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Revamp of the Сolumn K-201 on Visbreking Unit at JSC «LUKOIL Neftochim Burgas»

«The Project of reconstruction the main fractionating column K-201 of the Visbreaking Unit of JSC „LUKOIL Neftochim Burgas“ was implemented in 2013.
During the Project implementation, Contractor made the calculations, then changed the technological scheme of the column, changed the point of input of raw materials, made the calculations for internal devices in the lower part of the column and replaced.
As a result of two stages of works in 2010-2013, the flash point of Visbreaking residue increased, content of hydrogen sulfide in the residue reduced, the quality of fractionation of distillate products increased, the reliability of the flushing of the column K-201 achieved and increased, the fluid of the flow areas in the bottom of the column improved, the carbonization of the contact devices of the column minimized, the run-distance between overhauls of the column increased.
We confirm that the work was completed in the required time, quality and in accordance with the technical specification.»

Source of information: Letter JSC «LUKOIL Neftochim Burgas» of 23.06.2017, Ref.No.100-01-3545-23.06.2017

Reconstruction of the heat recovery and cleaning system of the regenerator gases at the Catalytic Cracking Unit.

" In 2014, AD «LUKOIL Neftekhim Burgas» implemented a Project for the reconstruction of the Heat Recovery and Cleaning System of the P-202 regenerator gases from the catalytic dust at the Catalytic Cracking Unit (FCCU) with a capacity of 2 million tons/year.
During the implementation of the Project, the Waste Heat Boiler was changed on new one with boiler water treatment station, the new gas cleaning system (Filter) from catalyst dust with a system for continuous monitoring of harmful emissions was installed, and the closed system for collecting and transporting captured catalyst dust from the boiler and filter to the separate silo for subsequent unloading was installed.
The scope of the contractor's work of the executed Project included the development of project documentation, equipment delivery, installation, supervision and commissioning.
According to the objective control data of the continuous emission monitoring system, the content of catalyst dust in the waste gases does not exceed 10 mg/Nm3.
After two years of industrial operation, the installed System maintains sustainable and reliable performance parameters for the steam capacity of the waste heat boiler, the efficiency of cleaning the regenerator gases from catalyst dust, and ensures compliance with the requirements of European standards (EU 201/75/EC).
The work was completed in the required time, efficiently and in accordance with the requirements specification."

Source of information: Letter of 23.06.2017, Ref.No.100-01-3542-23.06.2017

ENERGY EFFICIENCY ACTIONS

Ceramic coating of the furnaces — Applying High-Emissivity Ceramic coatings «Solcoat-Hi Grey» on the coils and refractory of furnaces is an effective energy-saving actinity. Allowing to significantly increase the efficiency of furnaces by increasing the heat load of the radiant section of the furnace and as a result reduce fuel consumption.

Source: Report of JSC «Gazpromneft — Omsk Refinery» at the Conference on refining technologies in Russia and CIS countries — RRTC-2014 on the topic «Prospects for technological development and ensuring environmental safety».

Ceramic Coating in Furnaces Saves Fuel

The results of monitoring of economic effect by the Office of Improving Production Efficiency and Department of Economics and Finance from Omsk Refinery, we can say today bold – activities carried out on L-35/11-1000 Unit, save for a month greater than 1000 tons of fuel.
The use of ceramic composition pays off in just a year and a half.

Source: Publication of JSC «Gazpromneft-Omsk Refinery» dated May 16, 2016.

The first coatings of this kind appeared at the Omsk Refinery in 2011.
To date, ceramic protection works on Furnaces of KT-1/1, AVD-6, AVD-8, L-24-9, Aromatic Complex, AVD-10 and L-35/11-1000 installations.
In the next few years, «ceramics» will additionally appear on the Aromatic Complex, AVD-10 and FCCU 43-103 installations.

The confirmed direct effect of fuel economy for different complexes reaches 14%.

Source: Publication of JSC «Gazpromneft-Omsk Refinery» dated May 16, 2016.

I am sending to you the best practices developed by our experts of the Competence Centers and specialized Network Groups for further development and implementation.

Appendix:
THE BEST PRACTICES
Item 6: «Application of High Emissivity Ceramic coatings to the coils and refractory of process furnaces.

