Repair mechanical works
REPAIR MECHANICAL WORKS
The function of Repair mechanical works is to provide readiness availability of the facilities of Salavatnefteorgsintez.
Repair mechanical works have been a major repair base of Salavatneftgeorgsintez Open Joint Stock company for over 40 years. At present it assists to reanimate operating processes of other plants and performs orders which no other repair unit can realize.
Nowadays it is common knowledge that many plants need their equipment renewal and repair. Without implementing said works it is practically impossible to achieve high-performance economic characteristics and approach the market with competitive products. Alongside with this not every company has sufficient resources to cover cardinal substitution costs of their production assets. Thus quality repair of aged and worn out facilities becomes first priority. Quality equipment repair will allow to bring up to date production assets of any enterprise without attracting considerable financial resources.
Said services are availed by Repair and engineering works for organizations and enterprises of all patterns of ownership.
The organizational structure of the Repair mechanical works comprises 6 custom shops. The total area of the plant equals to more than 50 thousand square meters. It is a powerful enterprise providing services for all subdivisions of Salavatnefteorgsintez JSC.
Moreover, high potential of the Repair mechanical works enables the plant to perform complex orders (frequently featured by their unique application goal) of outside organizations. For example, said works proved to be the sole enterprise in the republic able to manufacture the balance beam of snow-fighting vehicle to the order of Ufa airport.
Effective heavy overhaul of compressors and pumps is performed at the enterprise. It should be noted that at the plant (should the necessity arise) said repair works can be produced parallel with spare parts manufacturing. Manufacturing and repair of heat exchange installations, ventilation systems and nonstandard equipment are in persistent demand. All manner of pump and compressor spare parts as well as spare parts for chemical and petrochemical processing equipment can be fabricated at the Repair mechanical works. The following spare parts tools and accessories can be singled out among the mainstream nomenclature of fabricated spare parts: high pressure piping fittings, flanges, plungers, cylinder bushings, axles and pistons.
Production section for corrosion-resistant coating of internal and external surfaces of rail tank cars is a source of special pride of the Repair mechanical works. Severe requirements put forward to the owners of rolling-stock make them keep a sharp lookout for the rail cars technical condition and outside appearance. They especially refer to the internal surfaces which should meet high demands towards service time and consistency of cargo oil products. Said corrosion-resistant coating production section is a grass root plant which was put into operation not so long ago in 2003, but it has already approved itself.
Said production section is subordinated to a workshop with a production capacity of up to 30 rail cars coating per month. It is significant to note that the corrosion-resistant coating process in itself is complicate enough from the point of view of stringency of requirements of coating specification and quality control. Not every enterprise has highly trained staff available to fulfill a.m. works. Repair mechanical works are not upset with the complexity of works because they are capable to perform any challenging corrosion-resistant coatings to meet any demanding and strict quality objectives of the client. Besides maintaining the rolling-stock of Salavatnefteorgsintez JSC Repair and mechanical works successfully cooperates and executes orders of such largest shipping and forwarding agents as Gaspromtrans OOO (Moscow), Neftetransport ZAO (Saint Petersburg) on a contractual basis. State-of the-art equipment becomes first priority to produce quality product and services. As a structural unit of Salavatnefteorgsintez JSC Repair mechanical works enjoys a steadfast opportunity for retrofitting and re-equipment of its facilities by sophisticated tools and facilities. Let's say in the nearest future the repair works shall have thermal cutting bridge type machine tool "Kometa-2M" that has the balance of advantage in flat stock cutting. The issue of purchasing of short radius bend manufacturing unit for process piping and other piping widely used in oil and gas industrial complex has been resolved positively. And there's more to come. A unique portable spectrometer "PMI-MASTER" which allows to measure chemical structure of various types of alloys and different chemical elements without physical change as well as to secure consistency of operation under arduous operating conditions of the workshop has been procured following the plant equipment retrofitting program. All said activiities are aimed to sustain economic well-being of the Repair mechanical works and thus provide opportunities for keeping leading positions in the background of intense economic competition.
