Company formation: in 1966, the Kuibyshev Nitrogen Fertilizer Plant (construction started 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 entities. In 2006, KuibyshevAzot became an open joint stock company.

Field of activity: chemical industry.

Full title: Open Joint Stock Company KuibyshevAzot.

The head office of OJSC KuibyshevAzot is located in Kuibyshev. The enterprise produces caprolactam, technical thread, polyamide-6, carbamide, 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 products includes 30 commodity items.

"KuibyshevAzot" in faces

CEO - Viktor Ivanovich Gerasimenko

Chief Engineer - Anatoly Arkadyevich Ogarkov.

Commercial Director - Andrey Nikolaevich Bylinin.

Contact Information

CEO

Gerasimenko Victor Ivanovich
[email protected]

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Establishment of the company: On June 17, 2002 JSC "System Operator - Central Dispatch Office of the Unified Energy System" was established as the first infrastructure organization of the reformed power industry in Russia. Later, the central dispatch services of the regions were removed from the structure of OAO RAO UES of Russia and were part of OAO SO - CDU UES as branches.

Date of registration of the operator in the register: 26.11.2008

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

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

Start date of personal data processing: 01.01.2009

Subjects of the Russian Federation on the territory of which the processing of personal data takes place: Samara Region

Purpose of personal data processing: In order to: conduct production activities, personnel work and accounting, ensure compliance with laws and other regulatory legal acts, assist employees in employment, training and promotion, ensure the personal safety of employees, control the quantity and quality of work performed and ensure the safety of property, organization and control of measures to create safe working conditions, organization of measures for the protection of health and sanatorium treatment.

Description of the measures provided for by Art. 18.1 and 19 of the Law: Local acts on the processing of personal data have been developed. Internal control over the compliance of the processing of personal data with this Federal Law and the regulatory legal acts adopted in accordance with it, the requirements for the protection of personal data is carried out. Employees directly involved in the processing of personal data are familiar with the provisions of the legislation of the Russian Federation on personal data, including the requirements for the protection of personal data, documents defining the organization's policy regarding the processing of personal data, local acts on the processing of personal data. Published and posted on the website and information stands of KuibyshevAzot OJSC a document that defines 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 for machine carriers of personal data is provided. Recovery of personal data modified or destroyed due to unauthorized access to them is provided. Rules for access to personal data processed in the personal data information system have been developed. Legal measures: order “On the establishment of a commission for the classification of ISPDs of OJSC KuibyshevAzot” dated 18.08.2011. No. 409, Regulation on the processing of personal data dated July 30, 2012 No. P 0060-06, regulations for the operation and maintenance of the personal data protection system dated September 28, 2012, instructions for the administrator of the personal data protection system dated September 28, 2012, instruction of the user of the personal data protection system dated September 28, 2012, order “On the Enactment of the Regulations on the processing of personal data and the appointment of a person responsible for organizing the processing of personal data dated July 30, 2012 No. 417, order “On the admission of employees of OJSC KuibyshevAzot” to personal data processing” dated 17.12.2012 No. 675. Organizational measures: information is available to a strictly defined circle of employees, security and fire alarms are installed in buildings, information on paper is stored in safes or lockable metal cabinets, places for storing personal data are determined, physical security information system (hardware and information carriers), providing for control - access to the premises of the information system by unauthorized persons, the presence of reliable barriers to unauthorized entry into the premises of the information system and the storage of information media, accounting for all protected media by means of their marking and entering credentials in the accounting log with a note on their 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, state of health, position, length of service, data of an identity document, TIN, SNILS, education, specialty, profession, qualifications, information on attestation and advanced training, information on holidays, information on military duty and military service, information on awards (rewards) and honorary titles, photography, video recording data.

Categories of subjects whose personal data are processed: employees of PJSC KuibyshevAzot, family members of the employee, 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 the processing of personal data: Guided by: the Constitution of the Russian Federation, the Labor Code of the Russian Federation of December 30, 2001 No. 197-FZ (Art. 85-90), the Civil Code of the Russian Federation, the Tax Code of the Russian Federation, the Federal Law of July 27, 2006 No. 152-FZ "On Personal Data", the Federal Law dated 02.05.2006 No. 59-FZ “On the procedure for considering applications from citizens of the Russian Federation”, FZ-125 dated 10.22.04 “On archiving in the Russian Federation”.

