Refinery - industrial enterprise, the main function of which is the processing of oil into gasoline, aviation kerosene, fuel oil, diesel fuel, lubricating oils, lubricants, bitumen, petroleum coke raw materials for petrochemicals. The production cycle of a refinery usually consists of preparation of raw materials, primary distillation of oil and secondary processing of oil fractions: catalytic cracking, catalytic reforming, coking, visbreaking, hydrocracking, hydrotreating and mixing components of finished petroleum products. There are many oil refineries in Russia. Some refineries have been operating for a long time - since the war years, others have been put into operation relatively recently. The Achinsk Oil Refinery turned out to be the youngest plant among the considered enterprises; it has been operating since 2002.
The site compiled a rating of refineries supplying Russian regions with petroleum products.
1. - an oil refinery located in the Bolsheuluysky district of the Krasnoyarsk Territory. The company was founded on September 5, 2002. Owned by Rosneft.
2. Komsomolsk Oil Refinery is a Russian oil refinery located in the Khabarovsk Territory in the city of Komsomolsk-on-Amur. Also owned by OAO NK Rosneft. Built in 1942. It occupies a significant place in oil refining in the Russian Far East.
3. - Russian oil refinery in the Samara region. Included in the group of OAO NK Rosneft. Year of foundation - 1945.
4. - an oil refining enterprise, located in Moscow, in the Kapotnya district. The plant was commissioned in 1938.
5. - Russian oil refinery in the Samara region. Included in the group of OAO NK Rosneft. The refinery was founded in 1951.
6. Omsk oil refinery is one of the largest oil refineries in Russia. Owned by Gazprom Neft. September 5, 1955 put into operation.
7. - Russian oil refinery. Also known as "Cracking". Part of the TNK-BP group. Located in the city of Saratov. Founded in 1934.
8. - Russian oil refinery in the Samara region. Included in the group of OAO NK Rosneft. Works since 1942.
9. - Russian oil refinery in the Krasnodar Territory. The plant is a single production complex with a sea terminal of Rosneft's oil product supply enterprise - OAO NK Rosneft-Tuapsenefteprodukt. The main part of the products is exported. It is part of the Rosneft oil company. The year of foundation is 1929.
10. - Russian refinery, a leading Far Eastern manufacturer of motor and boiler fuel. It is part of the NK "Alliance". The enterprise's capacity is 4.35 million tons of oil per year. Founded in 1935.
The locations of the largest oil refineries in the world in 2007 are shown in Fig. 1. The refinery in Venezuela has the largest capacity (47 million tons/year) (Paraguana Refining Center, Cardón/Judibana, Falcon State), and the closest in capacity to it are located in the Asia-Pacific region ( South Korea, Japan), the Middle East (India, Saudi Arabia) and North America.
Figure 1. The largest refineries in the world in 2007.
In 2009, the picture did not fundamentally change, as shown in Table 6. There were changes in the capacities of some refineries (for example, an increase in capacity at the refinery in Ulsan from 35 to 40.9 million tons / year, in Ras Tannur from 26 to 27.5 million tons / year), a new “giant” appeared in India. Reliance Industries in Jamnagar commissioned the second stage of the refinery with a capacity of 29 million tons / year, given that the first stage of the plant already had a capacity of 33 million tons / year, this refinery (62 million tons / year) can be considered the largest in the world .
Table 6
Largest refineries in the world (2009)
|
Company |
Location |
Performance for crude oil |
|
|
mln t/year |
thousand barrels/day |
||
|
Paraguana Refining Center |
|||
|
Ulsan, South Korea |
|||
|
Yeosu, South Korea |
|||
|
Reliance Industries |
Jamnagar, India |
||
|
ExxonMobil Refining & Supply |
|||
|
ExxonMobil Refining & Supply |
Baytown, Texas, USA |
||
|
Formosa Petrochemical |
Mailiao, Taiwan |
||
|
Onsan, South Korea |
|||
|
ExxonMobil Refining & Supply |
Baton Rouge, Louisiana, USA |
||
|
Santa Cruz, Virgin Islands |
The data presented in Table 7 shows the location of the world's largest refineries in 2012. Compared to 2009, the following changes are visible:
1. Increasing the capacity of the refinery in Ulsan (South Korea) from 40.9 to 42 million tons/year, in Yeosu (South Korea) from 34.0 to 38.8 million tons/year.
