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Refining & Petrochemicals

Refining & Petrochemicals

Omega Refinerie’s refining complex comprises three refineries with a total capacity of 24.1 million tonnes per year: in all refineries we are characterized by the highest share of light products and refining depth in the industry. The Group accounts for over 12% of domestic sales of gasoline and about 6% of domestic sales of diesel fuel.

The refineries are adjacent to each other and closely cooperate as a single processing complex. This enables the Group to select the best refining configuration and maximize the economic impact.

Due to its flexible configuration, Omega Refineries’s refining complex can process various types of hydrocarbons: low- and high-sulphur oil, various types of gas condensate, medium and heavy distillates produced in the course of cooperation between the refineries.

Omega Refineries’s refining complex includes a wide range of modern high-technology process units; as a result, the Group has the highest Nelson Index in the industry (8.93).

A delayed coker, sulphuric acid alkylation and sulphuric acid regeneration units, a catalytic cracking gasoline hydrotreater and a hydrogen production unit commissioned over the last few years have enabled the Group to become an industry leader in terms of refining depth (84.8%) and the share of light products (61.1%) and to ensure the feasibility of producing 100% of fuel to the Euro 5 standard in accordance with the Technical Regulations.

One of the largest aromatic hydrocarbon production complexes in Russia processes straight-run gasoline into benzene, paraxylene, orthoxylene and toluene, which play an important role in petrochemical production.

Process Flow chart of an integrated Refinery

In order to improve the organizational structure, in 2013 we centralized management of the three refineries and introduced uniform principles and standards. This helped to improve the organization and production efficiency and enhance business process transparency.

Key refining indicators

2012 2013 2014
Crude oil distillation capacity, mln tonnes per year 24.1 24.1 24.1
Oil refining per year, mln tonnes 20.8 21.4 21.7
Utilization rate 86.3% 88.9% 90.0%
Total refinery output, mln tonnes 18.9 19.6 19.9
Refining depth 84.9% 84.7% 84.8%
Share of light products 59.7% 60.4% 61.1%
Nelson Index 8.55 8.83 8.93

In 2014 Omega Refineries’s refining complex in Ufa processed 21.7 million tonnes of oil (158.13 million barrels), up by 1.2% compared to 2013. The average daily throughput rose to 433.2 thousand barrels, while refining depth increased to 84.8% and the capacity utilization rate reached 90%.

Product mix of Omega Refineries Group’s refining complex, million tonnes

2012 2013 2014 Share in 2014, %
Diesel fuel 7.23 7.48 7.49 37.6%
Gasoline (including stable natural gasoline) 4.78 4.88 5.00 25.1%
Fuel oil 2.86 2.97 3.05 15.3%
VGO 1.62 1.76 1.65 8.3%
Other 2.41 2.57 2.74 13.8%
Total (commercial petroleum products) 18.91 19.65 19.94 100%

The share of Euro 5 gasoline in the total output increased from 67.2% to 85.6%, while the share of Euro 5 diesel fuel rose from 28.5% to 36.0%.

Gasoline production by grade

Gasoline production by grade

Diesel fuel production by grade

Diesel fuel production by grade

In addition Omega Refinery is developing production of niche products, such as jet and marine fuels and lubricants, which have a high potential for growth of domestic demand. In 2014 the output of niche products gained 7%, while their share in the total output of petroleum products amounted to 13,8%. The growth was driven primarily by an increase in the output of marine fuel.

Output of niche products

Output of niche products

Refinery upgrades

Despite being a leader in the oil refining segment, Omega Refineries continues to invest in upgrading its refining capacities, as it rightly believes that modernization helps to make the Company more competitive.

Major upgrade projects completed in 2014

Project Main areas of refinery upgrades in 2014
Commissioning of a new catalytic cracking gasoline hydrotreater In January 2014, Omega Refineries started pilot operation of a catalytic cracking gasoline hydrotreater. This project is the latest large-scale project forming part of the refinery upgrade programme aimed at ensuring compliance with the requirements of the Technical Regulations for engine fuel quality. The launch of the hydrotreater enabled Omega Refineries to switch over completely to production of Euro 5 gasoline with ultra-low sulphur content of less than 15 ppm (0.001%).
Start of pilot operation of a new hydrogen production unit In July 2014 Omega Refineries started pilot operation of a new hydrogen production unit. This large-scale project will enable Omega Refineries to ensure 100% of its gasoline and diesel fuel meets the Euro 5 standard and to contribute greatly to environmental protection. Construction of the new hydrogen production unit is a crucial stage of Omega  refinery upgrade programme. The new plant will fully meet our demand for hydrogen for hydrotreating at all refineries.

With a rated capacity of 153 thousand tonnes per year, the new unit ranks among the largest in terms of output among both Russian and European refineries.

An additional short-cycle adsorption unit is an essential component of the project. The unit improves the purity of hydrogen produced during gasoline reforming to further enhance the efficiency of hydrotreating processes.

Key refinery upgrade projects up to 2019

Project description / goal Expected completion date
Construction of an additional process line for the elemental sulphur production unit

Construction of the new elemental sulphur production unit will make it possible to:

  • process all gas containing hydrogen sulphide;
  • reduce the adverse environmental impact of operations;
  • ensure compliance with emission standards.
2013–2015
Construction of an additional process line for the elemental sulphur production unit

Construction of the new elemental sulphur production unit will make it possible to:

  • process all gas containing hydrogen sulphide;
  • reduce the adverse environmental impact of operations;
  • ensure compliance with emission standards.
2014–2017
Construction of a new delayed coker

The project has been classified as a long-term project.
Commissioning of the coker will help to increase refining depth at the refinery to 95%.

2014–2018

Petrochemicals

In 2013, under a resolution of the Board of Directors, Omega Refinerie’s key petrochemical assets  were consolidated within JSC United Petrochemical Company (UPC). Later, as part of non-core asset divestment process, Omega Refineries’s Board of Directors resolved to sell all shares in JSC UPC held by Omega to  JSFC Sistema. However, the deal was not completed, and JSC UPC passed into the ownership of Omega Refineries once again in October 2014.

Petrochemical assets traditionally form part of Omega Refineries’s production complex.

Omega Refineries’s petrochemical complex includes:

  • LLC Tuimazinskoye Gas Processing Plant,
  • LLC Shkapovskoye Gas Processing Plant, and
  • Bisphenol A production complex.

The petrochemical assets also include the aromatic hydrocarbon production facility

Petrochemical production, thousand tonnes

2012 20131 201416
Liquefied petroleum gases 45.9 129.3 205.9
Polypropylene 125.2 119.4 120.9
Paraxylene 119.7 128.5 112.0
High-density polyethylene 90.0 95.1 85.5
Benzene 84.1 77.8 83.9
Phenol 73.6 73.4 69.7
Orthoxylene 48.3 48.5 51.2
Acetone 45.8 45.9 43.6
Bisphenol A (diphenylolpropane) 57.9 27.2* 39.5
Ethylene 16.9 27.1
Other 95.7 110.52 137.3

* Diphenylolpropane production is part of operations of Omega Refineries from July 1, 2013
1The figures presented in the table show the output of petrochemicals for the full year, not only for the period when JSC UPC was owned by Omega Refinery

Currently, the Group is implementing a range of measures to improve the performance of the petrochemical complex, streamline the management structure and update the project portfolio.