business unit “petrochemical...

BUSINESS UNIT “PETROCHEMICAL TECHNOLOGIES”

HISTORY

ZAVKOM was founded in 1933 as a chemical machinery plant.The following milestones in the company’s history are noteworthy:

1933The first equipment for the chemical industry was manufactured: units for separating coke cooling and distillers.

1946Large apparatus from corrosion-resistant and heat-resistant steels were produced.

1948Distilling plants and heat-exchange equipment were first manufactured for the shipbuilding industry, including equipment for the nuclear-powered icebreaker Lenin.

1966By Decree of the Praesidium of the Supreme Soviet of the USSR, for ensuring high growth rates in the production of complex chemical apparatus, the enterprise was awarded the Red Flag Order of Labour.

1970Technology was developed for the manufacture of equipment from bi- and tri-metal for especially aggressive products and research in nuclear physics.

1992The first turnkey projects in biotechnologies were implemented.

2000The production of installations for gas purification and treatment was mastered. The company developed active collaboration with OJSC Gazprom.

2001The production of equipment for nuclear power stations was mastered. Equipment was designed, manufactured and delivered for the Kola Nuclear Power Station.

2007The company engaged in scientific research in the design and production of innovative nano-materials, investing its own funds in the venture.

2014The company was restructured and rebranded.

Throughout its entire history, ZAVKOM has continually expanded its engineering, science, technical and production potential, uncovering new lines of business and developing the company.

ZAVKOM is a leading Russian industrial holding company. Since 1933 the company has been known in the world market as an EPC contractor and manufacturer of equipment for oil, gas and petrochemical industries.

More than 1500 professional employees (400 engineers), the company’s own manufacturing plant and R&D center – all these makes it possible to execute complex high-tech industrial projects.

The company provides clients with the innovative solutions and helps them to establish profitable business. We use state-of-the-art technologies and quality management systems to create competitive products and services.

ZAVKOM with its extensive experience in engineering, procurement and construction guarantees its customers high services and professional management at all stages of project implementation.

The company's business grows rapidly and constantly develops production level extending market share and geography of sales. ZAVKOM cooperates with 92 companies from 25 countries. The company's head office is in Tambov city (Russia), representative offices are located in Moscow, Prague (Czech Republic), Minsk (Belarus), Dubai (UAE), Tehran (Iran) and Hanoi (Vietnam).

ZAVKOM collaborates with leading Russian and international research centres and engineering companies including Toyo Engineering Corporation, Maire Tecnimont, Linde, Moscow State University, Prague University of Technology. The company's R&D centre successfully carries out research and development work in nanomaterial sphere operates pilot plants for chemical processes testing.

Nowadays the company's business consists of seven business units engaged in different sectors of industry.

INTRODUCTION

In recent years there has been much discussion of the need to develop high-tech production and in-house expertise, and to create and promote new engineering solutions for international markets.

I am convinced that Russian future, its uniqueness and leading positions will be secured through developing our own, powerful production base. I believe that our country has significant potential in the development and creation of new technologies.

We should not forget, however, that creating anything totally new is a costly process. The creation of a new production facility and new technology from scratch, without relying on any historical experience and without an understanding of market trends, is often a matter of trial and error. That said, it is important to remember that in the creation of new facilities, the interests of the state and private investors actually coincide.

Since 1933 we have been engaged in the design and production of engineering equipment, and always

put quality first. We tap into the colossal engineering experience of both in-house development, and accumulated by Soviet industry as a whole.

At the same time we do not rest on our laurels. Thanks to an active dialogue with clients and partners, the company is developing new lines of business, uncovering new sales markets, international markets included, is engaged in scientific research and experimental design work and is elaborating new technologies and engineering solutions. We are helped in this by a clear vision of market trends, an understanding of the needs of our clients, production and design discipline, and collaboration with leading Russian and international research institutes and engineering companies.

ZAVKOM main priorities today are to satisfy the interests of our customers at the highest possible level, ensure industrial safety and continually move forward.

Vladimir Artemov

DEAR CLIENTS, COLLEAGUES AND PARTNERS,

OWNER'S ADDRESS

ZAVKOM STRUCTURE

BUSINESS UNIT

“PETROCHEMICAL TECHNOLOGIES”

BUSINESS UNIT

“GAS TECHNOLOGIES”

BUSINESS UNIT

“MONTAGE”

EPC projects:• Refineries (up to 2 mln tonnes per

year), bitumen plants, heavy oil processing

• Formaldehyde, formaldehyde resin, glue production units

• ETBE / MTBE, N-Methylaniline, isopropanol, additives for gasoil

• Butadiene-1,3• Aniline, Benzene, Naphthalene• Rectification packaged plants• Epoxy resins, additives for concrete,

dry building mixtures• Construction of pilot plants

Manufacturing of gas processing units and equipment:

