R&D program of Gazprom. Interview with Andrey Kleimenov, Head of the Scientific and Technical Development Department of the Gazprom Neft Oil Refining Directorate
principled technology system units 35-11/300
Raw material from the tank farm through the raw material flow meter is fed to the intake of centrifugal pumps TsN-1.1 a, which is supplied for mixing with the circulating hydrotreating gas. The constancy of the flow of raw materials is regulated by a valve installed on the pipeline for supplying raw materials from the pump TsN-1.1 a.
The raw gas mixture (raw material and circulating hydrogen-containing gas) passes through the annular space of the T-1/1,2,3 heat exchangers, the convection section and eight pipes of the 1st radiant chamber of the P-1 furnace, then the cylindrical vertical furnace and then enters the series-connected reactors R -1, R-2 (see Fig. 2.3).
Reactor of the hydrotreating unit of the catalytic reforming unit L-53-11/300
1 - product input; 2 - product output; 3 - zonal thermocouple; 4 - external thermocouples along the circumference; 5 - fitting for unloading the catalyst; 6 - light fireclay; 7 - reactor vessel; 8 - shotcrete lining.
Reactor of the catalytic reforming unit of the L-35-11/300 unit
1 - product input; 2 - product output; 3 - zonal thermocouple; 4 - external thermocouples; 5 - fitting for unloading the catalyst; 6 - porcelain balls; 7 - reactor vessel; 8 - shotcrete lining; 9 - output of products during system ejection during catalyst regeneration.
The temperature at the inlet and outlet of the convection chamber of the P-1 furnace, the temperature at the exit from the 1st radiant chamber P-1 to the P-104 furnace is measured by instruments.
The constancy of the temperature of the raw gas mixture at the outlet of the P-104 furnace is maintained by a regulator operating in a cascade control system with a fuel gas pressure regulator supplied to the P-104.
Control over the temperature of the catalyst bed is carried out in each reactor by 2 multi-zone thermocouples.
From the R-2 reactor, the gas-product mixture with a temperature of not more than 400°C as a coolant enters the pipe space of the heater T-3 of the K-1, T-1 / 1,2,3 stripping column, through the refrigerators X-101, X-1 /1,2 and with a temperature not exceeding 60°C enters the C-1 separator.
For more flexible plant operation and for production repair work bypassing of Kh-101, Kh-1/1.2 refrigerators and bypassing of Kh-6, Kh-ba refrigerators is envisaged (Fig. 4).
Refrigerator of the reformer block
1 - body; 2 - flanges; 3 - bottom; 4 - floating head cover; 5 - tube grids; 6 - tubes 20 25x3; 7 - partitions; 8 - junction box; 9 - gas product mixture inlet Dy 300 mm; 10 - output of the gas-product mixture Dy 300 mm; 11 - water inlet Dy 250 mm; 13 - descent; 14 - air vent; 15 - fixed support; 16 - movable support
In the C-1 separator, the reaction products are separated into a hydrogen-containing gas and an unstable hydrogenate.
The liquid phase of the C-1 separator - unstable hydrogenate - passes through the tube space of the T-2 heat exchanger, where it is heated by the heat of the stable hydrogenate - the bottom product of the K-1 column, then is fed to the 23rd plate of the K-1 stripping column. To control the inlet temperature to K-1, a bypass of the T-2 heat exchanger is provided.
In the stripping column, light hydrocarbons, hydrogen sulfide and moisture are stripped from the unstable hydrogenate. The top product of the K-1 column with a temperature not exceeding 150°C passes through the XK-101 air-cooled refrigeration condenser and XK-1 water cooler and enters the S-102 separator.
For the convenience of work and repair, it is possible to bypass refrigerators ХК-101, ХК-1.
The temperature of the top of the column K-1 is controlled by the device pos. TR 174-3, temperature of product exit from refrigerator ХК-101 and ХК-1 by devices pos. TR 82-5, TR 82-3.
To control the temperature of the top of the column, an injection of acute irrigation is provided on the upper plates K-1 (30.28) of the liquid phase of the separator S-102 using TsNG-118 (119) pumps. The constancy of the irrigation flow rate of the K-1 column from S-102 is controlled by a circuit, the valve of which is installed on the discharge line of the TsNG-118 (119) pumps.
The level in the C-102 separator is maintained by a regulator, the valve of which is installed on the pipeline for discharging excess product from C-102 to the light gasoline line at 24-6/3 or at K-6. There is a scheme for discharging excess product from S-102 from the inlet and outlet lines of TsNG-118 pumps (119).