Source: Letter of PJSC «Gazprom neft» dated August 23, 2017 with Ref.No.NK-17/17491

Efficiency Technologies

The introduction of new technological solutions that can increase production efficiency is mandatory for every major repair. In particular, this year a lot of attention was paid to the modernization of furnaces — the most resource consumption element in a lot of Units at Refinery. New larger-diameter coils were installed at the primary oil processing. This reduces the load on the equipment. After installation, all coils were coated with a High-Emissivity Ceramic coating. According to specialists of the Office of Improving Production Efficiency at Omsk Refinery, the ceramic coating reliably protects the coil pipes from high-temperature corrosion caused by vanadium oxide and other combustion products. And thanks to special additives, the ceramic composition increases the «degree of blackness» of the metal, that is, its ability to accept the radiant energy of the torch. As a result, the pipelines working more efficiently and much longer. A similar coating was applied to the coils of the furnaces of the 43-103 catalytic cracking unit.

Source: Online Magazine «Siberian Oil» (No.147, December 2017).

Applying of energy-saving ceramic coating «Solcoat Hi-e» to the refractory and coils of 36 Furnaces have been performed at the facilities of JSC «Gazpromneft -Omsk Refinery» in the period 2011-2018.

The economic effect of fuel economy on the technological Furnaces of the Omsk Refinery after coating was on average 3-5% for the inter-repair run.

The similar technology of applying ceramic coatings is also used at other enterprises of our Company: LLC «Gazpromneft – SM» (6 furnaces) and PJSC «NIS GAZPROM NEFT» at the Panchevo Refinery (Serbia) (2 furnaces).

Source: Letter JSC «Gazpromneft – Omsk Refinery» from 07 February, 2018, Ref.№ 20/3208

… since 2012 at the present time (May 04, 2017) on the furnaces of these installations (KT-1/1, CPA, AVD-6 of JSC «Gazpromneft – Omsk Refinery») the SOLCOAT coating is in a well-preserved state.

HEC coating has a stable positive effect during the operation of the furnaces after application, to be exact, reducing the wall temperature of the furnace coils in an average of 100-150 ° C; increasing the furnace efficiency up to 3%; fuel savings on average 3-5% (depending on the type of furnace and the ratio of liquid and gas fuel).

Source: Letter from JSC «Gazpromneft – Omsk Refinery» to LLC «Lengiproneftekhim» PJSC «Surgutneftegas» dated May 04, 2017 Ref.№78/10961

Conclusions:
1. The Ceramic Coatings applied to the lining and coils of the Furnaces P-1, P-2 of the AVD-6 Unit and P-1, P-2 of the L-24/9 Unit in 2012-2013 are in a remain preserved.
2. Based on the results of the inspection, it was determined that the coils of the AVD-6 furnaces contain deposits that can be easily removed by mechanical action using a hand tool (medium-hard brush). The formation of deposits is caused by the operation of furnaces in the combined fuel mode (with the use of liquid fuel). During the overhaul in 2015, the coils of the AVD-6 furnaces were cleaned of deposits, and the ceramic coating on the coils and lining was preserved in a complete state after cleaning.
3. Furnaces of the L-24/9 Unit run on fuel gas, deposits on the coils and lining are practically absent. Mechanical cleaning of the coils is not required.

Source: Report of Department of Chief Technologist JSC «Gazpromneft — Omsk Refinery» on the technical condition of the Ceramic Coating in the furnaces of the L-24/9 and AVD-6 Units in 2015 after more than two years of operation

Result:
The minimum economic effect provided for in the Requirements Specification (Activity Passport) was achieved as a result of the works performed. According to the data recorded by JSC «Gazpromneft – Omsk Refinery», the actual consumption of equivalent fuel by the L-35/11-1000 Unit per ton of raw materials was 10% lower than planned in February 2016.
According to the data recorded by JSC «Gazpromneft – Omsk Refinery», the actual consumption of conventional fuel by the L-35/11-1000 unit per ton of raw materials was 10% lower than planned in February 2016.

Source: Excerpts from the Act on achieving economic effect of March 2016

Based on the results of the Aromatic Production Complex (CPA) energy survey, our Specialists developed measures to improve the energy efficiency of the Complex. The largest of them are associated with the furnaces of CPA.
The coils and refractory of five furnaces were coated with a ceramic coating that reliably protects pipes and equipment from high-temperature corrosion. And thanks to special additives, the ceramic composition increases the «degree of blackness» of the metal, that is, its ability to accept the radiant energy of the torch. The first coatings of this kind appeared at the refinery in 2011.
The Confirmed direct effect of fuel economy for different units and processes reaches 5-7%.