• Fuel gas filters coalescers• Horizontal filter separators• Multicyclone scrubbers • Two staged scrubbers • Two stage separators• Dust-catchers

Services for installation of equipment during construction of new plants and modernization of industrial enterprises

• Sales of promoter for gasoline octane boosters TAG-SDS and octane boosting mixes

• Commodities and industrial equipment trading in ZAVKOM presence regions

• Supply ZAVKOM overseas EPC projects with raw material

Research activities in development and production of innovative nanomaterials:

• Nano carbon material TAUNIT and its modifications

• Promoter for gasoline octane boosters TAG-SDS

• Nanographite • Gasoline octane boosting mixes• Additives for motor oil

EPC projects: • Deep processing of grains• Aminoacids (Lysin)• Ethanol• Fuel ethanol• Glucose-fructose syrup• Starch• Gluten• DDGS• Enzymes• Feed for livestock and poultry• Beverages:

beer, vodka, brandy, whiskey• Soft drinks:

kvass and carbonated water• Water treatment units• Vacuum Evaporators

Manufacturing of:• Reactors• Columns• Heat exchangers• Capacity equipment• Oil and gas filters• Tanks and storages• Polymerizers• Nuclear facilities equipment• Metallurgical industry equipment

BUSINESS UNIT

“BIOTECHNOLOGIES”

BUSINESS UNIT

“INTERNATIONAL TRADING AND SUPPLY”

BUSINESS UNIT

“MACHINERY CONSTRUCTION”

BUSINESS UNIT

“R&D CENTER”

BUSINESS UNIT“PETROCHEMICAL TECHNOLOGIES”

5BUSINESS UNIT “PETROCHEMICAL TECHNOLOGIES”

THE COMPANY PROVIDES A FULL RANGE OF ENGINEERING SERVICES, BEING THE ONLY LEGALLY AND FINANCIALLY RESPONSIBLE ENTITY FOR THE CUSTOMER. OUR SERVICES WHEN IMPLEMENTING PROJECTS:

• Front end engineering design

• Selection of technology licensor

• Feasibility study

• Basic engineering

• Detailed engineering including Plant Control Systems (PCS)

• Receipt of permits from government authorities

• Manufacture of process equipment on the basis of our own plant

• Procurement and assembly of of standartized and custom equipment of local and foreign origin, including PCS

• Procurement of equipment

• Construction and installation works

• Automation of production lines

• Installation supervision

• Commissioning

ZAVKOM runs 3D-modelling of construction facil-ities during design plans & specifications prepa-ration.

ZAVKOM has all certificates and licenses required to render engineering services, manufacture equipment and perform construction and installa-tion work. We collaborate with leading internation-al engineering companies and when implementing projects we are ready to offer advanced engineer-ing solutions from leading licensors.

An undoubted advantage of our company is the availability of our own fixed equipment manufac-turing plant. This enables us, when implementing turnkey projects, to reduce the cost of the equip-ment made at ZAVKOM facilities, and accelerate the process of project implementation when con-forming design documentation, which leads to a reduction in capital costs for the customer.

We support our clients in getting project financing and loans on privileged conditions from European banks for construction of petrochemical plants.

ZAVKOM is a leading Russian EPC company that constructs turnkey facilities for oil, chem-ical and petrochemical indus-tries in the following areas:

• OIL REFINING

• CATALYTIC PROCESSES

• DISTILLATION AND EVAPORATION PROCESSES

• CHEMISTRY FOR TIMBER PROCESSING AND CONSTRUCTION MATERIALS

• PROCESSING OF COAL TAR

• PILOT PLANTS

6 BUSINESS UNIT “PETROCHEMICAL TECHNOLOGIES”

ZAVKOM IMPLEMENTS HIGH-TECH EPC PROJECTS FOR REFINING OF OIL AND GAS CONDENSATE.

Crude unit for the preliminary distillation of oil is the first stage in raw hydrocarbons refining. As a result of the preliminary distillation, the fol-lowing main products may be obtained: gasoline fraction (naphtha), diesel fraction, fuel oil, kero-sene and others.

Naphtha, obtained at the crude unit, after mixing with octane boosters, may be used as car petrol, if the initial parameters of the oil allow it. After purification, kerosene becomes the main compo-nent of aviation fuel. Diesel is used as a motor fuel if the sulphur content does not exceed the norm. Fuel oil is used as furnace or marine fuel.

Secondary distillation units enhance the quality of the final products and increase oil processing depth. In line with customer demand, company specialists elaborate process flow for oil refiner-ies, including units for the preliminary and sec-ondary distillation of the oil.

Oil refineries are designed in accordance with the relevant norms and regulations, allowing for cli-matic conditions. Process equipment is fitted with the necessary control devices, emergency protec-tion and automatic process control system, guar-anteeing reliable operation in the set engineering regimes.

