Ministry of Education and Science of the Russian Federation

Federal State Budgetary Educational Institution of Higher Professional Education (SAMARA STATE TECHNICAL UNIVERSITY).

Topic: "Educational practice."

Completed by: student I-ХТ-3

Pishchikov Alexander Igorevich

Teacher: Sokolov

Alexander Borisovich

Samara 2012

OJSC "KuibyshevAzot"

OJSC KuibyshevAzot is one of the leading enterprises in the Russian chemical industry. The company operates in two main ways directions:

- caprolactam and its processed products (polyamide-6, high-strength technical yarns, cord fabric, engineering plastics);

- ammonia and nitrogen fertilizers.

In addition, KuibyshevAzot produces process gases that meet the needs of its main business areas, and at the same time are independent commercial products.

The full range of products includes about 30 items.

Key indicators for 2000-2011

BASIC INFORMATION:

The enterprise is located 1000 kilometers southeast of the capital of Russia - Moscow, in Togliatti, Samara region, on the banks of the Volga River, the largest in Europe.

The plant was founded in 1966.

Company area - 3,000,000 sq.m. (300 Hectares), number of workers - 5.1 thousand people.

KuibyshevAzot today:

It is one of the ten largest global producers and ranks first in the CIS in the production of caprolactam

Leader in the production of polyamide-6 in Russia, the CIS and Eastern Europe

One of the top ten enterprises in the domestic nitrogen industry

The only enterprise in Russia that produces cord fabric based on high-strength technical thread

Has an integrated management system certified for compliance with the requirements of Russian and international standards ISO 9001:2008 (GOST R ISO 9001-2008); ISO 14001:2004; OHSAS 18001:2007 (GOST R 12.0.230).

CAPROLACTAM PRODUCTION TECHNOLOGY

Caprolactam (hexahydro-2-azepinone, e-aminocaproic acid lactam, 2-oxohexamethyleneimine).

Caprolactam is a white crystal, highly soluble in water, alcohol, ether, and benzene. When heated in the presence of small amounts of water, alcohol, amines, organic acids and some other compounds, caprolactam polymerizes to form a polyamide resin, from which caprone fiber is obtained. An important property of Caprolactam is the ability to polymerize to form a valuable polymer - polycaproamide

Physical properties of caprolactam

The main industrial application of caprolactam is the production of polyamide (nylon) fibers and threads (polyamide 6). In addition, caprolactam is used in the production of engineering plastics and polyamide films. In small quantities, caprolactam can be used in the formation of polyurethane and lysine synthesis, rigid textile linings, film coatings, synthetic leathers, plasticizers, paint solvents.

Caprolactam production technology:

In industry, caprolactam is obtained from benzene, phenol or toluene according to the following schemes:

In industry, the most widely used method is the synthesis of caprolactam from benzene. Technology system involves the hydrogenation of benzene to cyclohexane in the presence of Pt/Al2O3 or a nickel-chromium catalyst at 250-350 and 130-220 °C, respectively. Liquid-phase oxidation of cyclohexane to cyclohexanone is carried out at 140-160 °C, 0.9-1.1 MPa in the presence of Co naphthenate or stearate. The resulting cyclohexanol is converted into cyclohexanone by dehydrogenation on zinc-chromium (360-400 °C), zinc-iron (400 °C) or copper-magnesium (260-300 °C) mixed catalysts. Conversion to oxime is carried out by the action of an excess of an aqueous solution of hydroxylamine sulfate in the presence of alkali or NH3 at 0-100°C. The final stage of caprolactam synthesis. - treatment of cyclohexanone oxime with oleum or conc. H2SO4 at 60-120 °C (Beckmann rearrangement). The yield of caprolactam based on benzene is 66-68%. In the photochemical method for the synthesis of caprolactam from benzene, cyclohexane is subjected to photochemical nitrosation into oxime under the action of NOCl under UV irradiation. The method for the synthesis of caprolactam from phenol includes hydrogenation of the latter into cyclohexanol in the gas phase over Pd/Al2O3 at 120-140 °C, 1-1.5 MPa, dehydrogenation of the resulting product into cyclohexanone and further processing as in the synthesis method from benzene. Yield 86-88%.