The water settled in the S-102 separator with hydrogen sulfide and ammonia dissolved in it is drained into a special. sewerage.
Hydrocarbon gas from the C-102 separator is fed into the K-3 absorber, which operates as a droplet separator. Hydrocarbon gas from the K-3 absorber is discharged into the plant's fuel network.
The hydrogenation product freed from hydrogen sulfide, ammonia, dissolved gases and water from K-1 enters the annular space of the T-3 reboiler, the annulus of the T-2 heat exchanger, then it is fed by the TsN-2 pump (3) to the T-206 Pakinoks heat exchanger (Fig. 5).
Heat exchanger "Paquinox"
Feedstock and circulating HSG are mixed inside the heat exchanger.
The Pakinox welded plate heat exchanger consists of a bundle of plates inserted into a calender. The bundle is made of corrugated stainless steel plates obtained by explosion molding, stacked one on top of the other and separated by spacers along the edges (between the plates). The feedstock is injected into the "lower part of the heat exchanger (cold side) through the injection tubes. It is entrained in the bundle by the circulating gas (SHG). The mixture is propagated in the bundle where there is a thermal exchange with the outflowing product (hot). The C+SHG mixture begins to evaporate. Upper header allows even distribution of the hot stream.
To prevent deformation of the beam, the latter is placed in a calender, the pressure in which is constantly maintained by circulating HCG.
In conditions normal operation recycle gas circulates the charge in the bends of the catalytic reformer plates and pressurizes the calender. The recycle gas in the calender is present in a stagnant state. The calender is heated by beam convection. The bundle is placed on two supports located in the upper part of the calender. Starting from this level, the beam can change in size freely, the differential thermal expansion of the steel is taken over by compensators. The distance between the plates is not more than 2.5-5 mm. The apparatus is isolated from the outside.
Scheme of operation of the heat exchanger "Pakinoks"
To control the temperature at the bottom of the K-1 column, the vapor phase from the T-3 reboiler is returned in the form of a "hot jet" to the K-1 column below the evaporative zone. To control the temperature of the "hot jet" on the T-3 reboiler, a bypass of the gas-product mixture coming from the reactors is provided.
"url="http://newgaztech.ru/news/default/view/id/121">Program innovative development Gazprom until 2025 was approved in June 2016. The main goal of the program is to constantly improve the technological and organizational level of the company's development in order to maintain the position of a global energy company and a reliable supplier of energy resources. As part of Gazprom's innovative development program up to 2025, much attention is paid to research and development (R&D) and experimental design (R&D) and pre-investment studies. For these purposes, the company annually allocates a significant amount of funds. In 2017, Gazprom allocated RUB 8.2 billion for research and development.
In 2017, over 325 R&D results were implemented at Gazprom Group facilities, the expected economic effect of which exceeds RUB 310 billion.Recall that the effect of the results of R&D implemented at Gazprom in 2016 was estimated at more than 279 billion rubles . Gazprom improves corporate system intellectual property management. In particular, the company's patent strategy until 2025 is being developed. It will optimize work in the field of legal protection created technical and technological solutions. It's about about a large amount of work - in 2017 alone, Gazprom received more than 200 patents and filed over 250 new applications. The program has been formed and has been implemented since 2017 scientific research and developments carried out by the institutes of the Russian Academy of Sciences in the interests of Gazprom. An important direction in the implementation of the innovative development program is cooperation with Russian institutes and universities. In 2017, 4 new research and development programs were approved that universities are doing for the company. Gazprom is actively involved in the development of new and improvement of existing educational programs that meet the strategic long-term interests of the company. In 2017, such work was carried out in 72 programs. In addition, Gazprom closely cooperates in science and technology with companies from related industries and foreign partners. The Board of Directors approved the progress report on the implementation of the 2017 innovation development program and the updated Gazprom Innovation Development Program until 2025. Former Gazprom Management Board
Andrey Vladimirovich, please tell us about the priority R&D areas of Gazprom Neft. What is on the agenda in the first place?
As you know, we have approved strategic guidelines until 2025. By this time, we must take a leading position in the catalyst business, introduce own technologies and establish itself as a leader in the development of fundamentally new products and technologies. Among them are catalysts for catalytic cracking, catalysts for hydrogenation processes, reactivation technology.
- What do you see as the key advantage of the company in the development of the catalyst business?