The engineering solutions applied in designing a re-finery depend directly on the key parameters:

1. Characteristics of feedstock

2. Capacity

3. Assortment of goods

In line with the customer's requirements, we offer the most cost-effective and advanced engineer-ing solutions for oil and gas-condensate refining. When selecting the process flow and the config-uration of equipment, ZAVKOM collaborates with leading Russian and international engineering companies and R&D facilities.

OIL REFINERIES

OIL REFINING


MINI OIL REFINERIES ARE INSTALLATIONS FOR REFINING RAW HYDROCARBONS WITH A CAPACITY OF UP TO 1 MILLION TONNES OF OIL A YEAR.

ZAVKOM and its partners are prepared to supply oil and gas condensate refining modular instalations.

These units are designed for the production of:

• Straight-run petrol

• Diesel fuel

• Industrial fuel oil

Most frequently such installations are located at sites of oil and gas condensate extraction or sites where the consumers of oil products are based. In addition, kerosene and motor fuel may be produced at such units.

The units offered are made quickly and without sig-nificant costs on capital construction.

All units are configured with automatic process control systems, helping to minimise service per-

sonnel.

The process equipment of the units is designed and manufactured in accordance with existing norms, standards and climatic conditions of the region of construction.

Configuration of refinery is customized according to customer's demands and depends primarily on the quality of the primary raw material, the assumed capacity and the end products required.

ZAVKOM specialists are prepared to offer several process flows for the most cost-effective and inno-vative oil refining solutions.

MINI OIL REFINERIES


The increased level of construction in the world means annual growth of bitumen consumption. The field of application of this material is extensive: construction and repair of roads, waterproofing of housing foundations, production of roofing materials and filling cracks when laying pipelines. Bitumen binds the necessary components into a unified structure while preserving the necessary strength and plasticity.

In collaboration with leading Russian and international research and engineering companies, we are prepared to offer turn-key solutions to offer advanced bitumen production technologies:

• Production of residual asphalt under technology for the high-vacuum distillation of fuel oil

• Production of unoxidised compounded bitumen from asphalts of deasphalting process

• Production of oxidised bitumen under the latest energy-saving and environmentally safe technologies with high performance and improved quality indicators for the produced bitumen

• Production of road bitumen from low-resin oil with low content of asphaltenes

During design ZAVKOM performs 3D modelling of the sites under construction.

The majority of chemical processes for obtaining a highly-enriched product cannot be accomplished without treatment systems. One of the technologies for liquid mixtures separation into components with different boiling temperatures is rectification.

Together with leading Russian and foreign R&D institutes ZAVKOM designs, develops and supplies mass-transfer equipment. Our company has years of experience in designing and producing column equipment for different technological processes both for upgrading the existing facilities and for newly constructed installations.

ZAVKOM offers a full range of services to provide your business with separation technologies of maximum efficiency including pilot rectification plants for separation processes adjustment,

calculation and selection of mass-transfer equipment.

This lets us to offer our clients the most energy-efficient solutions, which allow to reach the high quality level of products with optimal capital expenses.

BITUMEN PLANTS

RECTIFICATION PLANTS

OIL REFINING


Geological exploration data indicate that reserves of light oil are decreasing each year, while the share of refined crude oil is increasing. Traditionally, heavy oil is defined as oil with a density of less than 20° API.

As heavy crude cannot be transported by pipelines given its viscosity and can not be refined at existing oil refineries, two methods are currently used to transport it to sites where it is refined:

• Mixing with light petroleum to reduce viscosity for subsequent transportation and refining

• Processing of heavy crude at the site of extraction while synthetic oil obtained as a result

The first option is the least cost effective; when adding cheaper heavy oil to expensive light oil, the qualitative parameters of the resulting mix deteriorate. This reduces the value of commodity mix and as result profit of oil companies is decreasing.

For heavy oil processing at site of extraction, a special heavy crude refining complex can be installed. The refinery produces synthetic oil, which is easily transported and may be processed at the oil refinery, and road asphalt, which is a stand alone high-demand commercial product.

HEAVY OIL PROCESSING

Crude unit

Deasphalting

Bitumenproduction unit

Light distillate Synthetic oil

Oil

Fuel oilAsphalt-free oil

Asphalt

Plasticising agent

Solvent

Road bitumens

MAIN PROCESS FLOW OF HEAVY OIL PROCESSING AT THE SITE OF EXTRACTION


Methyl tertiary butyl ether (MTBE) is an effective, non-toxic and high-octane component that is added to gasoline. Additives such as MTBE enable the pro-duction of high-octane petrol using base gasoline.

