CHALLENGES FACING RUSSIA IN THE EFFORTS TO MODERNIZE THE PETROCHEMICAL AND GAS CHEMICAL INDUSTRY
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1 OAO VNIPIneft CHALLENGES FACING RUSSIA IN THE EFFORTS TO MODERNIZE THE PETROCHEMICAL AND GAS CHEMICAL INDUSTRY V.M. Kapustin OAO VNIPIneft General Director, Gubkin Russian State Oil & Gas University, Head of the Oil Refining Technology Department, RF Honoured Scientist Moscow, April 2014
2 SITUATION IN GLOBAL PETROCHEMICAL INDUSTRY IN GLOBAL PETROCHEMICAL INDUSTRY Annual investment into the global petrochemical industry is ~ USD 25 bln. Main trends of the global petrochemical and gas chemical industry: The global petrochemical and gas chemical industry will continue its development with the pace exceeding the world GDP growth rates; the lead factor will be 1.1 to 1.2 for well-developed countries and 1.4 to 1.5 for developing countries, including India and China. Large-scale petrochemical and gas chemical production is moving to regions with nonexpensive raw materials, convenient logistics and fast-growing demand (Middle East, North- Eastern Asia). Major petrochemical and gas chemical clusters will continue to be built in China, India, and the USA. RUSSIAN PETROCHEMICAL INDUSTRY The investments to the RF gas chemical industry increased by 4.3% and amounted to 12 bln Rbls in Petrochemical throughput increased by 19.3% and amounted to 9.9 MTA. A share of the petrochemical industry in the industrial sector is 2% in Russia, while it is 30% in China and 25% in the USA. The maximum pyrolysis unit capacity ~ 650 kta (over 1 MTA in the world). Produced: (% to 2012) olefins 4.3 MTA (+13%) polyethylene 1.64 MTA (+18%) polypropylene 0.90 MTA (+36%) PVC 0.62 MTA ( 0%) 1
3 RF GOVERNMENT MEASURES AIMED AT ACCELERATING PETROCHEMICAL INDUSTRY DEVELOPMENT Approval of a plan for the gas chemical and petrochemical industry development till 2030, including: Ethylene capacity expansion; The establishment of six new oil and gas chemical clusters in the North-Western, Volga, West-Siberian, Caspian, East-Siberian and Far-Eastern regions. 2
4 PETROCHEMICAL SECTOR OF THE RUSSIAN FEDERATION Baltic BalticPetrochemical Complex Complex North Western Sibur-Neftekhim Kazanorgsyntez Nizhnekamskneftekhim United Petrochemical Company Sibur-Khimprom Caspian Volga SANORS Gazprom Neftekhim - Salavat West Siberian Tobolsk-Polymer ZapSibneftekhim Tomskneftekhim East Siberian Belogorsky Gas Plant Vostochnaya Petrochemical Company Stavrolen LPG-line planned to be built Gas pipelines planned to be built According to the RF Ministry of Energy Sayansky Gas Chemical Complex Ethane pipeline Ethylene pipeline Angarsk Polymer Plant Facilities planned to be built Far Eastern Existing facilities 3
5 WEST-SIBERIAN CLUSTER OOO TOBOLSK POLYMER General Designer: OAO VNIPIneft Configuration: Propane dehydration and propylene plant kta (Licensor: UOP, USA) Polypropylene plant kta (Licensor: INEOS, USA) OAO VNIPIneft s scope of work: PD Development Development of Operating Manual and Emergency Localization and Response Plan Participation in the development of Detail Engineering for process units Project Status: The plant was opened in October
6 WEST-SIBERIAN CLUSTER OOO ZAPSIBNEFTEKHIM (Tobolsk) General Designer: OAO VNIPIneft Configuration: Ethylene Plant - 1,500 kta (Licensor: Linde) Polyethylene Plant - 1,500 kta (Licensor: INEOS) Polypropylene Plant kta (Licensor: LyondellBasell) OAO VNIPIneft s scope of work : Pre-project work Participation of the development of FEED and PD for Ethylene Plant Development of PD for the complex as a whole Project Status: Complex FEED and PD have been developed (Ethylene Plant - Linde; Polyethylene Plant - Technip; Polypropylene Plant - Uhde) OAO SIBUR have not yet made any final decision as regards the Project. 5
7 WEST-SIBERIAN CLUSTER OOO NOVY URENGOY GAS CHEMICAL COMPLEX General Designer: OAO VNIPIgazdobycha Configuration: Ethylene Plant kta (Licensor: Linde) LDPE Plant kta (Licensor: Basell) OAO VNIPIneft s scope of work: Updating of Civil & Construction Detail Design for Ethylene and Polyethylene Plants and warehouses Participation in Field Supervision Project status: Construction of the process units is underway; the Complex is ~ 60% ready. To be put into operation in
8 VOLGA CLUSTER OAO NIZHNEKAMSKNEFTEKHIM Configuration: Ethylene plant - 1 MTA (Licensor: CB&I) Polyethylene plant kta (Licensor: INEOS) Polyethylene plant kta (Licensor: Basell) OAO VNIPIneft s scope of work: Pre-project work Project Status: Ethylene plant FEED (CB&I) has been developed; FEED for Polyethylene plant and Polypropylene plant (Tecnimont) has been developed; - PD has been developed To be put into operation in
