From the collection plate of the first section, the LVG is fed to the intake of the H-9 pump. Part of it is fed under the battery to the switchgear in the third section, the other part is pumped through the X-3 refrigerator, where it is cooled to 600C. The required amount of cold LVG is supplied through the distributor of the upper circulating irrigation to the top of the regular nozzle in the first section, the balance part is removed from the installation.

Heavy vacuum gas oil from the accumulator of the K-4 column enters the intake of the H-7 pump and is sent for mixing with the heavy vacuum gas oil of the K-1 column, and then it is removed from the unit through the X-1 cooler.

The tar from the bottom of the column is taken by the H-8 pump and fed for oxidation.

Principal technological scheme of oxidation

Start.

Raw materials with a temperature not exceeding 260 °C are continuously taken from the vacuum unit by the H-8 pump and fed into the oxidizing column through the side fitting. After reaching the level in the column of 1/3 of the working level, air is supplied to it through the receiver with a pressure of at least 3-4 kg / cm² air in the amount of 1/3 of the optimal amount.

The amount of air supplied in the first 15 minutes should not exceed 100 Nm³/h.

Then, as the column is filled, the air flow rate increases to 400 Nm³/h. The change in the amount of air supplied is made by changing the automatic setting in the control program.

Oxidation of raw materials continues until the reducer reaches the softening temperature according to R&D within the required parameter. After that, transfer the oxidation process to the operating mode.

Operating mode.

The raw material enters the built-in GZhKVA (gas-liquid cavitation-vortex apparatus) of the K-6 column (Figure 4), which consists of two functional chambers, through the branch pipe.

In the first mixing chamber, the swirling gas flow interacts to form a gas-liquid mixture. In the second chamber, the formation of a finely dispersed phase - foamy.

In the foam chamber, fine foam is formed due to the contact of the air flow and the bubbles of the liquid phase of the high-speed gas-liquid jet. The resulting fine foam enters the "antifoam" chamber. From the defoamer, the gas-liquid mixture flows upward along the entire height of the K-6 column into the separation zone of the column.

When the gas-liquid mixture moves upwards, an additional oxidation reaction takes place with further contact of the liquid phase and air oxygen.

The air required for the oxidation process is taken from the atmosphere by compressors through filters and fed into the K-6 column through an air receiver. The air flow in the built-in GZHKVA is regulated by the FRC device.

The oxidation temperature is recorded by the TJRSAH instrument.

According to the maximum oxidation temperature of raw materials in the K-6 column of 260 °C, there is an alarm, according to the maximum oxidation temperature of 275 °C, there is a blockage in the air compartment supplied for oxidation by cut-off valves.

The oxidized product (bitumen) with a temperature not exceeding 260 °C is pumped out from the side of the K-6 column by the pump N-10 through the T-7 immersion cooler into cubes finished products R-1-3.

Figure 4

To achieve the indicators corresponding to the requirements, pumping is carried out from the upper or from the lower level. The lower branch pipe of the column is provided for complete unloading of the column. From R-1-3 cubes, the finished product is poured through the drain manifold into tank trucks or railways.

If the bitumen quality indicators are not reached, the installation switches to work with recirculation in the intermittent operation mode. The valve on the raw material supply line is closed, and the line for pumping bitumen into cubes of finished products is also closed. The valve on the recycling line opens.

In order to avoid boiling of the finished product before pouring it into the tanks, an anti-foam additive PMS 200A is added.

The level of bitumen in cubes for finished products R-1-3 is measured and there is an alarm for the maximum level.

The temperature of the oxidized bitumen at the outlet of P-1-3 is recorded accordingly. According to the minimum temperature of oxidized bitumen at the outlet of R-1-3, there is an alarm (130 0 С).

The product level in the K-6 oxidizing column is controlled by a device, the valve of which is installed on the product pumping line from the bottom of the K-6 column to R-1÷3 stills. There is an alarm for the maximum level in K-6 (85%) and for the minimum level (55%), for the minimum level (51%) there is a blockage of the cut-off of the air supplied for the oxidation of raw materials to the K-6 column.

The pressure in the K-6 oxidizing column is controlled by a device, the valve of which is located on the outlet line of the oxidation gases from the K-6 column to C-2, and should not exceed 0.6 kgf / cm 2 (g).

Oxidation gases, stripping vapors from the top of the K-6 column enter the C-2 separator, which serves to separate the oxidation gases from the condensed water and carbon vapors.

Oxidation gases, exhaust air and non-condensed part of the distillate are discharged from above from C-2 through a flame arrester to the afterburner of oxidation gases.

The temperature in the combustion chamber of the furnace is controlled by a device whose valves are located in the fuel gas supply line and liquid fuel to oven nozzles. There is an alarm for the maximum temperature in the afterburner chamber of the furnace 1100 0 С.

The temperature of the flue gases at the exit from the furnace is measured by the device and should not exceed 1000 0 С.

The condensed part of the distillate vapor (black diesel fuel) is collected in the lower part of the C-2 separator. The black solarium is periodically pumped out through the T-7 submersible cooler into the fuel oil pipeline.

In order to maintain the required temperature (120-230 °C), R-1÷3 finished product cubes have electric or steam heating.

The temperature in cubes for finished products P-1÷3 is recorded at the top and bottom, respectively.

If there is no place in the cubes of the finished product R-1÷3, the bitumen is pumped into the fuel oil pipeline or the pump park.

The Moscow Oil Refinery (Moscow Refinery) is an enterprise built in the 1930s. near Moscow in the river. Hood.

The need for the construction of this enterprise arose to supply Moscow and the region with motor fuel and bitumen. During its existence, the Moscow Oil Refinery has justified its purpose, providing the capital with its products. The non-stop operation of the plant gave excellent results, the Moscow Refinery processed 400 million tons of oil. tons of oil. A large-scale production of petroleum bitumen was built and its deficit in the Moscow region was completely eliminated. In a dozen of such domestic oil refineries, Moscow Oil Refinery ranks 7th in terms of oil refining volumes. Moscow Oil Refinery was the first in Russia to master AI-93 high-octane gasoline without a lead antiknock agent. And also, the first deep oil refining complex in our country based on a combined catalytic cracking unit was built at the plant. Thanks to this innovation, the Moscow region received an additional 1 million rubles. tons of high-octane gasoline annually without attracting raw materials, which are equivalent to 10 million tons of oil per year.

The plant produces AI-80EK, AI-92EK, AI-95EK gasolines, bitumen, diesel fuel, jet fuel, polymers, sulfur, etc.

Plant products sold by TransService

Bitumen BND 60/90 GOST 22245-90 (s / w)

Bitumen BND 40/60 GOST 22245-90 (s / w)

Bitumen BN 70/30 GOST 6617-76 with amendments 1-5 (non-packed) (s / w)

Insufficient production of oil bitumen in Russia is the result of a number of objective and subjective reasons. Objective reasons include the seasonality of consumption, and hence the production, of road grades of bitumen, as well as the sharply increased degree of "paraffin content" (high content of paraffin hydrocarbons of a normal structure) in oils in the last 10-15 years. The latter circumstance does not allow providing the entire necessary set of operational properties of road bitumen without the use of modern technologies.

At the same time, it should be noted that world experience suggests quite specific ways to solve these problems. Thus, the influence of the seasonality of the consumption of road bitumen in many cases can be dampened by the production of bituminous materials with a certain all-season use or a long shelf life (for example, bitumen emulsions or polymer-bitumen materials). The dependence of the quality of road bitumen on the quality of raw materials in most European countries is eliminated by the targeted use of special heavy, resinous oils. Unfortunately, in Russia this is difficult both because of the existing centralized pipeline supply of raw materials to most large refineries, and the lack of technological capabilities for separate processing of two or more types of oils.

The most important of the subjective reasons is an inadequate pricing system, in which the selling price of bitumen is only 60-70% of the cost of the original oil. Wherein technology system production of petroleum bitumen includes, as you know, at least five most complex processes that require appropriate material, operational, energy and other costs. Such "profitability" of bitumen production at most Russian enterprises (see table) arises due to:

Low workload of existing production capacity(less than 40% with the global average of 90-96%);

Use of outdated technologies and equipment;

Inconsistencies in the quality of raw materials;

Absences modern systems filling and packing;

Low degree of automation of management of all stages of the process.

The reasons listed above explain not only the low investment activity of the largest Russian oil companies on the creation of modern bitumen production, but also an almost paradoxical situation in which it is economically beneficial for companies not only not to improve the quality of road bitumen produced, but also to completely stop their production. At the same time, alternative technological methods for the processing and disposal of tars (production of lubricating oils or coke, gasification, involvement in boiler fuels or cracking feedstock, etc.) at refineries have a fairly high degree of economic attractiveness. The situation is aggravated by the development of "wild Russian business", aimed at making a profit in any way, even at the expense of product quality, and the unpredictability of the annual and seasonal pricing policy largest Russian oil companies. This leads both to the uncivilized commercial storage of bitumen and profit by almost doubling their prices during the construction season, and to the construction of low-tonnage regional plants (vacuum and bitumen blocks) with uncontrolled quality of raw materials and products. In any case, it is not necessary to talk about the durability of road surfaces based on such materials.

The way out of this difficult situation is the organization of a serious state support both at all stages of basic pricing (examples - EEC countries, Kuwait, etc.), and in the form of stimulating the production of high-quality road bitumen and the construction of private roads.

Table 9. Bitumen production in Russia as of 2006

According to experts in the road sector, at present, up to 25-28% of road bitumens used for the preparation of asphalt concrete mixtures are substandard, i.e. do not meet the requirements of GOST 22245-90 for one or more indicators. The results of surveys of a number of asphalt concrete plants (APZ) in different regions the countries confirmed that in about three cases out of four the reason for the marriage is non-compliance with the technologies for transporting, transshipment and storage of bitumen, the use of bitumen with an unpredictable chemical composition, namely: from small-tonnage local installations; of undetermined origin, after commercial storage, overheated during transshipment, contaminated and regraded during transportation, etc. Thus, the "contribution" of the major major Russian manufacturers road bitumen in the total amount of bituminous marriage does not exceed 25%. However, this is an unacceptably high percentage for such a high-tech industry as oil refining. The main reasons for the production of substandard refineries include the use of outdated (again, obviously, due to the above economic prerequisites) production technologies.

Modern technology should ensure the stable production of commercial bitumen from tars and other semi-products of various compositions and qualities, as well as provide an opportunity to produce not only products that exceed the requirements of the all-Russian standard in quality (for example, according to the corresponding standard of the organization), but also promising materials. This is achieved by equipping plants with automation systems for all technological operations, in-line quality analyzers, hermetic racks for loading and packing products. Commodity and raw material tank farms of modern bitumen production should be equipped with heating and compounding systems. When designing and operating bitumen production environmental problems must certainly be taken into account. It is clear that the creation of such a modern bitumen production requires serious financial investments.

The instability of the quality of the processed raw materials (first, the commercial mixture of oils, and then the tars) and, at the same time, ensuring the quality of the product and the stability of its operational properties is the main problem of technological oxidative bitumen plants column type, which now form the basis of production. A negative "contribution" to the instability of the quality of the tar is also made by technological features operation of vacuum columns: efficiency of contact devices, fluctuations temperature regime, vacuum depth, flow rates, amount of "failed" circulating irrigation. Therefore, the scheme of modern bitumen production should include a special block for the preparation of raw materials to optimize the fractional and group chemical composition tar. Solutions to both tasks are largely interrelated: tar weighting is also a way to reduce the degree of its paraffin content, and increasing the degree of its aromatization (for example, by compounding) allows you to simultaneously control the fractional composition of the prepared tar.

Preparation of raw materials - increasing the content of resinous compounds in it and simultaneously reducing the degree of its "paraffin content".

The most modern in this regard are the bitumen production facilities at Novokuibyshevsk Oil Refinery, which produces bitumen of the Novobit brand (Fig. 1), at OJSC Yaroslavnefteorgsintez, Permnefteorgsintez, and Nizhegorodnefteorgsintez.

The process of production of oxidized bitumen at most Russian refineries is technologically well developed and does not cause any serious problems. In recent years, some refineries have modernized and re-piped existing oxidizing columns in order to increase the degree of use of atmospheric oxygen in the production of mainly high-melting bitumen. First of all, these include the development of a scheme for the oxidation of fuel oils (JSC Moscow Oil Refinery), the creation of columns with internal or external separation of reaction and separation zones (JSC Ryazanskaya NPK) and columns with a quenching section. Such solutions make it possible to increase the efficiency of the oxidizing column by reducing air loads and increasing the oxidation temperature in the reaction zone. For the same purpose, mechanical mixing of the phases in columns (OAO Yaroslavnefteorgsintez, TAIF#NK), the use of gas-liquid cavitation-vortex or ultrasonic dispersants (OAO Permnefteorgsintez, Novokuibyshev Refinery) are quite effective.

At the same time, there are publications on the development of special designs of stationary air mother liquors, which make it possible to reduce the air load and significantly reduce the oxygen content in the off-gases of oxidation (JSC Kirishinefteorgsintez, Moscow Oil Refinery, Novokuibyshev Oil Refinery). , which allows minimizing the effect of fluctuations in the quality of a mixture of commercial oils and the mode of previous technological installations on the properties of oxidized bitumen of road grades, and a modern automated oxidation unit is a sufficient guarantee for the stable production of road bitumen corresponding to GOST 22245-90. High Quality(the so-called "branded") should be based on the use of a modern product compounding unit, which has the necessary reservoir capacities and is equipped with metered mixing systems, in-line analyzers, etc. With its availability and the use of the necessary intermediates and additives, one or another can be significantly improved performance characteristics road bituminous materials.

An assessment of the economic aspects of bitumen production in Russia makes oil refiners consider bitumen not only as a commercial product, but also as a semi-finished product. For example, the organization of the production of polymer-bitumen binders (PBB) materials and bitumen emulsions allows solving a number of important problems:

Increasing the profitability of bitumen production in general;

Year-round employment of personnel in production;

Stability of providing the road industry with high-quality bituminous materials.