The method for the synthesis of caprolactam from toluene includes: oxidation of toluene at 165°C in the presence of Co benzoate; hydrogenation of the resulting benzoic acid at 170°C, 1.4-1.5 MPa in the presence of a 5% suspension of Pd on fine coal; nitrosation of cyclohexanecarboxylic acid under the influence of nitrosyl hydrogen sulfate (nitrosyl sulfuric acid) at 75–80 °C to raw caprolactam. Some stages of this scheme are not selective enough, which leads to the need for complex purification of the resulting caprolactam. The yield of caprolactam is 71% based on the initial product.

Caprolactam obtained by any of the above methods is pre-purified using ion exchange resins, NaClO and KMnO4, and then distilled. A by-product of the production of (NH4)2SO4 (2.5-5.2 tons per 1 ton K.), which is used in agriculture as a mineral fertilizer. There are also known methods for producing caprolactam from non-aromatic raw materials (furfural, acetylene, butadiene, ethylene oxide), which have not found industrial application.

Solid caprolactam is transported in five-layer paper bags with a polyethylene liner, liquid - in specially equipped tanks heated in a nitrogen atmosphere (the oxygen content in nitrogen should not exceed 0.0005%). Ignition temperature - 135°C, self-ignition temperature - 400°C, lower ignition limit 123°C; LD50 450 mg/m3 (mice, vapor inhalation), MAC 10 mg/m3.

In the world, caprolactam is produced mainly from benzene - 83.6%, from phenol - 12%, from toluene - 4.4%.

Ammonium nitrate production technology:

Ammonium nitrate is obtained by neutralizing nitric acid with ammonia gas, and then granulating the melt.

The method of producing ammonium nitrate from coke oven gas ammonia and dilute nitric acid was no longer used as economically unprofitable.

The ammonium nitrate production technology includes the neutralization of nitric acid with ammonia gas using the heat of reaction (145 kJ/mol) to evaporate the nitrate solution. After forming a solution, usually with a concentration of 83%, excess water is evaporated to a melt, in which the ammonium nitrate content is 95 - 99.5%, depending on the grade of the finished product. For use as a fertilizer, the melt is granulated in sprayers, dried, cooled and coated with compounds to prevent caking. The color of the granules varies from white to colorless. Ammonium nitrate for chemical applications is usually dehydrated, since it is very hygroscopic and the percentage of water in it (ω(H2O)) is almost impossible to obtain.

In modern plants producing virtually non-caking ammonium nitrate, hot granules containing 0.4% moisture or less are cooled in fluidized bed apparatus. The cooled granules are packaged in polyethylene or five-layer paper bitumen bags. To give the granules greater strength, ensuring the possibility of bulk transportation, and to maintain the stability of the crystalline modification during a longer shelf life, additives such as magnesite, hemihydrate calcium sulfate, products of decomposition of sulfate raw materials with nitric acid and others are added to ammonium nitrate (usually no more than 0.5 % by weight).

In the production of ammonium nitrate, nitric acid is used with a concentration of more than 45% (45-58%), the content of nitrogen oxides should not exceed 0.1%. In the production of ammonium nitrate, waste from ammonia production can also be used, for example, ammonia water and tank and purge gases removed from liquid ammonia storage facilities and obtained during purging of ammonia synthesis systems. In addition, distillation gases from urea production are also used in the production of ammonium nitrate.

With rational use of the released heat of neutralization, concentrated solutions and even melted ammonium nitrate can be obtained by evaporating water. In accordance with this, there are schemes for obtaining a solution of ammonium nitrate with its subsequent evaporation (multistage process) and for obtaining melt (single-stage or non-evaporation process).

The following fundamentally different schemes for producing ammonium nitrate using neutralization heat are possible:

Installations operating at atmospheric pressure (excess pressure of juice steam 0.15-0.2 at);

Installations with a vacuum evaporator;

Installations operating under pressure, with a single use of juice steam heat;

Installations operating under pressure, using double heat from juice steam (producing concentrated melt).

In industrial practice, they are widely used as the most efficient installations operating at atmospheric pressure, using neutralization heat and partially installations with a vacuum evaporator.

The production of ammonium nitrate using this method consists of the following main stages:

1. obtaining a solution of ammonium nitrate by neutralizing nitric acid with ammonia;

2. evaporation of the ammonium nitrate solution to a melt state;

3. crystallization of salt from melt;

4. drying and cooling salt;

5. packaging.

The neutralization process is carried out in a neutralizer, which allows the heat of reaction to be used for partial evaporation of the solution - ITN. It is designed to produce ammonium nitrate solution by neutralizing 58 - 60% nitric acid with ammonia gas using the heat of reaction to partially evaporate water from the solution under atmospheric pressure according to the reaction:

NH3 + HNO3 = NH4NO3 + Qkcal

The safety of the neutralization process is ensured by automatic interlocks that stop the supply of raw materials to the heat pump apparatus when the ratio of consumption of nitric acid and gaseous ammonia is violated or when the temperature in the reaction zone rises above 180 0C; in the latter case, water vapor condensate is automatically supplied to the heat pump.

The nitric acid heater is designed to heat 58 - 60% nitric acid from the temperature at which it is stored in the warehouse to a temperature of 80 - 90 0C due to the heat of juice steam from the ITN apparatus. The ammonia gas heater is designed to heat ammonia to 120 - 180 C. The neutralizer is designed to neutralize with ammonia the excess acidity of the ammonium nitrate solution continuously supplied from the heat pump apparatus, and sulfuric and phosphoric acids introduced as additives. Highly concentrated melt is obtained in a one-stage evaporator under atmospheric pressure. Washing and filtering equipment is necessary for washing ammonium nitrate dust carried away by the air from the tower, aerosol particles of ammonium nitrate from the steam-air mixture of the evaporator, air from the towers, juice steam from the heat pump apparatus, as well as ammonia from these flows.

The granulation tower consists of three parts: the upper part - with a ceiling and an adapter to the washing scrubber; the middle part is the body itself; the lower part has a receiving cone. The product is discharged onto a reversible conveyor through a rectangular slot in the lower housing. The apparatus for cooling granules in a fluidized bed is designed to cool granules leaving the granulation tower from 110 - 120 to 40 - 45 0C. Fluidization refers to the process of transition of a layer of granular material into a “fluid” state under the influence of a flow of a fluidizing agent - air. If air is supplied under a layer of granules at a certain speed, the granules begin to move intensively relative to each other and their layer increases significantly in volume. Upon reaching a certain speed, the smallest granules begin to leave the boundaries of the layer and are carried away by the air flow. This phenomenon occurs if the pressure of the air flow exceeds the gravity of the granules. The resistance of a layer of materials is almost independent of gas velocity and is equal to the weight of the material per unit area. The fluidized layer of granules acquires the properties inherent in a dropping liquid. The temperature of the entire volume of the fluidized bed of granules, like any boiling liquid, is almost the same.

Modern large-scale chemical production units have a number of specific features that should be taken into account when developing automation systems for such facilities:

Consistent technological structure with rigid connections between the individual stages of the process in the absence of intermediate containers;

High productivity of individual devices, designed for the full power of the unit;

Territorial dispersion of apparatchik jobs.

The high power and sequential structure of the unit set increased requirements for the reliability of control, regulation and protection, since the failure of an individual element often leads to a complete shutdown of the unit and, as a consequence, to large economic losses.

Ammonium sulfate production

Ammonium sulfate is obtained from sulfate solutions for the production of caprolactam and cyanide salts by evaporation and crystallization, followed by centrifugation and evaporation.

Ammonia production

Synthetic ammonia is produced at a pressure of 25 to 30 MPa, at a temperature of 470-550 C on an iron catalyst from a nitrogen-hydrogen mixture, according to the AM-600 scheme

Ammonia production diagram.

No. Apparatus Purpose of the apparatus, processes occurring in it.

pipeline A pre-prepared mixture is supplied, consisting of 3 volumes of hydrogen and 1 volume of nitrogen.

2. turbo compressor The nitrogen-hydrogen mixture is compressed to a certain pressure required for this process.

3. synthesis column The synthesis column is designed to carry out the process of ammonia synthesis. The contact apparatus contains shelves with a catalyst. The synthesis process is highly exothermic and proceeds with a large release of heat, part of which is spent on heating the incoming nitrogen-hydrogen mixture. The mixture leaving the synthesis column consists of ammonia (20-30%) and unresolved nitrogen and hydrogen.

4. refrigerator Designed to cool the mixture. Ammonia is easily compressed and turns into liquid at high pressure. When leaving the refrigerator, a mixture is formed consisting of liquid ammonia and unreacted nitrogen-hydrogen mixture.

5. separator Designed to separate liquid ammonia from the gaseous phase. Ammonia is collected in a collection located at the bottom of the separator.

6. circulation pump Designed to return unreacted mixture to the contact apparatus. Thanks to circulation, it is possible to increase the use of the nitrogen-hydrogen mixture to 95%.

7. ammonia pipeline Designed for transporting liquid ammonia to the warehouse.

Urea production

Ammonia and carbon dioxide are converted into urea through ammonium carbamate at a pressure of about 140 bar and a temperature of 180-185°C. Ammonia conversion reaches 41%, carbon dioxide – 60%. Unreacted ammonia and carbon dioxide enter the stripper, with CO2 acting as a stripping agent. After condensation, CO2 and NH3 are recycled and returned to the synthesis process. The heat of condensation is used to generate steam for the CO2 compressor.

This process can have different hardware design. Below is the Urea 2000plusTM Technology - synthesis with a pool condenser.

Rice. 1.2. Urea 2000plus technology: synthesis with Pool Capacitor

This technology is successfully used in a 2,700 ton/day urea production facility in China (CNOOC), launched in 2004, as well as in a 3,200 ton/day capacity in Qatar (Qafco IV), launched in 2005.

The second embodiment of this process involves the use of a pool reactor. The advantages of synthesis using a pool reactor are:

In this case, 40% less heat exchange surface is required compared to a vertical film-type condenser,

The HP capacitor and the reactor are combined in one apparatus,

The height of the production structure is significantly reduced,

The length of HP pipelines made of corrosion-resistant steel is significantly reduced,

Decrease in investment,

Easy to operate, stable synthesis insensitive to changes in the NH3/CO2 ratio.

Below is a diagram of this process.

Rice. 1.3. Urea 2000plus technology: synthesis with a flooded reactor

Rice. 1.4. Pool reactor diagram

At the moment, there are also developments of mega-urea plants with a capacity of up to 5000 tons/day. Below is a diagram of the mega plant proposed by Stamicarbon.

Rice. 1.5. Mega-production of urea (Stamicarbon).

A variant of the stripping process proposed by Snamprogetti involves the use of ammonia as a stripping agent. NH3 and CO2 react to form carabide at a pressure of 150 bar and a temperature of 180°C. Unreacted carbamate is decomposed in the stripper by the action of ammonia. A simplified process diagram looks like this:

Rice. 1.6. Snamprogetti NH3 stripping process

The final stage of all technological processes Urea synthesis is the production of commercial urea granules.

Company creation: in 1966, the Kuibyshev Nitrogen Fertilizer Plant (construction began in 1961, the first production was put into operation in 1965) produced its own ammonia - the enterprise began to operate in a full technological cycle. In 1975, KuibyshevAzot was created - a production association that includes four enterprises, which later became independent legal units. In 2006, KuibyshevAzot became an open joint-stock enterprise.

Field of activity: chemical industry.

Full title: open Joint-Stock Company KuibyshevAzot.

The head office of OJSC KuibyshevAzot is located in Kuibyshev. The company produces caprolactam, technical thread, polyamide-6, urea, ammonium nitrate, ammonia, urea, ammonium sulfate. KuibyshevAzot also produces process gases both for its own main business areas and as a commercial product. The entire range of manufactured products includes 30 product items.

"KuibyshevAzot" in person

CEO - Victor Ivanovich Gerasimenko.

Chief Engineer - Anatoly Arkadyevich Ogarkov.

Commercial Director - Andrey Nikolaevich Bylinin.