Availability of cross-border transmission: No

Database location details: Russia

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: student I-XT-3

Pishchikov Alexander Igorevich

Teacher: Sokolov

Alexander Borisovich

Samara 2012

JSC "KuibyshevAzot"

OAO "KuibyshevAzot" is one of the leading enterprises in the Russian chemical industry. The company operates on two main directions:

- caprolactam and products of its processing (polyamide-6, high-strength technical threads, cord fabric, engineering plastics);

- ammonia and nitrogen fertilizers.

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

The full range of products includes about 30 items.

Main indicators for 2000-2011

	U measurement			Growth
Volume of sales
Volume of production
Caprolactam
Polyamide-6				New Product
technical thread				New Product
cord fabric				New Product
Ammonium nitrate
Urea
Ammonium sulfate
Cargo turnover

BASIC INFORMATION:

The enterprise is located 1000 kilometers to the south-east from the capital of Russia - Moscow, in the city of Tolyatti, Samara region, on the banks of the Volga, the largest river in Europe.

The plant was founded in 1966.

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

KuibyshevAzot today:

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

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

Included in the top ten enterprises of the domestic nitrogen industry

The only company in Russia that produces cord fabric based on high-strength industrial yarn

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).

TECHNOLOGY OF CAPROLACTAM PRODUCTION

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

Caprolactam is a white crystal, readily soluble in water, alcohol, ether, 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 capron fiber is obtained. An important property of Caprolactam is the ability to polymerize with the formation of a valuable polymer - polycaproamide

Physical properties of caprolactam

Systematic name	azepan-2-on
traditional name	caprolactam
Description	White, hygroscopic, crystalline solid
Molecular formula
Molar mass	113.16 g/mol
Density (at 70 °C)
Boiling point	136-138 °C / 10 mm Hg
melting point
Conversion factor	1ppm=4.6mg/m3 @ 25oC

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

Caprolactam production technology:

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

In industry, the most widely used method is the synthesis of caprolactam from benzene. The technological scheme includes 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 cyclohexanol resulting from oxidation is converted into cyclohexanone by dehydrogenation on zinc-chromium (360-400 °C), zinc-iron (400 °C) or copper-magnesium (260-300 °C) mixed catalysts. The 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 in the synthesis of caprolactam. - treatment of cyclohexanone oxime with oleum or conc. H2SO4 at 60-120°C (Beckmann rearrangement). The output of caprolactam based on benzene 66-68%. In the photochemical method for the synthesis of caprolactam from benzene, cyclohexane is subjected to photochemical nitrosation to 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 obtained 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 action of nitrosyl hydrosulfate (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 output of caprolactam 71% based on the original product.

Caprolactam obtained by any of the above methods is preliminarily 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 of 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 caprolactam is transported 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 point - 400 ° C, lower ignition limit 123 ° C; LD50 450 mg/m3 (mice, vapor inhalation), MPC 10 mg/m3.

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

Production technology of ammonium nitrate:

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

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

The technology for the production of ammonium nitrate includes the neutralization of nitric acid with gaseous ammonia using the heat of reaction (145 kJ / mol) to evaporate the nitrate solution. After the formation of a solution, usually with a concentration of 83%, excess water is evaporated to the state of a melt, in which the content of ammonium nitrate 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 anti-caking compounds. The color of the granules varies from white to colorless. Ammonium nitrate for use in chemistry is usually dehydrated, as it is very hygroscopic and the percentage of water in it (ω(H2O)) is almost impossible to obtain.

At modern plants producing practically non-caking ammonium nitrate, hot granules containing 0.4% moisture or less are cooled in fluidized bed apparatus. The cooled granules arrive on packing in polyethylene or five-layer paper bituminous bags. To give the granules greater strength, providing the possibility of bulk transportation, and maintaining the stability of the crystalline modification with a longer shelf life, additives such as magnesite, hemihydrate calcium sulfate, decomposition products of sulfate raw materials with nitric acid, and others are added to ammonium nitrate (usually not 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, wastes from ammonia production can also be used, for example, ammonia water and tank and purge gases removed from liquid ammonia storages and obtained by blowing ammonia synthesis systems. In addition, in the production of ammonium nitrate, distillation gases from the production of carbamide are also used.