2. Commissioning of a plant in Onsan (South Korea) with a capacity of 33.4 million tons per year, which moved the first stage of the refinery in Jamnagar from 4th place.
3. Power reduction by large factories ExxonMobil Refining&Supply from 84 to 82.8 million tons/year.
These facts once again emphasize the tendency of territorial shift of capacities in the oil refining industry towards the Asia-Pacific Region and the Middle East.
Table 7
The largest refineries in the world in 2012.
|
Company |
Location |
Performance for crude oil |
|
|
mln t/year |
thousand barrels/day |
||
|
Paraguana Refining Center |
Cardon/Judibana, Falcon State, Venezuela |
||
|
Ulsan, South Korea |
|||
|
Yeosu, South Korea |
|||
|
Onsan, South Korea |
|||
|
Reliance Industries |
Jamnagar, India |
||
|
ExxonMobil Refining & Supply |
Jurong/Pulau Ayer Chawan, Singapore |
||
|
Reliance Industries |
Jamnagar, India |
||
|
ExxonMobil Refining & Supply |
Baytown, Texas, USA |
||
|
Saudi Arabian Oil Co (Saudi Aramco) |
Ras Tanura, Saudi Arabia |
||
|
Formosa Petrochemical |
Mailiao, Taiwan |
||
|
Marathon Petroleum |
Gariville, Louisiana, USA |
||
|
ExxonMobil Refining & Supply |
Baton Rouge, Louisiana, USA |
||
|
Santa Cruz, Virgin Islands |
|||
|
Kuwait National Petroleum |
Mena Al Ahmadi, Kuwait |
Russia, one of the world leaders in oil production, has serious capacities for the production of refined products of "black gold". The plants produce fuel, oil and petrochemical products, while the total annual production of gasoline, diesel fuel and heating oil reaches tens of millions of tons.
The scale of Russian oil refining
Currently, 32 large oil refineries and 80 more mini-enterprises are also operating in this industry in Russia. The total capacity of the country's refineries provides the possibility of processing 270 million tons of raw materials. We present to your attention the top 10 oil refineries in terms of installed production capacity. The enterprises included in the list belong to both state and private oil companies.
1. Gazpromneft-ONPZ (20.89 million tons)
The Gazpromneft-ONPZ enterprise is better known as the Omsk Oil Refinery. The plant is owned by Gazprom Neft (Gazprom's structure). The decision to build the enterprise was made in 1949, the plant was launched in 1955. The installed capacity reaches 20.89 million tons, the depth of processing (the ratio of the volume of raw materials to the number of products produced) is 91.5%. In 2016, the Omsk Refinery processed 20.5 million tons of oil. Pronedra wrote earlier that the actual processing at the refinery in 2016 decreased compared to the level of 2015.
Last year, 4.7 million tons of gasoline and 6.5 million tons of diesel fuel were produced. In addition to fuel, the plant produces bitumen, coke, acids, tar and other products. Over the past few years, due to the modernization of facilities, the enterprise has reduced the amount of emissions into the atmosphere by 36%, by 2020 it is planned to reduce the degree of harmful impact on environment another 28%. In total, over the past 20 years, the amount of emissions has decreased five times.
2. Kirishinefteorgsintez (20.1 million tons)
The Kirishi Oil Refinery (Kirishinefteorgsintez, an enterprise of Surgutneftegaz) with a capacity of 20.1 million tons is located in the city of Kirishi, Leningrad Region. Commissioning took place in 1966. In fact, on average, it processes more than 17 million tons of oil with a depth of 54.8%. In addition to fuels and lubricants, it produces ammonia, bitumen, solvents, gases, xylenes. According to the company, in recent years, according to the results of the analysis of 2.4 thousand samples, no excesses of the standards for emissions of harmful substances into the atmospheric air have been identified. No environmental violations were found within the control points of the sanitary protection zone of the complex.