The fact that we not only develop, but also test all technologies ourselves on our own assets. This allows you to make sure that the results obtained are highly reliable, that the new technology will increase production efficiency. During tests, we get objective information about how promising the technology is and how quickly it can be introduced into production processes.
- Tell us about the catalystoligomerization. What is its advantage?
It was developed jointly by specialists from Gazprom Neft and UN T. This year, industrial tests of the new oligomerization catalyst were successfully completed. An experimental run showed that in terms of technical characteristics it exceeds the performance of similar catalysts presented on Russian market. The developed catalyst is guaranteed to demonstrate an increased inter-regeneration run, 2.5 times in comparison with the analogue. The output of the oligomerizate is increased by 30%. While the octane number of the oligomerizate is more than 93 pp.
- Is it possible to evaluate the economic effect of using this catalyst now?
Yes, the economic effect achieved at one unit of the Moscow Oil Refinery (NPZ) for the year, according to preliminary estimates, amounted to more than 180 million rubles. It is also important that a typical oligomerization catalyst after a month run requires regeneration in order to restore catalytic activity. The service life of the catalyst developed by us between regenerations is 55 days. The total service life of the catalyst has been increased from 2.5 to 5 years. Accordingly, this will greatly affect the effectiveness of the technology.
Experiments at the Omsk Refinery
- Tell me aboutaroforming. What is this technology?
Aroforming is sweeping the planet - similar technologies are being intensively developed in China, the United Arab Emirates and especially in the USA, for example, in Houston. Here we must understand that the time of discoveries is over, it is difficult to invent something new. Therefore, sometimes it makes sense to enter technologies that already exist and are effective on the market, and in exchange for introducing them to patent holders, to bear the costs of commercialization and promotion. This is exactly what happens with aroforming.
In the future, the aroforming unit at the Omsk refinery will be able to produce 450 thousand tons of high-octane component of motor gasoline per year.
- The component will be called "aromaformat"? What are the benefits of the technology?
Yes. Aroforming, by the way, is a registered trade name. It is important to immediately indicate that the composition of the aroforming catalyst does not contain platinoids. It is possible to use raw materials from our catalytic factory as co-components for this catalyst. The pressure is small - 5-10 atmospheres, several times less than in reforming. Equipment is lighter and cheaper. The aroforming catalyst processes fractions with a predominance of C 7 hydrocarbons, which are not suitable for processing by classical methods such as catalytic cracking or reforming. They are low-margin, because there are no reasonable methods for processing them. We have to pour them into stable gas gasoline, where there are a lot of low-octane components and further processing is difficult.
Aroforming just allows you to get high-octane commercial gasoline with a low content of benzene and sulfur from a low-margin product. Other technologies cannot process such low-octane fuel.
100% Recovery
If we talk about the catalytic cracking and hydrotreating catalysts most in demand on the market, what is their future fate? What are the R&D priorities?
The main priority is catalytic cracking catalysts (FCC), very high degree of readiness, with real economic effect. We will move towards reducing the sulfur content in products, towards Euro-6 environmental standards and, possibly, even higher. The world is already working on these standards, and we must be ready.
Some plants have certain advantages - and FCC catalysts can emphasize them if the catalyst composition is rationally tailored to the needs of the consumer. For example, for the Serbian company NIS, we developed and specially selected a catalyst that made it possible to obtain less gas and gasoline, but more kerosene and diesel fuel. Which, of course, turned out to be in demand in the Serbian market and allows you to increase economic efficiency.
In the field of hydrocracking catalysts, we are also actively developing. We got very good first results - at the level of foreign analogues. We will move on, including providing batch loading of catalysts for two-stage hydrocracking, which is now actively spreading in the world and will eventually be available at large Russian plants.
- What about hydrotreatment catalysts?
In terms of hydrotreatment, we observed a good effect when using the diesel fuel hydrotreatment catalyst reactivation technology developed by the company together with the Siberian Branch of the Russian Academy of Sciences. We took the spent catalyst from the hydrotreatment unit of the Omsk oil refinery, carried out oxidative regeneration, that is, the removal of carbon compounds deposited on the catalyst surface during the hydrotreatment of diesel fuel. Then they carried out a reactivation procedure - the restoration of active centers with special reagents. An industrial batch of catalyst for deep hydrotreating of diesel fuel, reactivated according to the developed technology, showed high efficiency- at the level of fresh catalyst - at the L-24-6 unit of the Omsk Oil Refinery as part of production program. The reactivated catalyst has demonstrated the necessary stability and stability under changing conditions technological process and properties of processed raw materials (up to 11% of catalytic cracking gas oil was involved in the raw materials) from May 2016 to April 2017, ensuring the production of Euro-5 diesel fuel.