Contact Information

CEO

Gerasimenko Viktor Ivanovich
[email protected]

Read also

Date of entry of the operator into the register: 26.11.2008

Grounds for entering the operator into the register (order number): 257

Operator location address: 445007, Samara region, Togliatti, st. Novozavodskaya, 6

Start date of personal data processing: 01.01.2009

Subjects of the Russian Federation on whose territory personal data is processed: Samara Region

Purpose of processing personal data: For the purpose: maintaining production activities, personnel work And accounting, ensuring compliance with laws and other regulations, assisting workers in employment, training and promotion, ensuring the personal safety of workers, monitoring the quantity and quality of work performed and ensuring the safety of property, organizing and monitoring activities to create safe conditions labor, organization of health measures and sanatorium-resort treatment.

Description of the measures provided for in Art. 18.1 and 19 of the Law: Local regulations on the processing of personal data have been developed. Implemented internal control compliance of the processing of personal data with this Federal Law and the regulations adopted in accordance with it legal acts, requirements for the protection of personal data. Employees directly involved in the processing of personal data are familiar with the provisions of the law Russian Federation about personal data, including requirements for the protection of personal data, documents defining the organization’s policy regarding the processing of personal data, local regulations on the processing of personal data. Published and posted on the website and information stands of OJSC KuibyshevAzot a document defining the policy regarding the processing of personal data and information on the implemented requirements for the protection of personal data. A model of security threats in the information system has been developed. Accounting of machine storage media of personal data is ensured. The restoration of personal data modified or destroyed due to unauthorized access to it is ensured. Rules for access to personal data processed in the personal data information system have been developed. Legal measures: order “On the creation of a commission for the classification of ISPD of OJSC KuibyshevAzot” dated 08/18/2011. No. 409, Regulations on the processing of personal data dated July 30, 2012 No. P 0060-06, operating regulations and Maintenance personal data protection system dated September 28, 2012, instructions for the administrator of the personal data protection system dated September 28, 2012, user instructions for the personal data protection system dated September 28, 2012, order “On the implementation of the Regulations on the processing of personal data and the purpose responsible for organizing the processing of personal data dated July 30, 2012 No. 417, order “On the admission of employees of OJSC KuibyshevAzot to the processing of personal data” dated December 17, 2012 No. 675. Organizational measures: information is available to a strictly defined circle of employees, buildings are installed security and fire alarms, information on paper is stored in safes or locked metal cabinets, storage locations for personal data are determined, physical security information system (technical means and storage media), providing for control of access to the premises of the information system of unauthorized persons, the presence of reliable obstacles to unauthorized entry into the premises of the information system and the storage of storage media, recording of all protected storage media by means of their marking and recording of credentials in the accounting log with a note about them issuance (reception)

Categories of personal data: surname, first name, patronymic, year of birth, month of birth, date of birth, place of birth, address, marital status, social status, education, profession, income, health status, citizenship, place of residence and contact numbers, marital status and family composition, social position, income, health status, position, length of service, identification document details, TIN, SNILS, education, specialty, profession, qualifications, information about certification and advanced training, information about vacations, information about military duty and military service, information about awards (incentives) and honorary titles, photography, video recording data.

Categories of subjects whose personal data is processed: employees of KuibyshevAzot PJSC, employee family members, individuals, who are in contractual relations with PJSC KuibyshevAzot.

List of actions with personal data: collection, recording, systematization, accumulation, storage, clarification (updating, changing), extraction, use, transfer (distribution, provision, access), depersonalization, blocking, deletion, destruction of personal data,

Processing of personal data: with transmission over the internal network of a legal entity, without transmission over the Internet, non-automated

Legal basis for processing personal data: Guided by: the Constitution of the Russian Federation, Labor Code RF dated December 30, 2001 No. 197-FZ (Art. 85-90), Civil Code Russian Federation, Tax Code of the Russian Federation, Federal law dated July 27, 2006 No. 152-FZ “On Personal Data”, Federal Law dated May 2, 2006 No. 59-FZ “On the Procedure for Considering Appeals from Citizens of the Russian Federation”, Federal Law No. 125 dated October 22, 2004 “On Archival Affairs in the Russian Federation” .

Availability of cross-border transmission: No

Database location information: Russia