3. Ryazan Oil Refining Company (18.8 million tons)
The largest refinery of Rosneft with a capacity of 18.8 million tons - the Ryazan Oil Refining Company (until 2002 - the Ryazan Oil Refinery) - produces gasoline, diesel fuel, jet fuel, boiler fuel, bitumen for the construction and road industries. The company started operating in 1960. Last year, the plant processed 16.2 million tons of raw materials with a depth of 68.6%, while producing 15.66 million tons of products, including 3.42 million tons of gasoline, 3.75 million tons of diesel fuel and 4.92 million tons fuel oil. In 2014, an environmental research center began operating at the enterprise. There are also five environmental laboratories. Harmful emissions have been measured since 1961.
4. Lukoil-Nizhegorodnefteorgsintez (17 million tons)
One of the leaders in domestic oil refining, the Lukoil-Nizhegorodnefteorgsintez enterprise (owner - Lukoil), is located in the city of Kstovo, Nizhny Novgorod Region. The enterprise, whose capacity currently reaches 17 million tons, was opened in 1958 and received the name Novogorkovsky Oil Refinery.
The refinery produces about 70 types of products, including gasoline and diesel fuel, aviation fuel, paraffins and oil bitumen. Lukoil-Nizhegorodnefteorgsintez is the only company in Russia that produces hard-type edible paraffins. The processing depth reaches 75%. The plant has an ecological laboratory, which includes two mobile complexes. As part of the "Clean Air" program, the plant's tanks are equipped with pontoons to reduce the amount of hydrocarbon emissions into the atmosphere by dozens of times. Over the past ten years, the average indicators of environmental pollution have decreased by a factor of three.
5. Lukoil-Volgogradneftepererabotka (15.7 million tons)
The Volgograd (Stalingrad) refinery, launched in 1957, became part of the Lukoil company in 1991 and received a new name - Lukoil-Volgogradneftepererabotka. The plant's capacity is 15.7 million tons, the actual capacity is 12.6 million tons with a processing depth of 93%. Now the company produces about seven dozen types of refined products, including motor gasoline, diesel fuel, liquefied gases, bitumen, oils, cokes and gas oils. According to Lukoil, thanks to the implementation of the environmental safety program, gross emissions were reduced by 44%.
6. Slavneft-Yaroslavnefteorgsintez (15 million tons)
The Novo-Yaroslavl Oil Refinery (currently Slavneft-YANOS, jointly owned by Gazprom and Slavneft) began operating in 1961. The current installed capacity of the plant is 15 million tons of raw materials, the processing depth is 66%. The enterprise is engaged in the production of motor gasolines, diesel fuel, fuel used in jet engines, a wide range of oils, bitumen, waxes, paraffins, aromatic hydrocarbons, fuel oil and liquefied gases. Over the past 11 years, Slavneft-Yaroslavnefteorgsintez has significantly improved the quality of its industrial effluents. The amount of waste accumulated before has decreased by 3.5 times, and the volume of polluting emissions into the atmosphere - by 1.4 times.
7. Lukoil-Permnefteorgsintez (13.1 million tons)
In 1958, the Perm Oil Refinery was put into operation. Later, it received such names as the Perm Oil Refinery, Permnefteorgsintez, and as a result, after becoming the property of Lukoil, it was renamed Lukoil-Permnefteorgsintez. The capacity of the enterprise with a depth of processing of raw materials of 88% reaches 13.1 million tons. Lukoil-Permnefteorgsintez produces a wide range of products, including dozens of items - gasoline, diesel fuel, fuel for jet power plants, gas oils, toluene, benzene, liquefied hydrocarbon gases, sulfur, acids and petroleum cokes.
According to the assurances of the plant's management, the enterprise is actively implementing measures that make it possible to exclude emissions of polluting components into the environment in excess of the regulatory limits. All types of oily waste are disposed of using special modern equipment. Last year, the plant won the competition "Leader of Environmental Protection in Russia".
8. Gazprom Neft - Moscow Refinery (12.15 million tons)
The Moscow Oil Refinery (owned by Gazprom Neft), which currently meets 34% of the needs of the Russian capital in oil products, was built in 1938. The plant's capacity reaches 12.15 million tons with a processing depth of 75%. The plant is mainly engaged in the fuel segment - it produces motor fuel, but additionally produces bitumen. Liquefied gases for domestic and communal needs, fuel oil are also produced. According to Gazpromneft-Moscow Refinery, the company's environmental management system complies with international standards.