Source: Publication in «Neftegazeta» of JSC «Gazpromneft — Omsk Refinery», No.11 (199) dated November 19, 2018

Energy efficiency of the P-101N Furnace at the AVD-1 Unit

«In February 2015, during the overhaul period, there was Project implemented to increase the energy efficiency of the P-101N Furnace of the AVD-1 Unit (manufactured by Foster Wheeler Iberia S. A.) by applying a High-Emissivity Ceramic coating to the lining surface and the outer surface of tube coils in the radiant chambers.
According to the results of monitoring of the furnace operation carried out at the Unit during the 2015-2016 years of operation, a decrease in specific fuel consumption was recorded.

The actual achieved fuel economy affect was about 10% with a payback period of 4 months.

We confirm that the work was completed in the required time, quality was in accordance with the technical requirements specification.»

Source: Letter JSC «LUKOIL Neftochim Burgas» dated 23.06.2017 Ref. No.100-01-3544-23.06.2017

Energy efficiency of the P-1 furnace of the CR Unit.

«In March 2016, during the overhaul period, there was implemented the Project to increase the energy efficiency of the P-1 Furnace of the gasoline Catalytic Reforming Unit by applying a High-Emissiity Ceramic coating to the surface of the soft lining and the outer surface of the tube coils (in the radiant chamber of the furnace) inside the second and fourth chambers of the P-1 Furnace (manufactured by Foster Wheeler).
According to the results of monitoring of the furnace operation carried out at the Unit during the first year of operation, a decrease in specific fuel consumption was recorded.

The actual achieved fuel economy affect was about 11% with a payback period of 10 months.

We confirm that the work was completed in the required time, quality was in accordance with the technical requirements specification.»

Source: Letter dated 23.06.2017 Ref. No.100-01-3544-23.06.2017

High-Emissivity Ceramic coatings reliable protect pipelines and equipment from high-temperature corrosion. More than 2.5 thousand tons of gas fuel, or 14 million rubles a year — is the planned effect of applying «ceramics» to the coils and rafractory of the furnaces at the «Izomalk-2» Unit.
In the autumn, ceramic coatings will appear in the furnaces of Aromatic Production Complex (CPA). The expected effect is more than 26 million rubles a year.
The furnace burners will be replaced with more efficient ones with the individual fuel supply system. The planned effect is 59.5 million rubles.

Source: Publication in «Neftegazeta» of JSC «Gazpromneft — Omsk Refinery» in No.4 (192) dated June 14, 2018

The Project of Denis Dmitrienko deserves attention. His proposed solution of using a special coating for tube furnaces was somewhat of a revelation to me.
The project has a very high potential for further implementation in the Company."

Denis Dmitrienko, Lead engineer of the Chief Technologist Department of JSC «Gazpromneft – Omsk Rifinery»:
" Economic Effect: The introduction of the New Technology on the 300H1-H4 furnaces at the L-35/11-1000 Unit will save about 18.5 million rubles per year.
The idea is to apply High-Emissivity Coatings for heating surfaces of tubular furnaces, which will reduce fuel consumption by at least 4%, reduce emissions of harmful substances to the atmosphere by up to 15%, and increase corrosion resistance.

Source: Speech at the conference of young specialists of PJSC «Gazprom Neft» with the symbolic name «Synergetic Effect» in the Section «Oil and Gas Processing and oil products supply» on the topic «Improving the efficiency of tube furnaces of the JSC „Gazpromneft Omsk Refiniry“ with the help of new technologies»

Conclusions on the operation of C-001 section Furnaces after overhaul:
Reconstruction of the KT-1/1 complex and the implementation of the energy efficiency improving projects at the Furnaces have reduced the specific fuel consumption of the Complex KT-1/1 by about 13.5%.

Expert assessment of 2012 according to the Program of consumption of equivalent fuel.

Source: Report of Heat-Technical Survey of furnaces P-701/1, H-601/1 and P-601/2 from Section S-001 of Deep Processing Complex KT-1/1 for refining the bottom of the column and residues from AD Unit dated March 23, 2012.

Analysis of completed work:
The actual economy of equivalent fuel on comparative loads of 1.3 kg per ton of raw materials (4.6%). At the same time, the actual (currently) negative ambient temperature is a lowering factor (about 0.5 kg equivalent fuel per 1 ton of raw materials), because these furnaces operate on injection burners. The comparative graph is in Appendix 3.

Conclusion:
The implemented measures aimed at energy efficiency of the furnaces correspond to the expected effect (the declared effect was 3.5% fuel economy).