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

The following fundamentally different schemes for the production of ammonium nitrate using neutralization heat are possible:

Installations operating at atmospheric pressure (excessive pressure of juice vapor 0.15-0.2 atm);

Installations with a vacuum evaporator;

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

Plants operating under pressure, with a double use of the heat of the juice vapor (obtaining a 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.

Obtaining ammonium nitrate by this method consists of the following main stages:

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

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

3. crystallization of salt from the melt;

4. drying and cooling of salt;

5. packing.

The neutralization process is carried out in a neutralizer, which allows using the heat of reaction for partial evaporation of the solution - ITN. It is designed to obtain a solution of ammonium nitrate by neutralizing 58 - 60% of nitric acid with gaseous ammonia 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 blockages that stop the supply of raw materials to the ITN apparatus in case of violations of the ratio of the flow rates of nitric acid and gaseous ammonia or when the temperature in the reaction zone rises above 180 0C; in the latter case, water vapor condensate is automatically supplied to the HP.

The nitric acid heater is designed to heat 58-60% of 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 the juice vapor from the ITN apparatus. the gaseous ammonia heater is designed to heat ammonia up to 120 - 180 C. The after-neutralizer is designed to neutralize with ammonia the excess acidity of the ammonium nitrate solution continuously supplied from the ITN apparatus and sulfuric and phosphoric acids added as an additive. A highly concentrated melt is obtained in a single-stage evaporator under atmospheric pressure. Washing and filtering equipment is necessary for washing ammonium nitrate dust carried away by air from the tower, aerosol particles of ammonium nitrate from the vapor-air mixture of the evaporator, air from the towers, juice vapor from the ITN apparatus, as well as ammonia from these streams.

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 is with a receiving cone. The product is unloaded onto the reversing conveyor through a rectangular slot in the bottom housing. Apparatus for cooling pellets in a fluidized bed is designed to cool the pellets leaving the granulation tower from 110 - 120 to 40 - 45 0C. Fluidization is understood as the process of transition of a layer of granular material into a "fluid" state under the action of a flow of a fluidizing agent - air. If air is supplied under the 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 pellets. The resistance of a layer of materials is almost independent of the gas velocity and is equal to the weight of the material per unit area. The fluidized bed 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-capacity 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 links between the individual stages of the process in the absence of intermediate tanks;

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

Territorial dispersal of jobs for apparatchiks.

The large 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 result, to large economic losses.

Ammonium sulfate production

Ammonium sulfate is obtained from sulfate solutions from the production of caprolactam and cyanide salts by their 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 nitric mixture, according to the scheme AM-600

Scheme of ammonia production.

No. Apparatus The purpose of the apparatus, the 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 Nitrogen-hydrogen mixture is compressed to a certain pressure required for this process.

3. Synthesis column The synthesis column is intended for carrying out the ammonia synthesis process. Shelves with a catalyst are located in the contact apparatus. The synthesis process is highly exothermic, 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 unreacted nitrogen and hydrogen.

4. refrigerator Designed to cool the mixture. Ammonia is easily compressible and turns into a 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 collector located at the bottom of the separator.

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

7. ammonia pipeline Designed for transportation of liquid ammonia to the warehouse.

Carbide production

Ammonia and carbon dioxide are converted to carbamide via ammonium carbamate at a pressure of about 140 bar and a temperature of 180-185°C. The conversion of ammonia reaches 41%, carbon dioxide - 60%. Unreacted ammonia and carbon dioxide enter the stripper, while CO2 acts as a stipper 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 - pool condenser synthesis.

Rice. 1.2. Urea 2000plus Technology: Pool Capacitor Synthesis

This technology has been successfully operated at a 2,700 t/d urea plant in China (CNOOC), launched in 2004, and a 3,200 t/d plant 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 condenser 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,

Ease of operation, stable synthesis insensitive to changes in the NH3/CO2 ratio.

Below is a diagram of this process.

Rice. 1.3. Urea 2000plus Technology: Flooded Reactor Synthesis

Rice. 1.4. Scheme of the pool reactor

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

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

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

Rice. 1.6. NH3 Stripping Process by Snamprogetti

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