One of our substantial advantages is as follows: we are capable to carry out preliminary design and construction work and process design for the customer (upon the customers' request). To realize said targets Repair and mechanical plant has such structural unit as Engineering department with a wide experience of work. Any applications and orders made to said unit by business entities, organizations and private individuals are studied in the shortest possible time. Sales department organizes and carries out all the contractual work. This is the department where everyone can get answers to all of their issues of interest.
Dear friends!
Hereby we provide the information on Repair Mechanical works business activities. Said information might be of interest to various organizations and business entities concerned since the Repair works provides services and produces goods which are highly requested throughout many industries, such as production sector, construction and transport. We are open for business cooperation and we are confident that our partners and potential clients can make the best use of our services and produce based on our wide range of experience which is a guarantee for growing long-term and mutually beneficial cooperation.
With kind regards,
A.Ju. Zaprometov
Director of Repair and Mechanical Works
Machinery overhaul workshop
specializes in compressors and pumps complete overhaul
Outside repairs workshop
executes orders on manufacturing and repair of heat exchanger and ventilation systems and non-standard equipment.
Mechanical repair workshop
produces mounting hardware and fittings, spare parts tools and accessories for pump-and-compressor equipment, chemical and petrochemical equipment. Mainstream parts authorization list includes high pressure piping fittings, flanges, plungers, cylinder bushings, axles and pistons.
Corrosion-resistant coating workshop
carries out works on corrosion-resistant coating of metal surfaces of pipelines and pipeline equipment including chromium coating, galvanization and brassing. It also specializes in manufacturing of non-metallic chemical-resistant equipment and parts. In the workshop there is also a production section specializing in anticorrosive protection and coating of all types of rail tank cars.
Tool-repair workshop
effects repairs of measuring instrument, weighing equipment, crane facilities. Spiral-wound gaskets are also fabricated in the workshop.
Casting and forging workshop
performs brass, steel and iron casting of pump-and-compressor equipment facilities. Operations of carbonization and nitrogen hardening of up to 6 meters length hardware are effected by then workshop.
Contact details:
Repair Mechanical Works
30 Molodogvardeitsev, Salavat
453256, Republic of Bashkortostan
Reception: Telephone-Fax: (34763) 9-20-62
Sales department: Tel.: (34763) 9-20-62, 9-563-60
e-mail: www.46yag@mail.ru
Chemical plant
1962 the Counsel of Minister of the former SU took a decision to produce a high efficient special brand of fuel production. This was specifically developed for use with space program. To achieve this goal Salavat industrial complex (SNHK) was chosen. In April 1965 this unit was putting into operation. Following this further units were put into operation for the production of this material. In 1966 a new zeolit production unit was developed. The brands of zeolits of NaA-2ЬШ, NaA-2КТ, CaEH-4B were specifically aimed for use in the refrigeration industry, cryogenic engineering and vacuum engineering.
1974 a pilot plant was build for production of dimethylaminopropylamine (DMPN). From this plant the material DMPN was developed by using hydrogenising. This material was successfully used for fire-proofing roofs.
1976 the unit for production of dimethylacetamide (DMAA), of chemical fibre feed were put into operation. They were used to produce parachute fabric and slings, special medical packets for military men.
The increase of interest of space engineering, spacecrafts has caused the necessity of production of the high -caloric fuel facilities. To reach this objective the Ministry of oil and chemical industry together with all-union scientific research institute and RSC Energia and SNKHK management on behalf of Government of the USSR in 1976 developed a new unit of high efficiency fuel from hydrocarbon compounds (propylene) on the basis of the former unit of production of extraction agents.
1986 former sulphur acid and catalyst production plant was integrated into Chemical plant as part of sulphur acid production, elemental sulfur production, foaming agent, paste РАС, BM (Bitolylmethane), PIB (polyisobutylene), MEK (methyl-ethyl ketone) productions according to the decision of SNKHK management.
A section of the production units were removed from the operation. But the remainder of the Chemical Plant carried on the production of special fuel as normal. The Company management decided in 2002 on 1 of April to integrate the Chemical Plant with the petrochemical products plant and created a new division of the Company called petrochemical plant.
From 1st June 2007 polyethylene production plant was integrated into monomer plant. Petrochemical plant has recently been reorganized and its name has been changed Chemical Plant.
At present Chemical Plant has the following structure: 4 processing workshops and 2 auxiliary shops.