However, since 2014, the plant has repeatedly been in the spotlight due to hydrogen sulfide emissions into the atmospheric air of Moscow. Although, according to the Ministry of Emergency Situations, the mentioned oil refinery really turned out to be the source of pollution, the corresponding official charges were not brought, and another three dozen industrial facilities located in the city fell under suspicion. In 2017, representatives of the Moscow Refinery reported that there were no excesses in pollutant emissions on the territory of the enterprise. Recall that the Moscow mayor's office announced the launch of a monitoring system for plant emissions.
9. RN-Tuapse Refinery (12 million tons)
The RN-Tuapse Refinery is the oldest oil refinery in Russia. It was built in 1929. The uniqueness of the enterprise also lies in the fact that it is the only refinery in the country located on Black Sea coast. The owner of the RN-Tuapse Refinery is Rosneft Corporation. The plant's capacity is 12 million tons (in fact, 8.6 million tons of raw materials are processed per year), the processing depth is up to 54%. The main range of manufactured products is gasoline, including process gasoline, diesel fuel, kerosene for lighting purposes, fuel oil and liquefied gas. According to the administration of the plant, the refinery managed to halve the amount of polluting emissions into the atmosphere in a short time. Also, the quality of effluents has been brought to the level of fishery reservoirs of the first category.
10. Angarsk Petrochemical Company (10.2 million tons)
In Angarsk, Irkutsk Region, the production facilities of the Angarsk Petrochemical Company, which specializes in oil refining, are located. The complex includes an oil refinery, chemical units, as well as a plant for the production of oils. Installed capacity - 10.2 million tons, processing depth - 73.8%. The complex was launched in 1945 as an enterprise for the production of liquid coal fuel, and in 1953 the first petrochemical facilities were put into operation. Now the company produces gasoline, diesel fuel, kerosene for aircraft, alcohols, fuel oil, sulfuric acid, oils. As part of the implementation of environmental safety measures, closed flares have been installed to neutralize waste gases, and a recycling water supply system is being built.
Leaders in oil refining: top regions and companies
If we talk about the Russian oil refining industry as a whole, then it is characterized by a large (up to 90%) degree of consolidation. The plants mainly operate as part of vertically integrated companies.
Most of the existing oil refineries in Russia were built back in the Soviet period. The distribution of oil refineries by region was carried out according to two principles - proximity to deposits of raw materials and in accordance with the need to supply fuels and lubricants and petrochemical products to specific regions of the RSFSR, or to neighboring republics of the USSR. These factors predetermined the picture of the location of oil refining capacities on the territory of the modern Russian state.
The current stage of development of the domestic processing of "black gold" is characterized not only by an increase in capacity, but also by a total modernization of production. The latter makes it possible Russian companies how to improve the quality of products to the level of the most stringent international standards and increase the depth of processing of raw materials, as well as minimize the negative impact on the environment.
Rosneft Oil Company is No. 1 in Russia in terms of oil refining capacity and volumes.
The Company's activities in the field of oil refining in recent years have been aimed at meeting the market demand for high-quality petroleum products.
For a number of years, Rosneft has been consistently implementing a program to modernize its refineries, which has made it possible to expand the range, improve the quality of products and increase their competitiveness. This is the largest in the Russian oil industry the program of modernization of oil refining capacities. In the course of the implementation of this program, from the end of 2015, a transition to 100% production of motor fuels environmental class K5 for domestic market RF, in accordance with the requirements technical regulation TR CU 013/2011. Since 2018, a number of the Company's refineries have organized the production of motor gasolines with improved environmental and performance properties AI-95-K5 "Euro-6", as well as AI-100-K5.
As part of the Company's Oil Refining Unit on the territory Russian Federation 13 large oil refineries operate: Komsomolsk Oil Refinery, Angarsk Petrochemical Company, Achinsk Oil Refinery, Tuapse Oil Refinery, Kuibyshev Oil Refinery, Novokuibyshevsky Oil Refinery, Syzransky Oil Refinery, Saratov Oil Refinery, Ryazan Oil Refinery Company, oil refinery complex of PJSC ANK Bash-Neft (Bashneft-Novoil) , Bashneft-Ufaneftekhim, Bashneft-UNPZ), Yaroslavl Oil Refinery.