Service life - up to 8 years
- Newly developed catalyst production technologyreformingstationary layer. Tell us about this technology.
It was developed by the Omsk (SB) RAS (IPGTU SB RAS). The first pilot batch of 15 tons will be produced at the Angarsk Catalyst Plant in 2018. The advantage of this catalyst is the reduction of aromatic hydrocarbons by 4-5% compared to imported and domestic analogues. Starting operating temperatures are also much lower - by 10-15 degrees. Octane number- at the level of 95-96 points.
Thus, the quality of the final gasoline increases, the total aromatics decreases, and the reformate yield remains at the level of imported analogues.
Currently, an international application has been filed in order to protect the company's rights to international market(in 150 countries). The service life of reforming catalysts is up to eight years. In 2019, a pilot run is planned at the L-35-11/300 unit at the Moscow Oil Refinery.
- In general, should the experience of cooperation with you be considered successful?
Our strategic partner in the development, production and application of cracking catalysts. Thanks to this partnership, Gazprom Neft regularly upgrades its range of catalytic cracking catalysts to meet the growing market needs. During a meeting of the Scientific and Technical Council of the Gazprom Neft Logistics, Refining and Marketing Block in December last year, a general agreement was signed: Gazprom Neft, Gazprom Neft-ONPZ, Gazprom Neft - Catalytic Systems and agreed to cooperate in the development of high-performance catalytic cracking catalysts for the company's refineries and its catalyst business until 2025.
Small Catalysts
At Gazprom Neft plants, there are not only hydrotreatment processes, but also hydrotreatment of raw materials?
- Right. In October, the Omsk Refinery launched a pilot run of a new isodewaxing catalyst GIP-14, developed as part of R&D for the production of diesel fuels of winter and arctic grades. As part of the production program, the catalyst ensures the production of winter diesel fuel in accordance with GOST 55475-2013 with a limiting filterability temperature in the range of −42...-44 °С (at the norm of −38 °С). The project was carried out as part of the import substitution program in cooperation between ONPZ / VNII NP, the resulting catalyst does not contain precious metals, and when using it, diesel fuel is obtained with the required low-temperature properties under milder conditions compared to the imported analogue.
- And what can you say about the "minor" catalysts, so to speak, of a small categoryand?
If, for example, we develop a catalyst that will allow us to get at least 2 times more paraxylene instead of the entire amount of xylene, it will be wonderful!
Summing up, we can say that we will strive to ensure that in a few years the company will be almost completely provided with its own catalysts. This will ultimately bring the independence of domestic oil refining from external suppliers in terms of main catalysts.
Oleg Martyanov: we go from fundamental research to ready-made solutions within one structure
In March of this year, as a result of the accession of the Institute of Hydrocarbon Processing Problems of the SB RAS (IPPU SB RAS, Omsk) to the Novosibirsk Institute of Catalysis of the SB RAS, the Federal Research Center "Institute of Catalysis of the SB RAS" was established.
Gazprom Neft is developing a catalyst production project in Omsk
Gazpromneft Catalytic Systems will receive pilot units for testing catalysts for hydrotreatment and hydrocracking processes, the press service of Gazprom Neft reported on March 12, 2019. » on the creation in Omsk of a modern complex for the production of domestic high-tech catalytic systems for key processes oil refining.
The Federal Research Center (FRC) "Institute of Catalysis of the Siberian Branch of the Russian Academy of Sciences" was established
March 13, 2019 - the date of the formation of the Federal research center(FIC) "Institute of Catalysis of the Siberian Branch of the Russian Academy of Sciences", specializing in the field of catalysis and related sciences. The catalytic FRC arose on the basis of the Institute of Catalysis of the SB RAS by joining the Institute of Hydrocarbon Processing Problems of the SB RAS (IPPU SB RAS, Omsk) as a branch called the Center for New Chemical Technologies of the IC SB RAS.
CPNI “Resource and Energy Efficient Catalysts and Processes” was formed
The Federal Agency for Scientific Organizations organized the development and formation of the Comprehensive Research Plan (CPNR) “Resource and Energy Efficient Catalysts and Processes”. KPNI are built according to the design principle.