Oil refinery
Oil Refinery has the following structure: 8 processing workshops, tankage facilities, feed tank, 5 stock tanks and 3 auxiliary shops.
Geological services has been successfully carried out within the territory of thr former Bashkir Autonomous Republic now Bashkortostan. 1953 the Ministry of oil industry adopted decision to build up and put into operation Novo-Ishimbayskiy oil refinery as part of concern No. 18. This plant was aimed to allow processing up to 3 mln. tn of sulfur crude oil of oil deposits Romashkinsiy, Shpakovskiy and Ishimbaiskiy.
The history of the plant development can be divided into a few stages:
The 1. Stage covers the period from 1955 to 1960.
In 1955 desalination unit ELOU-1, atmospheric and vacuum crude unit AT-1, 2 units of catalytic cracking 43-102, gas-fractionation plant were put into operation.
1956 - Commissioning of desalination unit ELOU-2,3, 3 units of AVT by designed capacity 3 mln.tn, 2 unit of thermo cracking . The first commercial product was achieved.
1957 - Commissioning of desalination unit ELOU-4, atmospheric and vacuum crude unit AT-2 for hydrogenation product vapor phase hydrogenising distillation in order to obtain gasoline and special fuel.
1958 - Commissioning of atmospheric gas fractionation plant, sulfuric acid alkylation unit, the 3-d catalytic cracking unit, hydro forming unit.
1959-1960 - putting into operation the following units: desalination unit ELOU-5, AVT-4 be design capacity 2 mln. tn/year and gas-fractionation plant GFU-2.
The 2nd Stage covers the period from 1961 to 1974.
When the large-scale oil deposits in the sound-western part of Bashkiria were developed the oil refinery was supplied by crude oil from Arlan deposit. This marked the beginning of a new stage in the history of the plant - sour oil processing development. At initial step the crude oil was delivered by rail way. In 1965 pipeline Kaltasy-Salavat was commercialized. To realize sour oil processing the reconstruction works on primary distillation of crude oil and thermo cracking units were done as well as the design and construction of secondary distillation of crude oil unit were started.
1965-1975 putting into operation one at a time the following units: hydrotreating units Л-24-6, Л-24-7, light hydrocracking unit polymerization unit, platformer unit Л-35-6/300, precision fractional distillation unit by 1500 kt/y, capacity catalytic reforming unit ЛЧ-35/11-600.
The 3d stage covers the period from 1975 to 1980.
A new step in the history of oil refinery started with the commissioning of Orenburg gas deposit - gas condensate processing, which involved at its initial stage reconstruction of thermal cracking units, stabilizer АГФУ for steam distillation, hydrotreating unit ЛЧ-24-7 for gasoline fraction hydrotreatment. With gas condensate processing development to commercial level the production capacities of oil crude are also increasing; retrofitting of primary and secondary processing capacities are required. In 1978 the condensate crude processing production complex put into operation. In marked an important event in the history of plant. The production complex included gasoline hydrotreatment unit by capacity 2 mln. tn\y and catalytic reformer by capacitu 1 mln. th/y. The total output of oil crude increased from 8 mln. th/y to 12,2 mln. tn/y. Following commissioning of a.m. technological units made it possible to process a total quantity crude oil from Orenburg oil deposit, to increase low-sulfur diesel fuel output as well as high-quality brands of gasoline.
The 4th stage covers the period from 1980 to 2003.
In the earlier 1980 the composition of crude oil for oil refinery changed. Crude oil supplies are reduced; gas condensate supplies from Orenburg deposit are decreased. The governmental take a decision to compensate the hydrocarbon material shortage by gas condensate from Karachaganak deposit (КГК).
That marked a new stage in the history of oil refinery. Initially the Karachaganak condensate was developed by available units of ELOU-1,4, ЕЛ-3, АГФУ-1. At the same time the units were modernized for the new crude oil processing.
1990 - After reconstruction a new gas condensate process unit was put into operation by capacity 1,3 mln, tn/y.
1999- Construction and commissioning of a new unit ELOU-AVT-4 by capacity 4 mln. tn/y. for condensate processing marked the final stage of development of gas condensate from Karachaganak deposit. The total control system usage allowed bringing the process technology to an upper level. The units found be outdated were removed from production. When a new unit of ELOU-AVT-4 was brought into operation this increase gas condensate share in total volume of process raw materials was 43, 5 per cent in 2002.