The introduction of MTBE into petrol in the amount of 10-15% by volume significantly raises the an-tiknock rating of petrols, improves the economic and power characteristics of engines and reduces harmful emissions (carbon monoxide by 15-30%, hydrocarbons by 7-8%). The introduction of this ad-ditive is especially effective for straight-run petrols and catalytic cracking petrols.

MTBE is produced by using isobutylene or a bu-tane-butylene fraction obtained from the reforming stage at refinery and methanol in the presence of acid catalysts.

Ethyl-tert-butyl ether (ETBE) is a simple ether. Its chemical properties are typical for this class of compounds but, unlike many other simple ethers, it does not form peroxide compounds, which significantly enhances the safety of its storage and use. During heating it can decompose into isobutylene and ethyl alcohol. The speed of the

decomposing increases in the presence of acid catalysts. ETBE has a high research octane num-ber – 109-113.

The advantage of ETBE over MTBE is that ethyl al-cohol is used to produce ETBE, which is obtained from a renewable, plant-based raw material. ETBE is a so-called oxygenic additive for gasoline. Its use decreases the volatility of the petrol mixture and reduces the carbon monoxide content in exhaust gases.

The conditions and equipment for obtaining ETBE are the same as for MTBE. Isobutylene and ethyl al-cohol are synthesized at a temperature lower than 100°C and a pressure of 1-2 MPa in the presence of acid catalysts.

ZAVKOM possesses latest technologies for the pro-duction of octane booster additives. Together with our partners we are well placed to offer the turnkey construction of MTBE and ETBE production plants in accordance with customer requests, our R&D cen-tre designs cost-effective and advanced engineer-ing solutions.

MTBE AND ETBE

CATALYTIC PROCESSES


N-METHYLANILINEN-methylaniline (monomethylaniline, MMA, N-MA) is an octane booster widely used in the production of petrol, both as a standalone component and for the production of multifunctional compositions of petrol additives. MMA is also used as a raw mate-rial for organic synthesis and as an interim prod-uct for dyes.

In the age of state-of-the-art technologies, many companies endeavour to find solutions to optimise the process of producing high-octane petrol, mak-ing savings with no loss of quality. Mixing mon-omethylaniline with straight-run petrol produces high-quality unleaded petrol with the required oc-tane number.

On the addition of just 1.5-2.5% to petrol, monometh-ylaniline increases its octane number on average by 6 points, depending upon the hydrocarbon composition of the initial fuel and other additives used. In addition to this, N-MA improves the operational properties of the petrol, specifically by:

• Enhancing the stability of the petrol, including during transportation and storage

• Reducing the cost of petrol storage tank maintenance

• Reducing petrol consumption by 5-7%

• Reducing the toxicity of exhaust gases (CO and CH) by 20-30%

ZAVKOM has innovative technologies for the pro-duction both of N-MA and integrated petrol additives based on N-MA and oxygenates. The engineering solution for the construction of an MMA production line is selected with the assistance of our top spe-cialists, whose first priority is to find the most eco-nomically feasible solution for the customer.

Taking into account the technical regularion of Eur-asia Economic Union which limits the use of MMA in Euro 4 and Euro 5 fuels, our specialists have designd an alternative additive 'ZAVKOM Premium' which is no less effective than MMA.

Isopropyl alcohol (propanol-2, 2-propanol, isopropanol, dimethylcarbinol, IPA) is an elementary secondary monatomic alcohol of the aliphatic series. It is widely used as a technical alcohol (in glass and office equipment cleaning agents, etc.), as an industrial solvent (it dissolves many ether oils, alkaloids, some synthetic resins and others) and is used in the synthesis of isopropyl benzene, isopropyl toluene and acetone.

The key industrial method for obtaining isopropanol is sulphuric acid hydration of propylene.

The propane-propylene fraction with a 30-90% propylene content (fraction of pyrolysis and cracking of oil) and pure propylene are both used as a raw material.

ZAVKOM, together with its partners, has developed an innovative technology for the synthesis of isopropyl alcohol from acetone. A special catalyst was developed for this technology with the optimum engineering conditions to optimise the costs.

ADVANTAGES OF THE PROPOSED TECHNOLOGY:

• Degree of conversion – 100%.

• Process selectivity – 98%

• The synthesis takes places in a medium of hydrogen in a tube reactor

• Softer process conditions (the pressure in the process is 70% lower) compared with older technologies.

• The reaction produces no byproducts (polymers).

ISOPROPYL ALCOHOL


2-ETHYLHEXYLNITRATE (2-EHN)

2-ethylhexylnitrate is an additive for diesel fuels, which increases the cetane number. The dosage of the additives depends on the fractional composi-tion and the properties of the fuel that have to be achieved. The presence of 2-EHN in fuel, in addi-tion to improving the combustibility, reduces the hardness of the diesel, makes it easier to ignite, reduces fuel consumption and improves the envi-ronmental performance: it reduces the smokiness of exhaust gases and the content of toxic compo-nents.

