PJSC Ukrtatnafta today s agenda in the light of 50 years of history 2016 Deputy Chairman of the Board for Production and Capital Construction Sergey Koshelyuk
Kremenchug Refinery is the only operating refinery in Ukraine with a full process cycle Capacity of crude distillation units constitutes 10.5 mln. tons/year. The refinery has totally 37 process units Product quality is compliant with the strictest requirements of the National Standards harmonized with European Standards Favorable geographical location optimal feedstock supply and product sale logistics Flexibility of the technological process - daily crude processing volume can vary from 4.5 thou. tons to 30 thou. tons High level of development of information systems for plant management Staff of high qualification is the basis of the company s steady development
Share of PJSC Ukrtatnafta in the Ukrainian Market Gasoline Ukrtatnafta 29% Ukrgasdobycha 8% Import 63% Diesel Fuel Ukrgasdobycha Ukrtatnafta 2% 10% Import 88%
PJSC Ukrtatnafta has a comprehensive quality management system implemented and functioning successfully DSTU ISO 9001:2009 Quality Management System Quality Guarantee DSTU ISO 14001:2006 Environmental Management System DSTU ISO 18001:2010 Occupational Health and Safety Management System
Automated Production Control System REFINERY CONTROL SAP R/3 I-LDS laboratory testing system PRODUCTION CONTROL PI System - information system SCADA CAPCS PROCESS CONTROL Manual data input
50 Years of Refinery s Steady Development Historical Perspective 1966-1969 Commissioning of the First Phase of the Refinery (Units AVT-12/5, L-35-11/300, Bitumen Plant 19/6, Gas Plant) 1970-1978 Commissioning of the Second Phase Facilities (units GK-3/1 1, LCh-35-11/600, LCh-24-7/68) Commissioning of the Third Phase the capacity reaches 18.6 million tons of crude oil per annum (units GK-3/1 2, LG-35-8/300B, LK-6u) Commissioning of the Lube Plant Fuels and Lubes Production Pattern (units G-36-37/1, G-37, G-39-40, G-24) Finished product slate exceeds 60 types 1997-2005 A complex of environment protection facilities - Gas Sweetening Unit, Sulfur Recovery Unit, Flare Gas Recovery Unit - Waste water biological and thermal treatment units - Sour Water Stripper сsince 2006 года The only refinery that has a closed-loop water supply system without dumping waste water into natural reservoirs Launch of the First Phase of Modernization Motor Gasoline and Diesel Fuel Quality Improvement to meet Euro-4 and Euro-5 quality requirements
Mln. t/year 20.0 Growth Crisis Refinery Life Cycle STABILITY Stability Crisis 18.0 16.0 14.0 12.0 Modernization program implementation requirement!!! 10.0 8.0 6.0 4.0 Third Phase Commissioning Second Phase Commissioning 2.0 First Phase Commissioning Switch to Euro 4 Switch to Euro 5 from 01.01.2018 0.0 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020
Development Problems Fuel quality before modernization When switching to Euro 4 Standard requirements Solutions Gasoline: Sulfur content up to 1000 ppm < 50 Gasoline sulfur content reduction to 50 ppm (catalyst systems change at L-35-11/600, L-35-11/300 Units). VGO sulfur content reduction to 2000 ppm (catalyst system change at Section 300-1 of LK-6y Unit). Aromatics content up to 53 vol. % < 35 Benzene content up to 3.0 vol. % < 1,0 Diesel fuel: Sulfur content up to 2000 ppm < 50 FCC gasoline sulfur content reduction (Prime G process implementation at Section 200 of LK-6u Unit). Gasoline benzene content reduction to 1 vol. % (benzene concentrate recovery scheme implementation at Sections 200 and 400 of LK-6u Unit). Hydrogen purification process (Pressure Swing Adsorption Plant construction). Diesel fuel sulfur content reduction to 50 ppm (upgrading and catalyst system change at LCh-24-7/68 Unit).
Development Problems When switching to Euro 5 (from 01.01.2018) Fuel quality before modernization Standard requirements Solutions Isomerization unit construction Gasoline: Sulfur content up to 50 ppm < 10 Upgrading VGO Hydrotreatment Section 300-1 of LK-6u Unit (reactor replacement). Refurbishing Section 300-2 of LK-6u Unit for diesel fuel hydrotreatment Diesel fuel: Sulfur content up to 50 ppm < 10 Upgrading G-36-37/1 Unit for vacuum tower resid deasphalting Refurbishing G-24 Unit for kerosene and deasphalted oil hydrotreatment
Main Projects of Modernization and Revamp of Existing Process Units in 2009-2016
Modernization of Catalytic Reformers LCh-35-11/600 and L-35-11/300 using UOP catalysts Reformate octane number, МON/RON Reformate sulfur content, mg/kg BEFORE MODERNIZATION AFTER MODERNIZATION BEFORE PROJECT AFTER PROJECT
Revamp of Section 300-1 of LK-6u Unit For FCC feed hydrotreatment using Shell Global Solutions/Criterion catalyst FCC feed sulfur content, mg/kg FCC gasoline sulfur content, mg/kg BEFORE REVAMP AFTER REVAMP BEFORE REVAMP AFTER REVAMP
Revamp of Pretreatment Unit of Section 200 of LK-6u Unit for FCC gasoline selective hydrotreatment using PRIME G technology by AXENS Stable reformate fractionation with recovery of benzene concentrate Стоимо сть реконст рукции $ 1 080 тыс. FCC gasoline sulfur content, mg/kg Stable reformate benzene content, vol. % BEFORE HYDROTREATMENT AFTER HYDROTREATMENT BEFORE PROJECT AFTER PROJECT
Revamp of LCh-24-7/68 Diesel Fuel Hydrotreatment Unit switching to Shell Global Solutions/Criterion catalysts for deep hydrodesulfurization and hydrodewaxing С т о и м о с т ь р е к о н с т р у к ц и и $ 4 4 3 0 т ы с. Hydrotreated diesel fuel sulfur content, mg/kg Cold filter plugging point, С AFTER PROJECT BEFORE PROJECT BEFORE PROJECT AFTER PROJECT
Construction of New Pumping Station for Fuel Blending with Additives Injection Package New-generation equipment made it possible to: Improve and stabilize the quality of production of finished gasoline and diesel fuel; Reduce harmful environmental emissions; Ensure accurate control of flow rates and component injection rates; Directly measure weights of added components.
Construction of PSA Plant at Gas Sweetening Unit with the purpose to increase hydrogen concentration in hydrogen-bearing gas for hydrogenation processes 100 Н2 concentration in HBG, vol. % 86 95 С т о и м о с т ь р е к о н с т р у к ц и и $ 4 4 3 0 т ы с. 80 60 40 20 0 BEFORE PROJECT AFTER PROJECT