The successive comprehensive development of the plant allows producing rival products. 2002 oil refinery received permission to produce the new brands of gasoline: Normal-80, Regular-91, Premium -95, Super-98, and 2001 - Regular -92, Normal -80, Regular-92.
2001 - To increase sales of light petroleum product automatic filling system for car fuel tanks has been set up. State of the art new gas condensate tank farm was introduced to provide stability of crude oil supply. The reconstruction works of the filling station were carried out in order to increase capacity of filling and discharging of oil products, gas condensate, and straight run gasoline.
The 5th stage through to present time.
Today oil refinery is capable to manufacture the following products:
nonleaded gasoline of Normak-80, regular-92, Premium -95, Super-98, pentane isopentane fraction, petrobenzene, petroleum toluene, kerosene absorbent, fuel oil, feedstock for oil road asphalt production, technical sulphur, oil asphalt.
Oil refinery continues to carry out updating the process technologies, modernization of units, integration of a new productions units. Currently the ОГ and КГ, Л-35.6, AVT-4, Л-16-1 were retrofitted. State- of -the- art
bitumen production unit is put into operation; visbreaking and catalytic cracking units are under construction. The tender was issued for alkylation, delayed coking, a new AVT-4 by capacity 4 mln. tn/y units.
Monomer plant
The order dd. 22 February 1991 was placed. This date was conception date for monomer plant. By that time monomer plant consistent of the following production units: EP-300, EP-60, ethyl benzene-styrene (old production) productions. Monomer plant produces the raw material for polymer production.
Initially the plant operated on a lease basis. Myachin S.I. was appointed as Director of the plant, Lishtakov A.I. - as Chief Engineer of the plant. EP 300 production together with unit No. 55f or pyrolysis process and production unit No. 56 for gas separation constitute the plant skeleton. The operating personnel was completed by the technical personnel of the previously shutdown production units included EP-45 production (workshop No.16). These were the highly qualified technician personnel, which had the suitable knowledge and experience of technology as well as of ethylene and propylene.
1996 - The structure of the plant was expended by benzene production unit. Commissioning was completed in the shortest possible time. Further the plastic unit was integrated into monomer plant which consisted of workshops No. 41,47. It was development in a period of economic turndown. During this period there was a shortage of raw material of styrene production. SNOS management and plant management have concluded contracts on styrene deliveries from Nizhnekamsk and Perm covering the material shortage of plastic production.
Autumn 2003 - The successfully commissioning of large scale ethyl benzene and styrene production at workshop No. 46 was carried out. This allowed to settle the issue of raw material shortage of plastic production with the further usage as a raw material for polystyrene production. Produced styrene corresponds to the super grade/ 20-25 per cent styrene is used only for own requirements of workshops No. 47, 41 to produce variable types of plastics.
2007 - Due to reorganization of petrochemical plant and Syntez plant HDPE production workshop No. 23 was integrated into monomer plant.
Tankage facilities was developed on the basis of gas deport and flammable liquid units.
The history of Monomer plant development as independent production unit consists of small and big events just like a history of any other plant.
Two large production sections are operated in Monomer plant: ethylene production, propylene and plastic production. The first consists of the following workshops: pyrolysis (workshop No.55), gas separation (workshop No. 56), benzene (workshop No.58), tankage facilities. Plastic production consist of the following workshops: HDP polyethylene (workshop No. 23), ethyl benzene -styrene (workshop No. 46), polystyrene UPS (workshop No. 41), polystyrene VP, general-purpose polystyrene PSM, high-impact polystyrene UPM (workshop No. 47)
The repair-mechanical workshop (РМЦ-8), electrical and instrumentation workshops, automatic process control system service are also part of Monomer plant. Full capacity operation of the existing production units is one of the major factors in the general process chain. This factor also directly affects the cost value of products, the Companies profit. Monomer plant produces the following products: oil benezene, propylene, ethylene, styrene, heavy pyrolysis residue, pentane- isoprencyclopentadiene fraction, butylene-butadiene fraction, polystyrene -UPS-0804L,0802PU, expandable polystyrene PSV-SU, general-purpose polystyrene PSM-115N,high-impact polystyrene UPM-0508,0703E, high-impact polystyrene sheet, polyethylene 154803-020, 158 black 901,17603-006, 17703-010.
This product is being shipped to more than 100 cities of the Russia and exported to 8 countries of CIS and non-CIS countries. The quality of the high-impact polystyrene (slurring process) was highly recognized on international exhibitions. Yomsin V.V. applied a lot of efforts to receive such recognition.
In 2007 polystyrene УПМ-0508 was entered into the list "100 best quality products of Russia" as a result of a participation in completion. The young specialists of Monomer plant are provided with career development perceptive. Competence, professional skills, goal orientation are of paramount importance in Monomer plant. High percentage of management and specialists of Monomer plant are recent graduates of technical schools.
The majority of labor forces are aimed to get additional training, to raise their qualification standards in-service training.
The overall personnel of Monomer plant equals to 2195 people of which 281 have high education, 695 - have comprehensive and vocational school education. At the same time 811 are young people of which 678 are workers, 46 people are engaged in management and 75 people are specialists.
Engineering staff consists mostly of young specialists former graduates of Ufa state oil technical university (УГНТУ) trained by SNOS on a contact basis as well as other technical schools of Russia.
The plant management always supports those who realize that life means movement towards future goals, appreciate initiative, prospective ideas and healthy life-style.
Gas chemical plant
Gas Chemical plant (ГХЗ) was organized dated 1 November 2007 in accordance with the decision of the SNOS Company management board No. 624 dd. 07.09.2007 in connection with production necessity as a new structural division.
This new plant was developed by reorganization of two plants fertilizer production plant (ЗМУ) and Sintez plant. Gas Chemical plant has the following structure:
-workshop No. 5 - nitrogen, oxygen and compressed air production;
- workshop No. 34 - 2-ethylhexanol, o- xylene and ether (ether head processing)
-workshop No. 48 - phthalaldehyde and plasticizer production;
-workshop No. 51 - synthetic gas and hydrogen production;
-workshop No. 52 - butyl alcohol and n- butyl aldehyde production;
- workshop No. 24- urea production;
-workshop No.50 - urea production;
-workshop No. 54 - ammonia production.
Base products of gas chemical plant are as follows:
Butyl and isobutyl alcohols, plasticizer DOP, phthalaldehyde, 2-ethylhexanol, o- xylene, urea, liguid ammonia, aqua ammonia.
Phthalaldehyde, 2-ethylhexanol, o- xylene are mainly used in own production. Retrofitting of hydrogenation block in workshop No. 34 allowed to load plasticizer DOP production unit and approach a international market with a new product 2-ethylhexanol.
Butyl and isobutyl alcohols are applied in paint industry, butyl acetate production, plasticizer production, oil additive production, phenol-formaldehyde resins production, medical industry.
Plasticizer DOP is widely used in plastic production, artificial leather, polymer constructional materials, PVC paste production.
When in 2002 issues connected with Plasticizer DOP quality were dissolved, it gave start for its exporting.
Phthalaldehyde, 2-ethylhexanol are mainly used in own production. Retrofitting of hydrogenation block in workshop No. 34 allowed to load plasticizer DOP production unit and approach a international market with a new product 2-ethylhexanol.
Ammonia is used as fertilizer and as crude stock for ammonia liquor and hydrogen nitrate. Ammonia and carbonic acid gas interaction results in high-concentration fertilizer- urea. Additionally ammonia is applies in a range of other industries, refrigerating engineering, medicine.
Urea is used as a raw material for resigns, adhesives etc. production. In agriculture it is used as nitrogen fertilizer. Urea can be applies as feed additive in cattle breeding. Liquid ammonia is used in agriculture as nitrogen fertilizer. The histories of two plants make the history of a newly formed gas chemical plant:
The History of Mineral Fertilizer Plant (ЗМУ).
Nitrogen fertilizer production - ammonia and urea- by industrial complex No. 18 (Salavatnefteorgsintez JSC) was not covered by original design.
The availability of high pressure facilities met technical requirements for ammonia and urea at the complex. The a.m. facilities belonged to the former shut-down coal hydrogenation plant. Operating hydrogen, nitrogen and oxygen production workshops constituted an integral part of process flow diagram of urea and ammonia production which also favored the above. Besides the availability of cheap feed stock (hydrocarbon gases) played a sufficient role.
Coal gasification units closed by then were redesigned for ammonia production and 1961 the first ammonia output was reached. From year to year the production unit increased its capacity.
In 1988 the large scale ammonia production unit АM-76 construction was completed (workshop No. 54).
Firs urea production was arranged on the production facilities basis of the former gas plant which was designed by construction department of the industrial complex. The workshop development faced a lot of problems, nevertheless after a few retrofitting works in 1974 the workshops gained its design capacity.
There was a strong domestic demand for nitrogen fertilizers. The existing fertilizer plants could not meet their demand for agricultural usage. Later on urea production workshops No.24-I, 24-II utilizing Holland technologies were put into operation.
Finally in 1975 the workshop No. 50, was commissioned and by 1984 fertilizer plant realized annual capacity of 860 kt/y. Economic conversion started in 1990 affected the fertilizer plant. Replacement one economical system by other caused heavy critical situation in the economy which resulted in sharp drop in production even to its shut-down.
In 1998 the economical default emerged and decision on the conservation of the ammonia and urea production was made in order to preserve its facilities. The 1990 marked the most painful period of the plant. New line in the history of mineral fertilizer plant was started by its transfer in January 1999 for lease holding to ZAO Bashkirskay Agrokhimicheskaya Kompaniya.
Dated March 1999 the fertilizer plant started the commercial output.
In December 20002 the lease agreement was terminated by leaseholder and fertilizer plant re-joined Salavatnefteorgsintez JSC.
From the beginning of 2000 dynamic works on production capacity increase, reduction of energy consumption and quality improvement of commercial products are in progress.
The History of Sintez Plant.
In the end 1950 the issue of organization of a new production unit was raised in connection with increased demand in butyl alcohol. Tacking into the account the availability of idle capacities of high pressure blocks in Salavat industrial complex the governmental decision on construction of butyl alcohol production plant was adopted. Branch office GIAP (Гипргазатомтоппром) in Dzerzhisk designed the project of butyl alcohol production based on technology of oxo synthesis over cobalt suspension catalyst in 1961. Design capacity is 30 kt/y of butyl alcohol of which 19 kt/y - NBA and 11kt/y - IBA.
The construction of a new project (workshop No. 21) started in 1961. However the workshop commissioning was delayed till 1966 due to difficulties connected with compressor station, high-pressure pumping station, synthesis block erection (initially start up of workshop No. 21 was planned for 1963). First commercial product was produced dated 6 April 2006; alcohol quality met the GOST requirements.
From 1963 butyl alcohol production workshop is included to Production No. 2 and 1966 it has been included in a newly organized Ammonia and Alcohols Plant. Soviet chemical and petrochemical industry development long-term plan for the period 1965-1969 placed an essential attention to synthetic fatty alcohols production.
Synthetic fatty alcohols production (workshop No. 34) by capacity 22, 3 kt/y was put into operation in December 1967. The project was designed by GIAP. In 1969 workshop No. 34 gained its design capacity.
Phthalic anhydride production within the plant Spirty (workshop No.48) was originated by directory of the Ministry of oil and chemical industry of the USSR under which it was requested to include such unit into the detailed project report for the third line of the industrial complex. Moscow project office Giprokhim prepaid the unit design by capacity 13 kt/y, the author of the process technology and catalyst is MNPO NIOPIK (МНПО НИОПИК).
Nerveless after the construction works completion in 1975 orthoxylene oxidizing contact apparatus faults did not allow to commission phtalic anhydride unit. The first output was produced in May 1976.