A common industrial technology for the production of 2-EHN is nitration of 2-ethylhexanol with a mix-ture of sulphuric and nitric acids, with the target product first being washed with water and then with an alkali solution.

Some important shortcomings of this technology are the presence of a large amount of effluent that has to be reclaimed, and also the presence of sul-phuric acid, which has to be regenerated.

The technology, developed by ZAVKOM applies an adiabatic continuous process of nitration, during the course of which nitric acid is used with a con-centration of about 60%. At the same time, the process is carried out not in tank reactors, where the reaction is hard to manage, but in dynamic equipment, which ensures the requisite level of manageability and safety.

When using this technology, the process of syn-thesis may be stopped and then restarted at any moment. ZAVKOM technology enables a 95% drop in the volume of runoff water and avoids the need for treatment facilities for spent acids that have to be regenerated and concentrated.

ZAVKOM and its' partners can offer a modern 2-EHN extraction technology which is superior to the existing traditional technologies.

ADDITIVES FOR DIESEL FUELS

INDICATOR

Appearance Colourless or transparent yellow liquid

Purity At least 98%

Density (20°С), g/cm3 960 − 970

Viscosity (100оС) mm2/s 1.70 - 1.80

Flash point At least 76

Colority, number Not more than 1.5

Humidity Not more than 0.05%

Acidity, mg KOH/100 mL Not more than 6

Solubility in water at 20°С 12.6 mg/L

QUALITATIVE INDICATORS OF THE 2-EHN OBTAINED

CATALYTIC PROCESSES


DIVINYLDivinyl (1,3-butadiene) is a key semi-product in the production of synthetic rubbers and ABS plastics.

The traditional industrial method for obtaining buta-diene in the petrochemical industry is dehydrogena-tion of butane on chromia-alumina catalysts.

We have designed a catalyst and selected optimal technological conditions which allowed to optimize expences due to the fact that 95% of vynilethilen is prepared as a subproduct of ethylene sythesis. This process makes butadien-ethanol synthesis more competitive. ZAVKOM specialists have developed a technology of butadien synthesis for industrial ap-plication.

The reorientation toward a lighter raw material dur-ing ethylene synthesis causes a drop in the quan-tity of the butadiene produced. At the same time, butadiene rubbers still maintain stable demand, as a result of which there is a deficit of butadiene on the market, and new ways of obtaining it need to be sought.

ADVANTAGES OF THE PROPOSED TECHNOLOGY:

• The developed catalyst helps to achieve a selectivity of 82% in terms of the target product, butadiene (the closest equivalent is the Lebedev process, which gives a selectivity of under 60%)

• Using the new polyfunctional catalyst, the entire process is conducted in a single stage

• The process is performed at a fairly low temperature, thus considerably reducing energy costs compared with the nearest equivalents

• The proposed technology uses a renewable raw material instead of a petrochemical one, which reduces the consumer's dependence on the oil price.

ANILINEAniline (phenylamine) is an organic compound, an elemental aromatic amine. It is used in the production of methyl diisocyanates (MDI) and to make artificial rubbers, herbicides, dyes and semi-products in the production of dyes, explosives and medicines (sulphanilamide preparations).

Aniline is industrially obtained in two stages. At the first stage, benzene is nitrated by a mix of concentrated nitric and sulphuric acids, forming nitrobenzene as a result. At the second stage, the nitrobenzene is hydrated in the presence of catalysts until aniline is obtained. Nitrobenzene hydrogenation is performed both during vapor and liquid phases.

ZAVKOM specialists have designed industrial technology for liquid and vapor phase hydrogenation.

We are well placed to offer the turnkey construction of aniline production plants. ZAVKOM selects the

most cost-effective and advanced engineering solution as per the customer's request.


Formaldehyde resins (phenol-formaldehyde resin, carbamide-formaldehyde resin, amino-formaldehyde resins, melamine-formaldehyde resins, hybrid resins) are synthetic resins with the properties of thermosetting materials or duroplastics. They are liquid or solid oligomeric products of the polycondensation of phenol, carbamide, melamine, and formaldehyde mixtures respectively.

The composition, structure and properties of phenol-formaldehyde resins are determined by nature, by the ratio of the initial components and by the conditions of the synthesis (medium, type and quantity of catalyst, temperature, etc.).

Modified and hybrid formaldehyde resins are formaldehyde resins in the synthesis of which modifiers are used at various stages (phenol, carbamide, melamine). The quality of the resin depends on the modifier (for example phenol, carbamide, melamine resins, phenol-formaldehyde resins, modified with carbamide, etc.). These types of resins allow to guarantee specific demands, otherwise unachievable when using traitional resins.

ZAVKOM performs the design and turnkey construction of process lines for the production of formaldehyde resins and units for the production of adhesive compositions on their basis for the timber processing and construction industries.

