feedstock for petroleum chemistry).
The complex KT-1 is unique in terms of set of process unit:
In 90-s taking into account gathered experience of KT-1 system operation there has been started an extensive modernization of the complex with involving research institutes and design companies in order to extend recovery of light oil products, and to make greater variety of output oil products as well as to enhance environmental situation. As a result of this reconstruction in KT-1 complex the parameter of oil processing depth has been brought up to 84 %, production of high-octane gasoline of grade AI-92 has been launched.
Within 2001-2007 in КТ-1 complex there were significant works performed in terms of replacement of process equipment and improvement of technologies which has allowed increasing output of target products by more than 4,0 %. The overall volume of gasoline is produced with octane number not lower than 92,0 points by research method. Catalytic cracking – capacity has been increased from 1250 thousand t/year up to 1868 thousand t/year; increased output of diesel fraction has been achieved. High quality of oil products is the main parameter of KT-1 performance.
Section 001 the unit of vacuum distillation of oil residue, which is designed for processing mazut by the vacuum distillation method in order to produce:
Section 100 is a vacuum distillate hydrotreating unit, intended for preliminary hydrogenation tempering of feedstock of catalytic cracking for decrease in sulphurous, nitrogenous, oxigenous, metallorganic compounds and polycyclic aromatics with simultaneous decrease in its coking capacity, and also gas treating with monoethanolamine fr om hydrogen sulphide.
Hydrotreating process of feedstock of catalytic cracking is carried out by traditional production procedure and consists of:
Section 200, included in the combined unit of KT-1, is designed for processing hydrotreated vacuum gasoil into more valuable oil products: high-octane component of motor gasoline, feed for producing liquefied hydrocarbon gas, component of diesel fuel, components of commercial fuel oil, also it includes the reaction block of catalytic cracking, the block of rectification and process condensate treatment, air compressor station.
For the reaction block the flow diagram of catalytic cracking is accepted as at the unit type G-43-107ML with a direct-flow riser and fluid catalyst of microspherical shape.
The catalytic cracking of the hydrotreated feed is target-oriented in the set of processes of complex КТ-1 and provides for yield of the following products:
Rectification of the given cracking products is carried out under the traditional process diagram for all models of catalytic cracking in the rectifying column К-201.
The reconstructed block of process condensate treatment (as a part of this section) allows upgrading the qualitative composition of condensate up to the standard level before its dumping to treatment facilities of the refinery.
The section of absorption and gasfractionating is intended for absorption, stabilization and fractionation of unstripped gas and unstable gasoline from the catalytic cracking section.
The section of absorption and gasfractionating consists of the following blocks: