OREANDA-NEWS. August 17, 2010. The two reactors for combined hydrocracker were delivered to the site of Oil Refining and Petrochemical Complex.

The bulk equipment was manufactured for TANECO by Objedinenniye mashinostroitelniye zavody (Uralmash-Izhora Group) selected on the basis of tender. The contract of reactors’ delivery was concluded in August 2007.

The reactors R0101 and R0102 are absolutely identical ones and are unique structures with length of 37,5 m, diameter is 5,18 m. The thickness of the vessel wall is 290 mm. Weight of each vessel is1250 tons. The sophisticated equipment with such weight and dimensional characteristics was manufactured for the petrochemical complex in the Russian Federation for the first time.

Engineering and manufacturing of the reactors was performed fully in accordance with the requirements of ASME and Russian regulations. The licensor of the project is Chevron Lummus Global (USA) – one of the largest energy companies in the world. The design and process documentation, developed by the specialists of Izhorskiye zavody, was approved by both Chevron Lummus Global and Fluor (USA), project management contractor, for Oil Refining and Petrochemical Complex in Nizhnekamsk. OJSC TANECO and Fluor specialists constantly monitored the equipment manufacture for the purpose of quality provision at each stage of production.

It should be noted that during reactors’ manufacturing, the new technologies were developed of smelting of large ingots from chrome-molybdenum-vanadium steels, of hammering of bulky shell rings, of basic and post-weld heat treatment, execution of welds with thickness up to 300 mm. Also, the technologies were implemented of out-of-furnace heat treatment of field welds.

The reactors R0101 and R0102 required also non-standard transportation. It was possible to delivery them to Nizhnekamsk only by water. The barge with two bulky reactors on-board covered the distance of 2200 km. Its route was in the rivers Neva and Svir, Ladozhskoye and Onezhskoye lakes, Volga-Baltic Canal, in the rivers Volga and Kama. OOO INCOTEC CARGO (Saint Petersburg) was selected on the basis of tender as a contractor for delivery of the equipment from the manufacturing plant to TANECO site.

The special loading dock section with a floating botaport was built for the purpose of receipt of reactors and other bulky and large-size equipment of TANECO. ZAO KSU Gidrospetsstroy was the general designer of the project, ООО Neftegasengineering was the general contractor for the construction and installation works. The construction started in January 2008, finished in May 2009 and was performed fully in accordance with the project requirements. Operating length of the dock section is 133,5 m, width is 19 m. Filling of the giant vessel with volume of 30 438 cubic meters is performed by three powerful electrically driven pumps.

The botaport, manufactured at Zelenodolsky shipbuilding yard named after А.M. Gorky, is a floating structure with metal case. By means of tow, this mobile wall is directed to the input to the dock and becomes a reliable barrier between the dock section and the river.

For the purpose of unloading of the reactors, the water level in the dock section was increased up to nearly 13 meters, what allowed to transfer them to the moving modular transporters of German companies Scheuerle and Goldhofer. The modules look like rectangular platform, equipped with wheels, some of which have a hydraulic drive. It allows manoeuvring even in restricted space.

The transporters, by means of which the delivery of the reactors to the site was performed, looked like a transporter train consisting of 16 6-axis modules of gross loading capacity of 1700 tons. The operation was performed with the assistance of the specialists of the Dutch company MAMMOET. The distance between the berth and the construction site is 17 kilometers. Delivery of the reactors was performed under routine operation.

The special platform with increased load-bearing ability, capable to bear the load of 12 kg per one cubic centimeter, was prepared for the purpose of receipt of the two bulky reactors. The works were carried out by OOO Neftegasengineering specialists. Special hardness of the coating is due to its multi-layer structure. Combination of chip stone, airfield and road plates allows the platform to bear the weight of the two reactors, of two cranes "Liebherr" with loading capacity of 750 tons each and of some other auxiliary devices. Now, the company SOPiG is doing the preliminary works concerning lifting and installation of the delivered equipment.

As explained by Mr. Sergei Lebedev, Head of OJSC TANECO Hydrocracker Complex, the reactors R0101 and R0102 are the most important constituents of the combined hydrocracker. On the whole, it includes the following process sections: hydrogen production (3100) with capacity 135 000 nм3/hour; hydrogen production with capacity 30 000 nм3/hour; hydrocracker with capacity 2,9 mln.tons/year; base oils production with capacity of 250 thousand tons/year; treatment and concentration of hydrogen with capacity of 10 000 nм3/hour.

The unit will allow to increase the level of treatment at Oil Refining and Petrochemical Complex, to produce the additional quantity of kerosene - 455 tousand tons/year from CDU-VDU, diesel fuel – 1,3 mln.tons/year. All the products are of European quality.

The delivery of the reactors to the site became the part of work concerning implementation of the following stage of Oil Refining and Petrochemical Complex project.