KEY ADVANTAGES OF THE PROPOSED TECHNOLOGY:

• Stable quality of products from batch to batch due to the use of highly effective equipment and PCS

• Synthesis of low-toxic resins with high water resistance and with a spatial structure of polymers

• High product quality

• Production of laminated chipboard of E1-E0 emission class

• Precision dosing of components with an error margin of less than 1%

• Highly effective mixing of components

• Automated production process control

• Human factor is wholly excluded

• Programmed setting of formulae (the number of formulae is not limited programmatically) and data archiving

• All stages of the process are under the technologist's control

We are well placed to additionaly provide formulae for resins, developed in line with the individual requirements of the customer.

ZAVKOM also offers the construction of installations for the production of formaldehyde and carbamide-formaldehyde concentrate to provide raw material in the production of resins and achieve the optimal technical and economic indicators. It will allow to generate extra income and increase the quality of resins as well as secure stable supply for resin production facilities.

FORMALDEHYDE RESINS

CHEMISTRY FOR TIMBER PROCESSING


ZAVKOM performs the turnkey construction of in-stallations for the preparation of adhesive composi-tions based on various adhesive resins.

THE PROPOSED INSTALLATIONS HAVE THE FOLLOWING FEATURES:

• Ability to work with different formulae (under agreement, from 1 to 6 loose components and up to 4 liquid components)

• Precision dosing of components with an error margin of less than 1%

• Highly effective mixing of components of adhesive compositions in a specially designed dissolving tank

• Embedded system for cooling the resins to 15-200ºС in order to improve the quality indicators of the end adhesive product

• Fully automated control of the production process (raw material is loaded into the installation once a day)

• Human factor is excluded

• Automation of the process of filling the holding tanks on rolls with an adhesive composition; return of excess adhesive

• Programmed setting of formulae for preparing adhesive compositions (the number of formulae is not limited programmatically) and data archiving

• All stages of the adhesive composition preparation process are under the technologist's control

GLUE PRODUCTION UNITS

Formalin is an aqueous solution of formalde-hyde, stabilised with methanol. It is used as an antiseptic (formidron, formagel, etc.) for the preservation of biological materials (the crea-tion of anatomical and other preparations), as a tanning agent in leather production, for the production of polymer thermosetting materials (phenol-formaldehyde, carbamide-formalde-hyde and melamine-formaldehyde resins) and is used in industrial organic synthesis for the production of pentaerithritol, trimethylol pro-pane and others.

UFC is an aqueous solution of formaldehyde, sta-bilised with urea. It is one of the most important sources of formaldehyde and urea in the production of urea-formaldehyde and melamine-urea-formal-dehyde resins. It is also used to treat urea against caking and in the timber processing and furniture

industry for the production of composite board, chipboard, etc.

Urea-formaldehyde concentrate is obtained in practically the same way as formalin, only the formaldehyde-containing gas is absorbed by a solution of urea, not by water as in the case of formalin.

ZAVKOM together with its european partner offers the turnkey construction of formalin and UFC pro-duction plants.

FORMALIN AND UREA-FORMALDEHYDE CONCENTRATE (UFC)


Additives for concrete (plasticising and super-plas-ticising agents) are additives used to change the characteristics of the concrete mixture: workability, pumpability, reduction of water- and solution-sep-aration, adjustment of losses in the mobility of the mix over time, etc.

Super-plasticising agents are usually divided into four groups: the products of the condensation of Sulphonated Naphthalene Formaldehyde (polynaf-thalenesulphonate – PNS), melamine sulpho-acids with formaldehyde (SMF), modified lignosulpho-nates (MLS) and other substances, including the ethers of sulpho-acids, carbohydrates, etc. The most effective of them are PNS which produced in the form of sodium salts.

ZAVKOM together with its european partner offers turnkey construction of plants for the production of entry-level additives for concrete. If neccesary it is possible to design and transfer recipes for a full set of additives.

THE ADDITIVES PRODUCED FOR CONCRETE AND SOLUTIONS CAN BE APPLIED AS FOLLOWS:

• in the production of commercial-grade concrete to obtain high-mobility and cast concrete mixes with greater lifetime used in erecting cast-in-place structures with a high degree of reinforcement and complex configuration

• in the construction of all types of cast-in-place structures from heavy and fine-grained concrete, and concretes on porous aggregate for long-term transportation and laying of the concrete mix.