Source: Report dated 31.01.2013 of the Heat Engineering Survey of Furnaces of the AVD-6 Unit after one annual inter-repair run of the Unit

Activity of No.3:
Mechanical cleaning of radiant coils of furnaces and application of High-Emissivity Ceramic coating (HEC) to the coils and lining into the radiation chambers of the furnaces P-101 and P-102 at AVD-10 Unit.

Result:
" In General, the effect of reducing the heat load on the coils and lining was achieved for the Р-101 and P-102 Furnaces. The increase in load is estimated by the difference in temperature of raw materials at the inlet/outlet before and after major repairs (for the Furnace P-101 by 15 degrees Celsius, for P-102 by 16 degrees Celsius). Raw material temperature trends for 2013 are in appendices 3.5 and 3.6. "

Source: Report on the inspection of the furnaces at the AVD-10 Unit with the results and assessment of implemented measures to increase energy efficiency during overhaul in 2013.

Result of visual inspection:
1. On the lining and coils of the furnaces BH-311, BH-312, BH-313, BH-314, BH-315 ceramic coating is intact under a thin layer of deposits (photo №1). Deposits of brown color are removed by manual mechanical action with effort.
2. On the lining and coils of the furnaces ВН-1031А, ВН-1031В ceramic coating is intact under a thin layer of deposits (photo №2). Deposits of gray-brown color are removed by manual mechanical action without much effort.

Conclusion:
The ceramic coating applied to the lining and coils of ВН-311, ВН-312, ВН-313, ВН-314, ВН-315, ВН-1031А and ВН-1031В furnaces during the overhaul in 2012 remain preserved.

Source: Report-2014 on assessment of the ceramic coating technical condition in the Furnaces at the Aromatic Production Complex (CPA) dated 03.12.2014 (через два года межремонтного пробега).

… after applying the HEC Solcoat, the inter-repair mileage of this part of the Coke Calcination Unit increased.

Source: Report of the Department of Chief Technologist of JSC «Gazpromneft — Omsk Refinery» on the topic «Practice of Improving urnaces» dated 06.05.2016

Practice of upgrading furnaces.

Solcoat coatings were applied in the Furnace of the 36/1-3 Dewaxing Unit of LLC «Gazpromneft — Omsk Lubricants Plant”.

Source: Report of the Department of Chief Technologist of JSC „Gazpromneft — Omsk Refinery“ on the accepted practice of improving furnaces, including the application of high-emissivity ceramic (HEC) coatings Solcoat.

We do not object to applying additional internal thermal insulation (based on ceramic compositions) with a High Emission Coefficient on the lining and on the external surface of the heating pipes for raw materials for the furnaces of the LK-6U installation (JSC «Achinsky Refinery VNK» of PJSC «Rosneft») in order to improve there thermal efficiency.

Source: Letter from LLC «LENGIPRONEFTEKHIM» of PJSC «Surgutneftegaz» to JSC «Achinsky Refinery VNK» of PJSC «Rosneft» dated March 16, 2016 Ref. No.17/07-1389EP

Conclusions:
Based on the collected monitoring data on operating of pyrolysis furnace F-15, OOO «Tomskneftekhim» BEFORE and AFTER execution of construction works on the application of High-Emissivity Ceramic (HEC) coatings SOLCOAT, the analysis and calculated the specific consumption of equivalent fuel according to an agreed contract Methodology of effect defining.
According to the results of the second Run, the actual effect of HEC coating applying to the lining surface inside the radiation chamber of the F-15 furnace, expressed in saving the specific consumption of equivalent fuel for the furnace, was 3.03% (three whole and three hundredths of a percent).

Source: Report No.2 from November 17, 2017 (excerpts)

For example, the Technology of High-Emissivity ceramic coating at the Omsk Refinery has gradually moved from the status of innovation to one of THE BEST PRACTICES.

In 2018, High-Emissivity coatings were applied to the coils and lining of the furnaces at the «Isomalk-2» Units and Aromatic Production Complex. As a result, this gave an economic effect of 17.5 million rubles.

Source: The publication of JSC «Gazpromneft — Omsk Refinery» — «Neftegazeta» dated February 11, 2019

The Savings in specific consamption of equivalent fuel for the period from 01/07/2018 to 27/12/2018 (AFTER applying the HEC*) compared to the period from 01/07/2017 to 31/12/2017 (BEFOR applying HEC*) has a value from 12.59% to 14.20% with loading the CR Unit with raw materials was from 104 to 122 ton per hour.

Source of Information: «The Report of the Actual Achieved Effect» dated was accepted by the Customer LLC «LUKOIL — Nizhny Novgorod Refining» after careful recalculations of figures, lengthy verification and approval on Janyary 28, 2019.