9 VOLGA CLUSTER OOO SIBUR KHIMPROM In 2012, a 220-kTA ethyl benzene plant (Licensor Badger) and a 100-kTA expandable polystyrene plant (Licensor Sunpor) were put into operation. General Designer: OAO VNIPIneft OAO VNIPIneft s scope of work: Complex PD development Participation in the development of PD for process units and Off-Site facilities, Field Supervision Development of styrene-chain production plants is working out, specifically: Expansion of the 60-kTA ethylene plant up to 73 kta; Expansion of the 220-kTA ethyl benzene plant up to 270 kta; Construction of a new 250-kTA styrene plant; Construction of a new 100-kTA polystyrene plant suitable for a phased expansion to kta. 8
10 VOLGA CLUSTER OOO SIBUR NEFTEKHIM (Kstovo) Project: Revamping of the 300-kTA ethylene plant. Capacity: expansion from 240 to 360 kta. Licensor: Technip. Project Status: PD and Detail Engineering have been developed; Equipment and Material procurement has been completed; Construction is at the final stage. 9
11 VOLGA CLUSTER OOO SANORS (Samara) Configuration: Pyrolysis complex for producing 1.2 MTA of ethylene, 600 kta of propylene and 120 kta of butadiene MTBE plant (150 kta) Benzene plant (300 kta) Toluene plant (140 kta) Project Status: Business-plan for developing the existing plants and building new plants (Technip) A joint-venture with OAO NK Rosneft has been established to implement the project. To be put into operation in
12 VOLGA CLUSTER OAO UNITED PETROCHEMICAL COMPANY (Ufa) Project: Grass-root petrochemical complex Configuration: Ethylene plant - 1 MTA HDPE plant kta LLDPE plant kta Polypropylene plant kta Butadiene - 85 kta MEG plant kta Project Status: A tender for a General Designer of the Complex is under way. To be put into operation in
13 CASPIAN CLUSTER OAO STAVROLEN (Budenovsk) Client: OAO LUKOIL Projects in progress: Revamping of a 350-kTA ethylene plant Construction of a new petrochemical complex: Ethylene pyrolysis unit kta Polyethylene plant kta Polypropylene plant kta OAO VNIPIneft s scope of work: Detail Engineering for EP-350 Unit recondition has been developed jointly with OOO LUKOIL- NizhegorodNIINefteproyekt. Feasibility Study for the Complex has been developed. Project status: Selection of Licensors is underway. To be put into operation in
14 FAR-EASTERN CLUSTER OAO VOSTOCHNAYA KOMPANIYA (Nakhodka) Client: OAO NK Rosneft Phase I configuration: Ethylene plant 1.4 MTA Polyethylene plant 1.4 MTA Polypropylene plant 600 kta Butadiene plant 190 kta Throughput: 3.4 MTA General Designer: OAO Angarskneftekhimproyekt Project status: Licensors have been selected: CB&I for pyrolysis, INEOS for polyethylene and polypropylene PD development is in progress To be put into operation in
15 PETROCHEMICAL AND GAS CHEMICAL INDUSTRY MODERNIZATION DIFFICULTIES Lengthy construction period High financial expenses and low payback of projects Increased project execution periods due to the fact that engineering and equipment procurement are executed by different contractors Small fraction of Russian technology and Russian equipment procurement 14
16 TECHNOLOGY PLATFORM DEEP CONVERSION OF HYDROCARBON RESOURCES Science and Education Business 56 industry-based and academic institutes and universities 46 state and private companies TECHNOLOGY PLATFORM Purpose: development of fundamentally new technologies for hydrocarbon resources refining and processing and catalyst production State assistance Research and Development Key Lines - Hydrogen and synthetic gas production process - Heavy oil and oil fractions refining - Ecologically clean motor fuel production process processes - Natural and produced gas processing - Processes and catalysts for petrochemistry - Polymer materials production
17 OAO VNIPINEFT AS A LEADING RUSSIAN ENGINEERING COMPANY FOR OIL REFINING, GAS PROCESSING AND PETROCHEMICAL INDUSTRY 85 years in the engineering service market Production personnel of OAO VNIPIneft numbers 872 employees OAO VNIPIneft s scope of services Pre-project work Design Procurement Construction management OAO VNIPIneft has a wide experience in designing pyrolysis units, polyethylene and polypropylene plants: 22 pyrolysis units of capacities from 60 to 1,500 kta; 8 polyethylene plants of capacities from 48 to 500 kta; 9 polypropylene plants of capacities from 110 to 550 kta. 16
18 CONCLUSION The RF Government adopted a plan of the development of gas chemical and petrochemical industries of Russia until The plan envisages a growth of ethylene production capacities from 2.3 to 14.2 MTA. Work began to establish new petrochemical and gas chemical clusters, including Volga, West-Siberian, East-Siberian and Far-Eastern clusters. Technology Platform Deep Conversion of Hydrocarbon Resources has been established to develop and implement domestic technologies. OAO VNIPIneft, being a leading Russian engineering company, is ready to provide the entire complex of engineering services required for the modernization and the construction of new gas chemical and petrochemical projects. 17
19 Thank you for your kind attention
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