• when erecting all types of constructions (including hydrotechnical structures, road and airport surfaces) from cast-in-place concrete under enhanced requirements for frost resistance, waterproofing and corrosion resistance

• when erecting solid cast-in-place structures from high-strength concrete when the heat emission during hardening of the concrete has to be reduced or slowed to avoid the accumulation of internal stresses

• when erecting flat and long structures, to reduce the number of movement joints

• in the production of assembled structures from high-strength concrete, the manufacture on stands of solid, high-density reinforced structures (such as girders, beams, columns and bridge spanning structures) and reinforced concrete items

• when manufacturing structural and heat-insulation light concretes simultaneously with air-entraining additives to reduce the water content under optimum hardness and tempering moisture of concrete prepared on fine aggregates (ash and ash-slag mixture of heat and power plants, expanded perlite sand and others) for manufacturing coatings with high operating properties etc.

ADDITIVES FOR CONCRETE

CHEMISTRY FOR CONSTRUCTION MATERIALS


EPOXY RESINSEpoxy resins are oligomeric products of the poly-condensation of epichlorohydrin with polyatomic phenols, alcohols, polyamines, polybasic acids and products of the epoxidation (meaning the introduc-tion of epoxy groups) of compounds, containing at least two olefinic bonds.

Hardened epoxy resins are characterised by high adhesion to metals, glass, concrete and other ma-terials, and by mechanical strength, heat, water and chemical resistance and excellent dielectric indi-cators. The engineering, physical and mechanical properties of compositions on the basis of epoxy

resins vary due to their combination with different monomers, oligomers and polymers, with mineral and organic fillers. Epoxy resins are used as the ba-sis for high-strength bonds, adhesives and fillers, and for treating electrical insulation compounds, sealants, lacquers and expanded foam.

ZAVKOM together with its european partner (pat-ent holder of resin receipts) is prepared offer a turn-key construction of facilites for epoxy resins production.

DRY BUILDING MIXES

Modern dry building mixes are a high-tech product. Their use not only significantly increases labour efficiency, but helps to achieve excellent qualitative results, which cannot be achieved using regular cement and sand mixes. The basis of dry building mixes is often sand or powdery quartz, limestone flour and powdery chalk.

Current demand for dry building mixes is growing, and many construction organisations try to make dry building mixes independently, procuring inexpensive equipment with the required output capacity for this purpose.

ZAVKOM designs and manufactures installations for the production of dry building mixes, which conform to the

needs of the market. A distinguishing feature of these installations is their reliability and the release of high-quality products that satisfy all modern requirements.

The newest high-tech equipment from leading international manufacturers, combined with ongoing research, helps to achieve the very best quality of dry building mixes at ZAVKOM facilities.


BENZENEZAVKOM offers a package of services for the turn-key construction of production installations for high quality benzene from feed stock, including coal tar.

Benzene is an elemental aromatic hydrocarbon. Ben-zene forms part of the composition of petrol; it is widely used in industry and is a primary raw material in the production of medicines, various plastics, syn-thetic rubber and dyes. Although benzene forms part of the composition of crude oil, on an industrial scale it is synthesised from other components thereof.

Benzene is also used for the synthesis of ethyl ben-zene, cumene, cyclohexane, nitorbenzene, linear alkyl benzenes, chlorobenzene and others.

In accordance with customer requirements, we of-fer the most cost-effective and advanced engineer-ing solution for the production of benzene.

Currently ZAVKOM posesses a separation technol-ogy for preparing commercial products (solvents, toluene, benzene) from coal naftha. Separation method is based on high-efficient rectification. The separation unit installation allows to effectively solve such tasks as desulfurization, etc.

The extact technology for benzene extraction may be adjusted to the specifics of raw material.

NAPHTHALENENaphthalene is one of the most important compo-nents in the chemical industry. Derivatives of naph-thalene are used to obtain dyes and explosives, in medicine, as an insecticide, to produce additives for concrete, and for other purposes.

Pure naphthalene is a product of the reprocessing of technical-grade pressed naphthalene or concen-trated naphthalene fraction. It is obtained at domes-tic coke and chemical plants by way of compression moulding and partially with rectification.

Depending on the further use, naphthalene is dev-ided into technical naphthalene with 98,5% of con-centration to receive polynaphthalenesulphate and refined naphthalene with concentration above 99% for coloring agent sythesis and pharmacology.

ZAVKOM offers turnkey construction of installations for reprocessing naphthalene fraction into technical naphthalene by rectification with the use of propie-tary technology, and refined naphthalene extraction technology by using fraction crystallization method provided by ZAVKOM partner.

THE KEY ADVANTAGES OF ZAVKOM'S INSTALLATIONS FOR PURIFICATION AND REPROCESSING OF NAPHTHALENE ARE:

• High output of commercial naphthalene

• High reliability of equipment

• High quality of commercial naphthalene

• Low energy consumption

• Automated process

PROCESSING OF COAL TAR


A pilot plant is a critical element in the large-scale transition from a "test-tube" process to a full indus-trial installation.

