Tengizchevroil operates most innovative processes and reliable facilities to produce crude oil, liquefied petroleum gas, dry gas and sulfur of highest quality.
KTL & Second Generation Plant
Tengizchevroil inherited an oil and gas separation plant when it took over operations at Tengiz in 1993. This first generation of the Tengiz plant is called the KTLs (Russian for Complex Technology Lines). TCO has invested in expanding and improving the KTLs over the life of the operation. Today, the KTLs consist of five oil and gas processing trains and are now significantly more efficient and environmentally friendly. In 2009, TCO eliminated routine flaring at KTL Plant.
Tengizchevroil's production capacity has risen with the commissioning of its latest expansion project - Second Generation Expansion - which included the Second Generation Plant (SGP) and Sour Gas Injection (SGI) facilities.
This expansion doubled the Tengiz production capacity and will help Kazakhstan meet its goals of significantly increasing production. TCO completed the expansion in the third quarter of 2008 which brought daily capacity to 75,000 metric tonnes (600,000 barrels) of crude oil and 22 million cubic meters (750 million standard cubic feet) of gas.
This expansion was also a huge Kazakhstani Content success. We worked hard to ensure that Kazakhstani companies played a significant role in the realization of the projects. TCO spent a total of $2 billion in Kazakhstani content for the expansion.
Second Generation Plant's full facilities now stabilize and sweeten crude oil, as well as separate and process natural gas into gas products and elemental sulfur. The Second Generation Plant is the largest single sour crude processing train in the world. Not only have we increased production, but the expansion has helped to increase environmental protection and maximize energy efficiency through the use of advanced technology.
Sour Gas Injection
SGI re-injects one third of produced sour gas back into the Tengiz reservoir at very high pressures to help preserve reservoir pressure. The injection compressor is like no other compressor in the world and represents the state of the art in sour gas injection technology.
Use of Innovation
Tengizchevroil took the opportunity to add several environmental innovations into the design of its expansion to minimize operational impacts on the environment and improve energy efficiency.
Compared to the existing facilities, Second Generation Plant uses half the energy of the previous technology to process a unit of oil; cutting emissions in half and freeing up fuel gas for export and domestic use. TCO is using low emissions and high energy efficiency technology and some of the largest steam generators in the world to provide enough power for the huge facility.
A key driver in the environmental design of the Tengiz expansion project was to conserve, recycle and reduce water usage.Tengizchevroil has reduced consumption of water per tonne of oil produced from 1.3 cubic meters in 1994 to 0.2 cubic meters today. With state–of–the–art technology our operations produce our own technical water for processing, steam generation, utility water and fire fighting.
One way to obtain demineralized water is the separation of water from oil-containing fluids which include oil, gas, salt, water and hydrogen sulfide. First, the crude is stripped of hydrogen sulfide in the stabilizer and sent for transport. The sour gas is treated to make sales gas, propane, butane and sulfur. In the process of steaming acid and salty water is cleaned from hydrogen sulfide and then this stripped water is sent to the evaporator, then the evaporator vaporizes the salty water and produces distillate. Next distillate is served to water treatment plant, and then returned to the system as demineralized water for manufacturing processes and production of steam. Water restoring coefficient on evaporator exceeds 96 percent.
Water is also produced as a natural part of the sulfur recovery process when hydrogen sulfide is converted into elemental sulfur. Additionally, the SGP open drain system collects run off water, rainwater and melting snow across the facility. This water is treated to remove solids and organic contamination and is also used as technical water. This water is treated to remove solids and organic contaminations and all that comes to water treatment plant to get demineralized water.