RPC Grasys stages of development
The Company has been established in 2001 for promotion of the membrane gas separation technology in the Russian market. It has commenced its activities with engineering and supply of nitrogen membrane packages for compressor plants. Already in 2003, the RPC Grasys has launched the first nitrogen membrane unit at EFCO-Sloboda facilities, and in 2004 – the first nitrogen membrane station for Arcticgas.
Since its foundation, the Company has been engaged in dynamic research of membrane technologies. The obtained findings and accumulated experience were instrumental in successful completion of such a complex project in 2005 as commissioning of the first highly fault-tolerant membrane unit for the Novosibirsk NZKhC plant of the TVEL Corporation producing the nuclear fuel, as well as supply the first high-performance stationary membrane unit of 600 m3/h to the Saratov Oil Refinery.
Equipment from the RPC Grasys becomes the key point in the OJSC Gazprom program on enhancement of safety in repairs and precommissioning.
In 2006 the Company has started intensive development of 3 new trends at once.
The central result of scientific activities of the Company was development of a proprietary hydrocarbon membrane, perable under extreme conditions in corrosive media. In 2010 after successful completion of the program on endurance testing of commercial hydrocarbon package units at oil and gas fields of Russia, the Russia’s first commercial membrane APG treatment unit was commissioned at the CS Novoukrainskaya, Rosneft.
At the same time, the Company has mastered a new gas separation technology – the pressure swing adsorption (PSA). In 2007 the world’s largest nitrogen PSA unit was developed for the CPF Vankor (6600 m3/h). An oxygen adsorption unit (1800 m3/h) was supplied in 2008 to the Vasilkovsky Ore Mining and Processing Industrial Complex.
Development of Company’s competences in technologies, engineering and design was logically followed up by entering into the first EPC contract in 2007 for arrangement of nitrogen supply to facilities of the Vankor field. Within the scope of the contract, several nitrogen producing membrane plants were designed and built.
The Company continued active development of the PSA activities — from serial generators of nitrogen and medical oxygen to high-performance PSA units. Large nitrogen PSA generators were commissioned for NORSI (3000 m3/h), Nevinnomysskt Azot (5000 m3/h), the Kuibyshev Oil Refinery (3000 m3/h) and Orsknefteorgsynthez (2500 m3/h). The RPC Grasys became a renowned expert in PSA technologies and to date remains the only Russian Company – developer of large PSA units.
As the leader in the membrane air separation market the RPC Grasys carries out more and more complex projects – for Otradnensky and Neftegorsk Gaz Processing Plants, SAMARATRANSNEFT-TERMINAL, Bashneft and LenNIIkhimmash, supplies nitrogen and air stations to the «Yuzhny Potok » (The South Stream) gas main.
Membrane technology of natural and associated petroleum gas treatment developed by the RPC Grasys was acknowledged by oil and gas companies and its implementation started on mine fields both in Russia and abroad. The Company designed, manufactured and supplied a NG treatment unit for NIS Velebit, Serbia, with production capacity about 200 mln. m3/year supplied APG treatment units for Rosneft, Rusvietpetro, Dagneftegas, CanBaikal and other Customers. Successful testing was carried out of the world’s first helium membrane unit at the Markovskoye field.
The Company comes to non-CIS markets, implementing projects to standards of ASME, CE and ЕРС contracts for TOTAL E&P (Congo), NOMAC (Saudi Arabia), ACWA (Morocco), Maersk Oil, SIIRTEC NIGI SpA, Lenstor Enterprises Ltd, and others.
In order to implement the increased number of ЕРС contracts the Project Office and the Research and Technology Department at the Engineering Center of the Company were expanded.
The RPC Grasys has successfully passed QMS certification of compliance to standards of the American Petroleum Institute (API Q1) – the most distinguished organization of the petroleum industry.
The Company enters into an ЕРС contract for construction of nitrogen/air station for the Omsk Oil Refinery, a Project Office is established in Omsk. The Engineering Center develops and supplies membrane APG treatment units to fields of Bashneft-Dobycha, completes the Stage 1 of the ЕРС contract with Dagneftegaz. The RPC Grasys becomes an authorized packager of GE high-speed piston compressors, manufactures the first oxygen unit of 99% purity grade for Çalik Holding Group (Turkey).
The Company carries out a wide range of projects – from medical oxygen and nitrogen supply for hospitals and enterprises to supplies of nitrogen and air compressor stations to the “Sila Sibiri” (The Power of Siberia) gas main.