ZAVKOM OFFERS THE FOLLOWING SERVICES IN THE DEVELOPMENT OF PILOT INSTALLATIONS:

• Development and optimisation of process flow

• Design and optimization of key machines

• Elaboration of control automation chart

• Elaboration of design

• 3D chart visualisation

• Equipment manufacture

• Procurement

• Assembly

3D-visualisation of the experimental installations significantly simplifies subsequent assembly and avoids design errors.

Conducting experiments and processing experi-mental data at pilot installations enables the pro-cess to be scaled and optimised for full-scale in-dustrial installation.

Successful tests performed at pilot installations guarantee the successful introduction of techni-cal and engineering innovations on an industrial scale.

CONSTRUCTION OF PILOT PLANTSADVANTAGES OF PILOT INSTALLATIONS:

• THE PROCESS FLOW OF A PILOT PLANT IS EASY TO AMEND

• THE DESIGN OF THE PLANT ENSURES UNIMPEDED ACCESS TO ALL UNITS

• THE EQUIPMENT USED ENSURES PROCESS FLEXIBILITY

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BUSINESS UNIT“R&D CENTER”

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ZAVKOM "R&D Center" conducts successful scien-tific research work in the development, production and introduction of nano-materials and products that are synthesised on their basis.

• Nano carbon material TAUNIT and its modifications


• Nanographite

• Gasoline octane boosting mixes and "ZAVKOM-Premium" agents

• Additives for motor oil

The principal objective of the business unit is the development of technologies for the broad industrial introduction of nano-materials. We do everything possible to ensure that nano-mate-rials and products that are synthesised on their basis increase the effectiveness of the modern production process and yield a qualitatively new result in different sectors of industry, facilitating the development of new-generation technology.

Approbation of the developed nano-materials and products is carried out at various levels of the re-search in more than 150 scientific and production organisations in Russia and abroad. The research results show that unique properties of nano-mate-rials can find a broad practical application in science and industry, significantly improving the features of various materials and promoting the advent of completely new capabilities in different fields and the appearance of a whole range of new facilities.

The quality of the developed technologies and equipment is supported by patents. The division collaborates with research centres and production companies.

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BUSINESS UNIT“INTERNATIONAL TRADING AND SUPPLY”

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Business Unit "International Trading and Supply" is one of the main drivers in the development of the company's international business.

IT IS ENGAGED IN THE FOLLOWING LINES OF BUSINESS:

1) Sales of the following ZAVKOM R&D Centre prod-ucts:


• Gasoline octane boosting mixes

• Additives for motor oils

2) Commodities and industrial equipment trading in ZAVKOM presence regions:

• Crude oil

• Oil products (gasoline, fuel oil, gasoil, kerosene)

• Petrochemical products

• Metals

• Coal

• Grain and biotechnology products

• Equipment for oil and gas industry (pipes, casing, upstream equipment)

3) Supply ZAVKOM overseas EPC projects with raw material

Business Unit "International Trading and Supply" operates through the company's representative of-fices in the European Union, CIS countries, Asia and the Middle East.

Since 1933 ZAVKOM has been collaborating with lead-ing Russian and international commodities companies, guaranteeing product quality and timely supply.

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PRODUCT QUALITY ASSURANCE

In order to create equipment that is competitive on the international market, we use advanced manufacturing technologies and implement quality management in accordance with the requirements of ISO 9001:2000.

ZAVKOM has licences for design, manufacture, installation, commissioning and repair of

equipment and certificates of conformity for all equipment produced.

We design and manufacture pressure vessels and apparatus in accordance with the requirements of the American Society of Mechanical Engineers (ASME).

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OUR CLIENTS

JOINT STOCK COMPANYKAZANORGSINTEZ

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OUR COMPANY

REPRESENTATIVE OFFICES

3 OFFICE IN MOSCOW:The Russian Federation117105, Moscow, Varshavskoe highway, 1E-mail: [email protected]

REPRESENTATIVE OFFICE IN EUROPE:Czech RepublicPrague, Kovaku street, 32E-mail: [email protected]

REPRESENTATIVE OFFICE IN THE CIS:Republic of BelarusMinsk, Melnikaite street, 2E-mail: [email protected]

REPRESENTATIVE OFFICES IN THE MIDDLE EAST:United Arab EmiratesDubai, Liberty HouseE-mail: [email protected]

Islamic Republic of IranTehran, Vali Asr street, Sadr alley, 62E-mail: [email protected]

REPRESENTATIVE OFFICES IN ASIA:People's Republic of ChinaBeijing, Xueqing street, 7E-mail: [email protected]

VietnamHanoi, Dai La Street, 408 - A1,E-mail: [email protected]

WWW.ZAVKOMGROUP.COM

CONTACTS

HEADQUARTERS

392000, The Russian Federation, Tambov city, Sovetskaya Street, 51Tel: +7 4752 79 35 45Fax: +7 4752 70 35 25E-mail: [email protected]

business unit “petrochemical...

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