SIBUR Tobolsk ZapSibNeftekhim
ZapSibNeftekhim LLC
Predominantly Chemicals Operations

From their website:

Production of monomers

Monomer production receives and processes a wide fraction of light hydrocarbons (NGL), which enters the enterprise via a product pipeline from the Western Siberian gas processing plants of SIBUR and other companies processing associated petroleum gas (APG). Subsequently, in a gas fractionation plant, the raw materials are divided into separate fractions: propane, butane, isobutane, and so on. Substances undergo additional stages of processing, after which they are sent to other production facilities to obtain olefins and polyolefins, and are also supplied in a liquefied state to storage parks for further shipment to end consumers using rail transport.

Monomer production facilities include:

  • NGL processing plant (CGFC) with a capacity of 8 million tons per year;
  • butadiene production with a capacity of 207 thousand tons per year;
  • production of isobutylene and MTBE with a capacity of 202 thousand tons per year and 155 thousand tons per year, respectively;
  • propane dehydrogenation production with a capacity of 510 thousand tons per year;
  • production of storage parks, shipment of raw materials and finished products;
  • a plant under construction for the production of maleic anhydride (MAN) with a capacity of 45 thousand tons per year.

Steam Cracking

The capacity is 1.5 million tons of ethylene, 500 thousand tons of propylene, as well as 240 thousand tons of high-margin by-products per year (butadiene, butene-1, MTBE, pyrogasoline).

A pyrolysis plant of such capacity is currently the only one in Russia and is in the top 5 in the world.

The "heart" of the plant is one of the world's largest pyrogase compressors with a capacity of 82 MW - this is 111,500 horsepower, which is comparable in power to 111 Formula 1 racing cars.

Pyrolysis furnaces are the main equipment where the thermal decomposition of hydrocarbon raw materials into components occurs. This process takes place at a temperature of 850 degrees Celsius, which is almost twice as hot as the surface of Venus. ZapSibNeftekhim operates nine pyrolysis furnaces (eight working and one backup). The height of each is 60 meters. Weight - 2600 tons.

The pyrolysis obtained in pyrolysis furnaces enters the distillation columns, where the final separation of the target products - ethylene and propylene - takes place, and then the supply of this raw material to the production of polyethylene and polypropylene. The height of each column for obtaining commercial propylene is 106 m, the diameter is 6,5 m, the weight is 917 tons (which is twice as long and eight times heavier than the Boeing 787 aircraft). The height of the commercial ethylene production column is 64 m, the inner diameter is 6.5 m and the weight is 501.4 tons.

Production of polyethylene

The capacity is 1.5 million tons of polyethylene per year.

Production includes:

  • four polymerization lines (two for the production of various grades of high-density polyethylene with a design capacity of 43.7 tons per hour each and two for the production of linear low-density polyethylene with a design capacity of 50 tons per hour each);
  • Five extrusion lines. Four lines are designed for the production of a product of natural color, a separate fifth line is for the production of pipe grade PE100 with the addition of carbon black (this brand is also in demand in the domestic market, currently mainly imported).

SIBUR at ZapSibNeftekhim uses two of the world's most common polyethylene production technologies, gas-phase and suspension, the combination of which allows the complex to produce a wide range of products. These technologies have not been used at Russian enterprises before, the ZapSibNeftekhim team has become a pioneer in the country in their development.

As part of the production of polyethylene is one of the tallest extrusion buildings in the world - 110 meters. It's like a 37-story apartment building.

Production of polypropylene

The total capacity is 1 million tons of polypropylene per year. This is the largest capacity in Russia and one of the largest in the world.

As part of the production, there are two installations with different technologies for obtaining the target product:

  • Installation based on Innovene technology from Ineos (UK). It was launched in 2013. Capacity - 500 thousand tons.
  • Installation based on Spheгipol technology of the American company LyondellBasell. It was introduced as part of the ZapSibNeftekhim project. Capacity - 500 thousand tons. It includes one propylene polymerization process line and two parallel extrusion lines, each with a design capacity of 40 tons of products per hour.

Logistics platform

ZapSibNeftekhim's logistics infrastructure covers 38.8 hectares and is designed for intermediate storage, packaging and shipment of the company's finished products. The total area of the finished product warehouse is 12 hectares, the storage capacity is 42 thousand tons.

The logistics platform includes a packaging, storage and shipment complex, silos for storing products, three pipeline overpasses, a container platform with four cranes with a lifting capacity of 36 tons and the ability to store 2400 40-foot containers, from which about 200 railway containers with products are shipped per day. There is also a site with a developed infrastructure for receiving, processing and distributing vehicles to warehouses for 270 cars.

Filling and packaging lines include eight mobile FFS machines that pack products at a speed of 2200 bags per hour each with a total volume of 440 tons per hour (in bags of 25 kg). Six throwing machines are also used to ship products in bulk into containers at a speed of 90 tons per hour.

Energy production and energy supply

To meet the needs of production, the company has its own energy system. It consists of:

  • Production of electric heat and steam generation (ETPG). The capacity is 665.3 MW for electric energy and 2223 MW for thermal energy. The main equipment in production includes five steam turbines, nine power boilers, three peak hot water boilers.

Power is supplied to the unified power system of Russia with a voltage of 220 kV and 110 kV. For the needs of the power system of petrochemical industries, the output is carried out with a voltage of 10 kV.

The source of the main fuel, natural gas, is the main line of the Urengoy-Chelyabinsk gas pipeline through the gas control station (GDS). The reserve fuel is fuel oil.

ETPG production is also a key supplier of heat for the housing stock and social facilities of the city of Tobolsk.

  • Auxiliary production: nitrogen-oxygen production (ACP), water supply and sewerage shop (VIC), industrial and wastewater neutralization and treatment shop (NOPSV), heat and gas supply and interdepartmental communications (CTGSiMCC).
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UserPic  Kokel, Nicolas
5/1/2024 7:29 AM
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UserPic  Braun, Uwe
7/11/2023 12:15 PM



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