R&P Co. Grasys successfully implemented large-scale projects such as:
R&P Co. Grasys implemented large-scale projects such as:
R&P Co. Grasys placed into operation the only across Russia and the CIS production of hollow fiber gas separation membranes and membrane cartridges. The high-tech complex in Dubna was built to fully locate the critical component of helium recovery unit produced at the Chayandinskoye oil and gas condensate field - resource base of the Power of Siberia gas pipeline. Grasys is one of just three companies worldwide engaged in hollow fiber production!
The delivery of localized membrane elements Grasys to the 3rd line of helium concentrate separation unit at the Chayandinskoye oil and gas condensate field has begun. Membrane elements installed in two stages of the membrane unit allow 11-fold reduction of helium concentration in natural gas, which in turn makes it possible to preserve this important resource for the future of our country. All three lines have been put into operation, the first two are already running at full capacity.
The stage of main process equipment commissioning completed - two nitrogen PSA generators of in-house design featuring 1000 m³/h capacity and 99.999% purity each, five compressors and air dryers. A major EPC project of Grasys nitrogen-air compressor plant construction for JSC Gazpromneft-ONPZ was completed.
A set of main process equipment was supplied to automobile gas filling compressor station (CNG filling station) for JSC Norilsktransgaz. This is the first sophisticated, parent, high-performance CNG filling station in Norilsk for refueling a large number of motor vehicles.
Nitrogen plant Nitropower Plus completed with a mixer to obtain a modified gaseous fluid mixer to obtain a modified gaseous fluid the Dymov Group of Companies was manufactured and supplied. New engineering solutions deployed in this project will find application in food industry as well.
Grasys in the shortest possible time increased its capacity and launched mass production of medical oxygen concentrators. Manufacturing facility ran non-stop, 24/7 in 3 shifts. This made it possible to meet 40% of Russia’s hospitals and specialized health care centers need for oxygen concentrators for для лечения
Production of oxygen concentrators to treat the COVID-19 patients continued to increase. During the pandemic, R&P Co. Grasys supplied oxygen concentrators and medical oxygen plants to the leading Russian healthcare providers, and supported regions affected by the coronovirus infection by donating oxygen concentrators AKS.
Jointly with the Ministry of Industry and Trade of Russia R&P Co. Grasys participated in supplying medical oxygen concentrators to India, Peru and Cuba as a humanitarian aid.
The entry into the market of new technologies with environmentally-friendly solution for deep natural and associated petroleum gas desulfurization using hydrogen sulfide liquid-phase oxidation unit with iron chelate water solution became the point of significance. The technology enables to highly selectively and cost-effectively separate hydrogen sulfide from the purified gas stream using aqueous chemical solution while regenerating working solution with atmosphere air.
Beyond that, there was carried out R&D related to development of helium membrane and new membrane types for biogas treatment/CO2 removal/hydrogen separation.
Cooperation with PJSC Gazprom continued in terms of manufacture and supply of nitrogen and air stations for the Power of Siberia gas pipeline. In 2021, as many as eleven equipment items were shipped – eight nitrogen plants and three booster compressor stations.
Within investment project implementation on infrastructure development for using natural gas as NGV fuel, R&P Co. Grasys supplied and started equipment for CNG filling stations at one of the major players at the bus filling stations in Russia, OOO "BRYANSKAYA NEFTYANAYA KOMPANIYA", located in the city of Pskov.
For the production of polyester staple fiber and supplying the entire facility with gaseous nitrogen, on-site plant constituting of two nitrogen lines featuring 100 m3/h capacity with 99% purity and 10 m3/h capacity with 99.99% purity, was delivered to Shakhty Polyester Factory LLC.
The delivery of Grasys membrane cartridges for helium concentrate recovery at the Chayanda field, the resource base of the Power of Siberia gas pipeline, was successfully accomplished. There are over 1,500 membrane elements in service.
The company goes on with supplies and commissioning of nitrogen plants and modular compressor units along the whole length of the Power of Siberiagas pipeline. Nitrogen and air compressor stations were manufactured and shipped for three PJSC Gazprom’s fields: Kharasaveyskoye, Kovykta, Orenburgskoye..
Within investment project implementation on infrastructure development for using natural gas as NGV fuel, R&P Co. Grasys supplied and started equipment for CNG filling stations at the Russia's largest bus filling stations. The development of high-pressure natural gas dryer line for CNG filling stations was completed and production started.
A high-volume production program was completed flying the flag of the Ministry of Industry and Trade:: the supply of medical oxygen plants to Russian health centers. Maintenance of the delivered plants was completed, and the healthcare provider’s staff were instructed.
Adsorption nitrogen unit was delivered and placed into service for Bauman Moscow State Technical University.The unit features such parameters as 5 m3/h capacity with 99.99% purity and 0.6 MPa pressure. The produced gas is feedstock for a pilot plant which is a liquefied nitrogen refrigerator.
Over 1500 projects have been implemented!
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