Prospects for development of the Sumgait Ashgarlar Production Complex

1.

Prospects for
development of the
Sumgait Ashgarlar
Production Complex "

2.

GENERAL INFORMATION AND CAPABILITIES
GENERAL INFORMATION
Name of Legal Entity:
Sumgait Ashgarlar JSC
Location:
Sumgait, the Republic of
Azerbaijan
Year of Production
Foundation: 1957
Land Area:
20.15 ha
Sumgait Ashgarlar OJSC has the following technological capabilities:
1. Hydrocarbon processing unit UPNNO-600 (KU-2)
2. Sludge dehydration (saponification) unit with a capacity of 70,000 tons/year
3. Shop for receiving, storing and running oil bitumen into big bags with a volume of 15,000 tons/month
4. Pyrolysis shop for processing of contaminated oil sludge with a volume of 3,500 - 5,000 tons /month
5. Electricity power is 7,640 kW
6. Gas consumption is over 500 m3/month.
7. 5km own railway tracks from Sumgayit Ashgarlar JSC to Taghiyev Station ,to Sumgait Station
8. Railway and automobile loading and unloading racks for 36 tank wagons.
9. Automobile access roads for delivery of raw materials and shipment of products.
10. Capacitive park for storage of 10,000 tons of finished products.
11. Capacitive park for storage of 10,000 tons of raw materials.
12. Open storage with a capacity of 60,000 tons.
13. The process of cleaning up territories and water bodies contaminated with oil waste
14. Gasoline fraction obtained by pyrolysis method
15. Diesel fraction obtained by pyrolysis method
16. Heating oil
17. Light oil distillate
18. Heavy oil distillate
19. Fuel oil
20. Tar
21. Vacuum gas oil
22. Composite fuel (for specific processing processes)

3.

GENERAL PROJECT CONCEPT
Project Benefits
• Production Complex is located in the industrial area of ​Sumgait, where there are all
necessary communications and developed transport infrastructure, which will help
reduce the costs associated with construction, further operation of the plant and sale of
finished products.
• Location of the facility allows to reduce the cost of purchasing raw materials, as the
largest oil refinery of the region is located in close proximity.
• A new 110/35/6 kV closed-type substation Sumgait-3 with a capacity of 200 megavoltamperes is in close proximity.
• The main buyers of the manufactured products are the industrial enterprises of Europe,
Russia and the CIS countries.

4.

GENERAL PROJECT CONCEPT
Sumgait Ashgarlar JSC develops new and improves existing production facilities for deep processing of oil
residues
Sumgait Ashgarlar Production Site
Existing production
OIL REFINING,
KU-2 Unit
Recoverable
production
Oil slime processing.
Pyrolysis, Saponification
Release of formalin
up to 20,000 tons/year
Release of
solvents
Release of methylal
up to 19,000 tons/year
Bitumen Prepacking Shop
Planned production
Delayed Coking Unit
Processing of fuel oil and
heavy oil fractions
up to 200,000 tons/year
Processing of oil asphalt and
polymer modified bitumen (PMB)
or polymer-bitumen binder (PBB)
up to 19,000 tons/year

5.

GENERAL PROJECT CONCEPT
Prospects for new productions
Formalin production
Production will create a raw material base for medical industry, as well as a base for further processing into various chemical
products: carbamide formaldehyde and phenol-formaldehyde resins.
Methylal production
Methylal is a promising initial reagent for production of isoprene and highly concentrated formaldehyde in cosmetic and
technical aerosols. It is used as a solvent, a reagent for production of ion-exchange resins, as an ingredient in adhesives, for
additives to fuels to reduce smoke formation, in production of insecticides and in pharmaceuticals. Methylal has low toxicity.
Fuel oil processing (delayed coking unit)
The main produced products will be Euro-5 quality diesel fuel and gasoline for industrial purposes (GIP). By-products are
petroleum coke, propane-butane and sulfur
Production of petroleum bitumen (road, construction, polymer modified bitumen (PMB) or polymer-bitumen binder (PBB))
The main task of this production is to obtain oil bitumen from refined petroleum products during the processing of oil sludge

6.

GENERAL PROJECT CONCEPT
Advantages of Methylal Production Project
The global methylal market was estimated at 234.3 million USD in 2020, and
expected to be at the level of 271.4 million USD by the end of 2026; during 20212026, the growth is forecasted at an average of 2.1%
The new production is considered as a further development of the formalin
production process on the existing non-idle equipment.

7.

GENERAL PROJECT CONCEPT
Advantages of Fuel Oil Processing Project
Reduced consumption of fuel oil in the power industry and restrictions on the use of
sulphurous fuel oil in bunkering lead to an increase in the spread between fuel oil and
diesel fuel, the main target product
• The project was developed on the basis of the documentation of the coking plant with
a capacity of 550,000 tons per year, operating in the EU (Darmonesti, Romania).
• All processes used in the Project are typical and used in the global oil refining industry.
• The main process used in the Project, delayed coking, has been widely used in industry
since the 1970s.

8.

DESCRIPTION OF PRODUCTION PROCESSES
EXISTING PRODUCTION
SOLVENTS
Obtaining solvents during the distillation of petroleum fractions, including
gas condensate, and pyrolysis resins with a volume of up to 10,000 tons per
month
КО-20 Kerosene, ТS-1 oil
products up to 600,000
tons/year
Oil products processing
Solvents
6-7,000 tons/month
Motor fuel
3-5,000 tons/month
Fuel oil
2-3,000 tons/month

9.