The total design capacity of the Company's main oil refineries in Russia is 118.4 million tons of oil per year. Rosneft also includes several mini-refineries, the largest of which is the Nizhne-Vartovsk oil refinery.
The share of PJSC NK Rosneft in oil refining in Russia is more than 35%. The volume of oil refining at the Russian refineries of the Company in 2018 amounted to more than 103 million tons, demonstrating an increase of 2.8% compared to 2017. The yield of light and refining depth is 58.1% and 75.1%, respectively, and the production of motor gasolines and diesel fuel of ecological class K5 in 2018 increased by 2%.
The volume of refining at the Company's mini-refineries in the Russian Federation in 2018 amounted to 2 million tons.
PJSC NK Rosneft also owns shares in a number of refining assets abroad - in Germany, Belarus and India.
In Germany, the Company owns shares (from 24 to 54%) in three highly efficient refineries - MiRO, Bayernoil and PCK, and in Belarus indirectly owns 21% of the shares of OAO Mozyr Oil Refinery. The Company also owns a 49% stake in one of the largest high-tech refineries in India, Vadinar, which has a primary oil refining capacity of 20 million tons per year.
According to the results of 2018, the volume of oil refining at German refineries amounted to 11.5 million tons. The volume of crude oil refining by JSC Mozyr Oil Refinery in the share of PJSC NK Rosneft in 2018 amounted to 2.1 million tons.
An industrial enterprise whose main function is the processing of oil into gasoline, aviation kerosene, fuel oil, etc.
Refinery is an industrial enterprise, the main function of which is the processing of oil into gasoline, aviation kerosene, fuel oil, diesel fuel, lubricating oils, lubricants, bitumen, petroleum coke, raw materials for petrochemicals.
The production cycle of a refinery usually consists of preparation of raw materials, primary distillation of oil and secondary processing of oil fractions: catalytic cracking, catalytic reforming, coking, visbreaking, hydrocracking, hydrotreating and mixing components of finished petroleum products.
Refineries are characterized by the following indicators:
Oil refining option: fuel, fuel-oil and fuel-petrochemical.
Processing volume (in million tons).
Depth of refining (yield of oil products in terms of oil, in % by weight minus fuel oil and gas).
Today, refineries are becoming more versatile.
For example, the presence of catalytic cracking at refineries makes it possible to establish the production of polypropylene from propylene, which is obtained in significant quantities during cracking as a by-product.
In the Russian oil refining industry, there are 3 profiles of refineries, depending on the oil refining scheme:
- fuel,
- fuel oil,
- fuel and petrochemical.
First, oil is dehydrated and desalted in special installations to separate salts and other impurities that cause equipment corrosion, slow down cracking and reduce the quality of refined products.
No more than 3-4 mg / l of salts and about 0.1% of water remain in the oil.
Then the oil goes to the primary distillation.
Primary processing - distillation
Liquid hydrocarbons of oil have different temperature boiling. Distillation is based on this property.
When heated in a distillation column to 350 °C, various fractions are separated from the oil sequentially with an increase in temperature.
Oil at the first refineries was distilled into the following fractions:
- straight-run gasoline (it boils away in the temperature range of 28-180 ° C),
- jet fuel (180-240 °C),
- diesel fuel (240-350 °С).
The remainder of the oil distillation was fuel oil.
Until the end of the 19th century, it was thrown away as waste products.
For the distillation of oil, 5 distillation columns are usually used, in which various oil products are sequentially separated.
The output of gasoline during the primary distillation of oil is insignificant, therefore, its secondary processing is carried out to obtain a larger volume of automotive fuel.
Recycling - cracking
Secondary oil refining is carried out by thermal or chemical catalytic splitting of products of primary oil distillation to obtain a larger amount of gasoline fractions, as well as raw materials for the subsequent production of aromatic hydrocarbons - benzene, toluene and others.
One of the most common technologies of this cycle is cracking.