Own raw materials source of plasticizer - synthetic fatty alcohol and phtalic anhydride- underlay the organization of construction works in SNHK. Branch office of Giproplast (Гипропласт) in Novisibirsk developed the plasticisers DAP -789, 810, 8 and DOP (workshop No. 48) production by capacity 30 kt/y original design. In December 1976 first output of plasticisers was obtained, DOP production unit gained its design capacity in 1979. In 1993 the second production line of plasticisers based on titanium process was put into operation. The project office MP Magus (МП «МАГУС») of Novosibirsk elaborated the original design. Phtalic anhydride and dimerol were used as raw materials for production of DAP-8; and phtalic anhydride and back alcohol as raw materials for DAP- 0 production. The capacities gained by that time did not meet the demand for butyl alcohols. Consequently the decision on construction of a new higher capacity butyl alcohols production complex based on naphtheno- vaporization process by design capacity 170 kt/y was adopted. VNIPIneft (ВНИПИнефть) implemented the original design. Butyl alcohols production complex consists of two sections: synthesis gas and hydrogen production (workshop No. 51) and own butyl alcohols production (workshop No. 52).
The production complex erection was conducted in two construction stages. The said construction still on in 1979 the commissioning of the first stage was proceeded and by 28 December the first output of standard converted gas was achieved. Since 14 June 1980 synthesis gas production unit (workshop No. 51) and butyl alcohols production (workshop No. 52) complete PFD were put into operation.
Ether head processing technology of butyl alcohols production (workshop No.52) was developed in 1994 by NPO Lennefteckim (НПО «Леннефтехтим») in order to increase the butanol production and reduce butyl alcohol production residuals. The first lot of butyl alcohol sum recovered from ether head was obtained in workshop No. 34 in 1994.
First line of butyl alcohol production in workshop No. 21 proved unprofitable by that time and after 30 years work it was removed from operation in 1995.
In late 90-s after the break of stable economic relations and centralized planning Spirty plant got into difficult economical situation. Due to unavailability of raw materials - C7 - C9 fatty acids fractions - synthetic fatty alcohols capacities were removed from operation since 1st January 1995 and therefore DAP -789 production became impossible. In connection with C8-C7 fatty alcohols fractions production capacities removal at Ufa oil refinery which were used as raw materials for plasticisers DAP-810 production the a. s. production was shut down. Upon these conditions the necessity of plasticisers production arrangement in the shortest possible period of time based on a higher quality feed stock came into existence. Company management arrived to a decision to organize C8 alcohols production. Front end engineering design of C8 alcohols production on the basis of butanol and C7, C8 alcohols productions reconstruction was fulfilled by NPO Lenneftechim (НПО «Леннефтехим») in 1994, design correction - in 1995. Construction and installation works and commissioning works have been conducted for more than 2 years. In March 1997 3 production sections were commissioned and the first 2- ethylhexenal product - an intermediate product of C8 alcohols was produced. Due to underfinancing hydrogenation section construction was not finished and therefore the final product C8 alcohols could not be obtained. New market relations required from phtalic anhydrite production the usage of new business patterns. Earlier the whole amount of liquid phtalic anhydride was used for own production only. But the demand for plasticisers dropped sufficiently in connection with it workshop No. 48 capacities were not fully realized. Taking into view the fluctuations of market for plasticisers and to preserve the production capacities of phtalic anhydrate in 1997 flake phtalic anhydride unit was erected. Fa. Fitpade developed the process technology. The firs lot of flake phtalic anhydride was produce in April 1999.
Following decision of Company decision in July 1998 Spirty plant was integrated into mineral fertilizer plant (ЗМУ). All fertilizer plant workshops except workshop No. 5 were removed from operation due to unprofitability of the main urea product. The plant renamed as ZAUS (nitrogen fertilizers and alcohols production plant).
In 1998 the plant got into difficult economic situation due to low export costs for butyl alcohols which are the main source of profit. Alcohol production was reduced down to one operation line. Lack of orthoxylene raw material and insufficient volume of dimerol output did not allow to commission plasticisers production. In 1998 this production was in operation only one month. Throughout this period the issue of flexible process scheme development became of major importance. This new trend of plan development was aimed to transfer oxo synthesis products to 2- ethylhexanol produce output in workshop No. 34 by way of implementing the capacities of workshops No. 51, 52. Thus plasticisers production will have its own raw materials to effect profitable product.
In 1999 2- ethylhexanol from 2- ethylhexenal production was developed
using the process of dimerol recovery from bottom products of butyl alcohol production. This process provided DOP plasticisers production with high quality stock.
In June 2007 workshop No. 5 was integrated into mineral fertilizer plant.
