First 1,000 tons of finished products received
For the time of operation of a new industrial (elemental) sulfur production unit of Gazprom neftekhim Salavat about 1,200 tons of sulfur have been produced. The new production facility helps purify the Oil Refinery emissions, reduce atmospheric air pollution and improve the environmental situation.
After the period of commissioning, the project, which is important from an environmental point of view, was fully implemented. Currently, the facility is operating normally, solving the main task, i.e. processing (utilization) of a byproduct of oil refining — hydrogen sulfide formed at hydrotreaters, a catalytic cracking complex and a number of other units of the Oil Refinery. The fact is that hydrogen sulfide volumes are increasing at the company, as various stages of the Oil Refinery modernization are implemented, aimed at reducing the sulfur content in motor fuels. Previously, the capacity of the existing elemental sulfur recovery unit (SRU) (38 ktpa) was sufficient for hydrogen sulfide processing; however, it has a lower degree of conversion, and over time its equipment has become worn-out and obsolete. At the moment, the SRU has been put on standby.
Sulfur, the commercial product of the new facility, is in demand by consumers
Modern technologies have been adopted at the new facility, which increases the efficiency of processes and helps reduce environmental impact. A five-stage oxidation process is used here, including a thermal stage, 3 catalytic stages according to the Claus process and one stage according to the direct oxidation process. Due to this, a higher degree of sulfur conversion from hydrogen sulfide is achieved: it increases from 92–94% to 99.2%, compared to the SRU unit.
Three catalysts are involved in the purification of hydrogen sulfide: aluminium titanium, aluminium oxide and iron oxide catalysts. After such treatment, the minimum content of harmful substances remains in the gas and is disposed of at the afterburner of remaining sulfur compounds. Thus, the already purified process gas is discharged into the atmosphere at the unit outlet.
The air purity at the unit outlet is monitored by several services. Constant monitoring is performed: upstream of the discharge to a chimney, permanent gas analyzers are installed that check gas purity against six parameters. In addition, laboratory staff daily takes samples for analysis and studies them.
The new unit is integrated into the existing chain for the utilization of hydrogen sulfide containing gas at the Oil Refinery
The equipment from Russian manufacturers is used at the new facility.
«The suppliers have proven themselves well, there are no complaints about the Russian equipment,» says Alexander Berezin, Head of the industrial (elementary) sulfur production unit. «We have passed the first stage of comprehensive testing, when the equipment was launched on natural gas, and have checked the operation of thermal reactors and thermal oxidizers. This year, the unit has been commissioned with the intake of hydrogen sulfide containing gas and the production of high grade sulfur. From then on, sulfur has been sold to consumers as a commercial product and used in the chemical, construction and road industries. »
For the period of the unit operation, about 1,200 tons of sulfur were produced. Today, sulfur from Salavat industrial site is transported to rail cars in bulk. It is also possible to ship products from a liquid sulfur filling unit to rail tanks.
The process men note that due to the higher degree of hydrogen sulfide conversion at the new facility, pollutant emissions should decrease by 4,670 tons per year and sulfur dioxide emissions will be reduced by 30%. As a result, the air basin of Salavat, Ishimbay and Sterlitamak will become much cleaner.
For reference:
Gazprom neftekhim Salavat is one of the largest oil refining and petrochemical complexes in Russia. The Complex was founded in 1948.
The Company is integrated into the Gazprom system. It has the basic advantage: consolidating on a single site a full cycle of crude hydrocarbons processing, petrochemistry and mineral fertilizers production. The Company comprises the Oil Refinery, Gas & Chemical Plant and the Monomer Plant.
Gazprom neftekhim Salavat produces more than 150 items, over 50% of which are bulk products including motor gasoline, diesel fuel, fuel oil, styrene, polystyrene, low density polyethylene, high density polyethylene, DOP plasticizer, butyl alcohols, sulphur, ammonia, urea, acrylic acid, butyl acrylate etc.
The products are shipped to all federal subjects of the country. Export supplies of oil products are mainly directed to European and CIS countries. Petro- and gas chemicals are exported to over 30 CIS and non-CIS countries.
High quality of Gazprom neftekhim Salavat output is confirmed by certificates of conformity to ISO 9001 and 14001, the international standards of quality and environmental safety.