In 1891, engineers V. G. Shukhov and S. P. Gavrilov proposed the world’s first industrial installation for the continuous implementation of a thermal cracking process: a continuous tubular reactor, where forced circulation of fuel oil or other heavy oil feedstock is carried out through pipes, and in the annular space is supplied with heated flue gases.
The yield of light components during the cracking process, from which gasoline, kerosene, diesel fuel can then be prepared, ranges from 40-45 to 55-60%.
The cracking process makes it possible to produce components from fuel oil for the production of lubricating oils.
Catalytic cracking was discovered in the 1930s.
The catalyst selects from the feedstock and sorbs on itself, first of all, those molecules that are able to dehydrogenate quite easily (give off hydrogen).
The resulting unsaturated hydrocarbons, having an increased adsorption capacity, come into contact with the active centers of the catalyst.
Polymerization of hydrocarbons occurs, resins and coke appear.
The released hydrogen takes an active part in the reactions of hydrocracking, isomerization, etc.
The cracked product is enriched with light high-quality hydrocarbons and as a result a wide gasoline fraction and diesel fuel fractions related to light oil products are obtained.
As a result, hydrocarbon gases (20%), gasoline fraction (50%), diesel fraction (20%), heavy gas oil and coke are obtained.
Hydrotreating
Hydrotreating is carried out on hydrogenating catalysts using aluminum, cobalt and molybdenum compounds. One of the most important processes in oil refining.
The task of the process is the purification of gasoline, kerosene and diesel fractions, as well as vacuum gas oil from sulfur, nitrogen-containing, tar compounds and oxygen. Hydrotreating plants can be supplied with secondary distillates from cracking or coking plants, in which case the olefin hydrogenation process also takes place. The capacity of the installations existing in the Russian Federation ranges from 600 to 3000 thousand tons per year. The hydrogen required for hydrotreatment reactions comes from catalytic reformers or is produced in special units.
The raw material is mixed with hydrogen-containing gas with a concentration of 85-95% by volume, coming from circulating compressors that maintain pressure in the system. The resulting mixture is heated in a furnace to 280-340 °C, depending on the raw material, then enters the reactor. The reaction takes place on catalysts containing nickel, cobalt or molybdenum under pressure up to 50 atm. Under such conditions, the destruction of sulfur and nitrogen-containing compounds with the formation of hydrogen sulfide and ammonia, as well as the saturation of olefins. In the process, due to thermal decomposition, an insignificant (1.5-2%) amount of low-octane gasoline is formed, and 6-8% of the diesel fraction is also formed during the hydrotreatment of vacuum gas oil. In the purified diesel fraction, the sulfur content can decrease from 1.0% to 0.005% and below. Process gases are cleaned to extract hydrogen sulfide, which is fed to the production of elemental sulfur or sulfuric acid.
Claus Process (Oxidative Conversion of Hydrogen Sulfide to Elemental Sulfur)
The Claus plant is actively used at oil refineries for the processing of hydrogen sulfide from hydrogenation plants and amine gas treatment plants to produce sulfur.
Formation finished products
Gasoline, kerosene, diesel fuel and industrial oils are divided into different grades depending on the chemical composition.
The final stage of refinery production is the mixing of the obtained components to obtain finished products of the required composition.
This process is also called compounding or blending.
The largest oil refineries in Russia
1. Gazpromneft-ONPZ (20.89 million tons)
2. Kirishinefteorgsintez (20.1 million tons)
3. Ryazan oil refinery (18.8 million tons)
4. Lukoil-Nizhegorodnefteorgsintez (17 million tons)
5. Lukoil-Volgogradneftepererabotka (15.7 million tons)
6. Slavneft-Yaroslavnefteorgsintez (15 million tons)
7. TANECO (14 million tons)
8. Lukoil-Permnefteorgsintez (13.1 million tons)
9. Gazprom Neft - Moscow Refinery (12.15 million tons)
10. RN-Tuapse Refinery (12 million tons)
Large independent refineries in Russia
1. Antipinsky Oil Refinery (9.04 million tons)
2. Afipsky refinery (6 million tons)
3. Yaya Oil Refinery (3 million tons)
4. Mari Refinery (1.4 million tons)
5. Kochenevsky refinery (1 million tons)