Production plan of KARPATNAFTOCHIM LTD. in 2017
Feedstock processing plan
| Denomination |
Quantity,
ths. tons |
| Naphtha |
434 |
| n-butane |
23 |
| TOTAL: |
457 |
Commercial products
| Denomination |
Quantity,
ths. tons |
| Ethylene |
19 |
| Propylene |
71 |
| Butylene-butadiene cut |
45 |
| Benzene |
44 |
| С9-cut |
30 |
| Heavy pyrolysis resin |
18 |
| Polyethylene |
59 |
| Suspension polyvinyl chloride |
141 |
| Caustic soda |
93 |
| TOTAL: |
520 |
Products of KARPATNAFTOCHIM Ltd. in 2017
mln. UAH
with VAT
| Products sale |
|
| Ethylene |
568 |
| Propylene |
1 552 |
| Butylene-butadiene cut |
496 |
| Benzene |
821 |
| С9-cut |
248 |
| Heavy pyrolysis resin |
90 |
| Polyethylene |
1 913 |
| Suspension polyvinyl chloride |
3 313 |
| Caustic soda |
873 |
| Total, incl. |
9 875 |
| domestic market |
2 681 |
| export |
7 194 |
| Implementation of works and services |
34 |
| |
|
| Total in 2017 |
9 909 |
Structure of KARPATNAFTOCHIM Ltd. production plants
KARPATNAFTOCHIM Ltd. consists of the ethylene and polyethylene production, suspension polyvinylchloride resin and caustic soda production and production support department.
Ethylene and polyethylene production consists of:
- cracking, compression and separation of cracked gas plant;
- hydrocarbons production plant;
- hydrocarbons bottling plant;
- ethylene halogen derivatives, its polymers and copolymers production plant.
Suspension polyvinylchloride resin and caustic soda production consists of four plants, namely:
- vinyl chloride production plant;
- chlorine and caustic soda by membrane method production plant;
- suspension polyvinylchloride resin production plant;
- air separation plant.
Production support department consists of:
- neutralization and treatment of industrial sewage water plant;
- water supply and waste water disposal plant;
- steam and gas supply plant;
- long-distance pipeline plant.
Process technology description
Vinylchloride production comprises of units for crude EDC production by means of direct ethylene chlorination and oxidative ethylene chlorination.
Technological process of vinyl chloride production is continuous with one technological flow.
Method of production is balanced by chlorine and is based on direct and oxidated chlorination of ethylene in the presence of catalysts with obtaining of crude dichloroethane with its following dehydration, rectification and pyrolysis to produce vinyl chloride.
Chlorine and caustic soda production plant
Process technology description
Technology of chlorine, caustic soda and hydrogen production is based on the process of membrane electrolysis of salt (NaCl) solution. Introduction of advanced modern technology for chlorine and caustic soda production by the membrane method, taking chlorine directly to production of organochlorine synthesis, we eliminated the intermediate stage of liquid chlorine storage and therefore removed from technological cycle units of condensation and evaporation of chlorine, which are potentially dangerous.
Process technology of chlorine and caustic production by membrane method by Uhde process consists of the following units :
- Salt unloading, treatment and storage.
- Brine preparation.
- Anolyte dechlorination.
- Chlorate decomposition.
- Sulphates removal.
- Chlorine cooling and drying, sulphuric acid re-concentration.
- Chlorine compression.
- Catholyte system.
- Caustic soda re-concentration.
- Caustic soda storage, loading/unloading rack, caustic soda pumping house.
- Hydrogen compression and storage.
- Hydrochloric acid synthesis.
- Demineralized water preparation.
- Waste water neutralization.
- Waste gas dechlorination.
S-PVC production plant
| Plant capacity: |
300 000 tpa |
| Year of start-up: |
2011 |
| Process developer: |
company Vinnolit, Germany |
| Design: |
company Uhde, Germany |
Process technology description
Basic raw material is vinyl chloride monomer from vinyl chloride production plant.
Production is based on the method of vinyl chloride monomer suspension polymerization to obtain six grades of S-PVC with whole range of application.
Production process technology consists of the following units:
- Cold and hot demineralized water storage;
- Fresh vinylchloride (VCM) and recovered vinylchloride (R-VCM) storage;
- Chemicals dissolving and preparation;
- Vinylchloride polymerization (two parallel lines with two reactors in each);
- Polyvinylchloride suspension degassing (two parallel lines);
- Unreacted vinylchloride recovery;
- Polyvinylchloride suspension centrifuging and drying (two parallel lines);
- Finished products storage and bagging;
- Waste water treatment;
- Demineralized water production unit;
- Cooling tower with a pump house.
Auxiliary subdivisions
Air separation plant
| Plant capacity: |
on nitrogen – 84 096 000 Nm3/year
on oxygen – 49 494 000 Nm3/year
on argon – 438 000 Nm3/year
on process air – 55 000 000 Nm3/year
68 000 000 nm3/drained air |
| Year of start-up: |
1996 |
| Process and design developer: |
company Linde, Germany |
Process technology description
Air separation plant is designed to produce liquid and gaseous nitrogen, argon, oxygen.
Production of nitrogen, oxygen and argon by plant is carried out through low temperature rectification of liquefied air as per low-pressure circuit.
At the same time, production of liquefied products is provided as well.
KARPATNAFTOCHIM Ltd. is supplied with electricity from the government enterprise Kalush CHPP-Nova and OJSC Prykarpattyaoblenergo.
GDS Kalush-2 from the main gas pipeline NJSC Naftogaz of Ukraine fully covers KARPATNAFTOCHIM Ltd. gas demand.
Steam is provided to KARPATNAFTOCHIM Ltd. from the government enterprise Kalush CHPP-Nova.
The company has its own source of industrial and potable water. Waste water treatment of KARPATNAFTOCHIM Ltd. and the town of Kalush is provided by treatment facilities of KARPATNAFTOCHIM Ltd.
KARPATNAFTOCHIM Ltd. railway department fully covers company feedstock and finished products transportation of the company.
As at 2017, there are two stations in the structure of railway department (Kropyvnyk – 10 railway tracks and Himik-Novyy – 11 railway tracks), total railway tracks distance is 52.9 km. There are 10 own diesel locomotives and 440 RTCs.
Railway freight traffic after start-up and bringing out of Chlor-Alkali Plant and S-PVC plant to optimum yield amounted to 2.9 mln. tons (or 43.4 mln. of t-km of transport work) per year.
Treatment facilities of KARPATNAFTOCHIM Ltd.
Treatment of KARPATNAFTOCHIM Ltd. wastewater and domestic waste of the city of Kalush is provided by their own treatment plants.
Treatment facilities of KARPATNAFTOCHIM Ltd. are intended for mechanical, physical and chemical and biological treatment of service-utility and industrial waste water of the town of Kalush and its industrial area.
Treatment facility consist of the following process lines:
- physical and chemical treatment of acid and alkali wastes of industrial sewage system;
- hypochlorite wastes treatment of industrial sewage system;
- joint biological treatment of organic and service-utility wastes of industrial sewage system;
- heat treatment and sludge dewatering.
Treatment facilities were started up in 1964.
Treatment facilities design was made by state design institute Ukrvodokanalproekt, Kyiv.
Revamp of treatment facilities was finished in 1989 together with olefin plant start-up.
Treatment facilities capacity after revamp is 81 382 m3/day, incl.:
- on hypochlorite wastes – 200 m3/day;
- on acid and alkali wastes – 16 522 m3/day;
on service-utility and organic wastes – 64 660 m3/day.