DESCRIPTION OF PRODUCTION PROCESSES
EXISTING PRODUCTION
OILY WASTE
Technological scheme for processing 5,000 tons of oily waste per month
with production of road bitumen and motor fuel. Further development of
production will allow processing up to 200,000 tons of waste and receiving
up to 14,000 tons of marketable oil products per month
Oil slimes
160 000 tons
Processing of oily waste
Acid sludges
40 000 tons
Motor fuel
30 000 tons/year
Petroleum solvents
8 000 tons/year
Stove fuel
60 000 tons/year
Oil asphalts
150 000 tons/year

10.

DESCRIPTION OF PRODUCTION PROCESSES
RECOVERABLE AND NEW
PRODUCTION
Production of formalin with a volume of up to 20,000 tons per year with a
turnover of up to $3.5 million per month.
FORMALIN
Methanol
Formaldehydes processing
Formalin
20 000 tons/year

11.

FOREIGN EXPERIENCE AND SIMILAR
FORMALDEHYDE PRODUCTION
Chemie Linz
Hexion (Borden)
USA, Canada
530,000 tons/year
Dynea
USA, Canada
640,000 tons/year
Georgia Pacific
USA
400,000 tons/year
USA
420,000 tons/year
Dupont
USA
250,000 tons/year
Monsanto
USA
120,000 tons/year
Hoechst
Italy
144,000 tons/year
BASF
Germany
450,000 tons/year
Dynea
Holland
150,000 tons/year
SHCHEKINOAZOT OJSC
METAFRAX PJSC
Russia
tons/year
Russia
tons/year
Derivados Forestales
CHEMSYNTHESIS CJSC
AKRON PJSC
Spain
220,000 tons/year
Russia
tons/year
Russia
tons/year
NIZHNEKAMSKNEFTECHIM PJSC
Russia
tons/year
China
tons/year
China
tons/year
South Korea
tons/year
China
tons/year
Australia
tons/year

12.

FOREIGN EXPERIENCE AND SIMILAR
FORMALDEHYDE PRODUCTION
Regional structure of capacities for formaldehyde
production in 2005, thousand tons
Structure of capacities for formaldehyde
production among producing companies in 2005
Structure of capacities for formaldehyde
production in Europe in 2005

13.

DESCRIPTION OF PRODUCTION PROCESSES
RECOVERABLE AND NEW
PRODUCTION
Production of methylal with a volume of up to 19,000 tons per year.
METHYLAL
Methanol
Formalin
Methylal
19 000 tons/year

14.

DESCRIPTION OF PRODUCTION PROCESSES
BFD scheme for advanced processing of fuel oil M 100 (t/year)
RECOVERABLE AND NEW
PRODUCTION
Circulating VSG
Amine purification
Absorber/desorber
FUEL OIL PROCESSING
AT DCU UNIT
Strait-run diesel
fraction
Diesel storage
volumes
Hydrogen-sylfide-containing gas
Saturated amine
Gasoline and
diesel hydrofining
Gas desulfirization
Sulfur
Power gas
Amine purification
Absorber
Gasoline for industrial
purposes
Diesel fuel
Natural gas
metan
Hydrogen
production
Н2 in balloons
Fr. 85-360˚С
Fuel oil М
100
Fuel oil storage
volumes
DCU fractioning
Light naftha
demercaptanization
Gasoline for industrial
purposes
TDK automation
Raw material for TU or fuel oil
blending
Delayed
coking
Oil coke

15.

DESCRIPTION OF PRODUCTION PROCESSES
RECOVERABLE AND NEW
PRODUCTION
FUEL OIL PROCESSING
AT DCU UNIT
Hydrotreating (HD)
The process of improving the quality of gasoline and coking diesel to the
level of Euro-5 by reducing the content of sulfur, aromatic and
unsaturated hydrocarbons
Steam Reforming (SMR)
Production of hydrogen from natural gas (methane), which is necessary for
operation of hydrotreater
Klaus
The process of extracting sulfur from fuel gas to acceptable environmental and
technological levels, which makes it possible to use the resulting gas for the
needs of the plant
Unit for demercaptanization of light coking
naphtha
The process of reducing the sulfur content in light fractions of
coking gasoline, which cannot be sent for hydrotreatment, to
Euro-5 environmental standards
Delayed coking unit (DCU)
The main process of the plant. Processes raw materials
into final products (gasoline, diesel, coke)

16.

Sumgait Production Site
KU-2 Unit
Vacuum distillation
Productivity: 300 t/day,
3 columns (diameters of
600, 1200, 1800 cm)
КУ-2; 2- different
technological
equipment at the site
of KU-2 Shop
Formalin Plant
Gas steam generators
(10 atm).
Electric heating
(3 substations, total
capacity of 5 MW)
Territory of
treatment facilities

17.

Master Plan of Production Complex

18.

Raw Material Supply Scheme
The main routes for raw
materials supply
Azerbaijan
Iran
Turkmenistan

19.

Product Sales Scheme
Main products
Petroleum products, formaldehyde, methylal:
Europe, CIS
By-products
Carbamide formaldehyde and phenol formaldehyde resins:
Europe, CIS

20.

Production Risks
Technological Risks:
Technological risks at the design stage are minimal, since all the documentation is developed
by large and experienced engineering companies with a high reputation at the world level.
Personnel Risks:
After the 1990s, there has been a systematic development of the city of Sumgait.
Thanks to the cooperation of the state and private business, new high-capacity
industries were created.
An aluminum plant, pipe production, and various chemical enterprises started
operating. In a relatively short period of time, a unique industrial complex, the
Sumgayit Industrial Park (SIP), was built here.
Thanks to cooperation with advanced industrial countries, by the decision of the
Azerbaijani government, a pilot school was opened in Sumgait, which trains
highly qualified personnel according to the existing system of vocational
education in Germany.

21.

Taghiyev Village, Sumgait,
AZ 5022, Azerbaijan
Tel.: +994 44 208 04 97
e-mail: [email protected]