The largest refineries Russian refineries: main plants and enterprises of the 10 largest refineries

Main refinery enterprises in Russia, operating today, were built in the post-war years, when the consumption of fuel of all grades by transport and industry increased sharply.

When choosing the plant sites, we were guided by the proximity both to the places of production, in order to reduce the cost of transporting oil, and to areas of intensive fuel consumption.

Distribution of capacities across the country

The largest oil refining capacities are concentrated in the Volga Federal District (Samara, Nizhny Novgorod, Orenburg, Perm, Saratov regions, the republics of Tatarstan, Mari El, Bashkortostan) - 122 million tons per year.

Large capacities of Russian refineries operate in Central(Ryazan, Yaroslavl and Moscow regions) and in Siberian(Omsk, Kemerovo, Irkutsk region and Krasnoyarsk region) federal districts. The plants of each of these districts can process more than 40 million tons of oil per year.

refinery Southern Federal District designed to process 28 million tons, Northwestern– 25 million tons, Far East– 12 million tons, Ural- 7 million tons. The total capacity of refineries in Russia is 296 million tons of oil per year.

The largest refineries in Russia are the Omsk Refinery (21 million tons), KirishiNOS (20 million tons, Leningrad region), RNA (19 million tons, Ryazan Oblast), Lukoil-NORSI (17 million tons, Nizhny Novgorod region), Volgograd Refinery(16 million tons), YaroslavNOS (15 million tons).

Virtually any questions about oil refining today can be answered from the mass media. Any information about refineries is available on the Internet, how many refineries there are in Russia, where they produce gasoline, diesel fuel, what else they produce, at which plants they produce especially high-quality products. If desired, it is easy to find.

Depth of oil refining

An important indicator of the oil refining industry, along with the volume of production, is the depth of oil refining, which refineries in Russia have reached. Today it is 74%, while in Europe this figure is 85%, and in the US - 96%.

The depth of refining is estimated as a quotient of the mass of produced products minus fuel oil and gas divided by the mass of oil received for processing.

The low yield of the main oil products is due to the absence of high modern technologies. Some of them were laid down in the pre-war and post-war years, the processing processes used on them are outdated, and the permanent crises since the beginning of the 90s have not given a chance for the modernization of production. Today, investments are gradually increasing, new shops and processing complexes are appearing, the quality and yield of petroleum products is growing.

From oil obtained by direct processing:

More complex refining processes make it possible to obtain substances, materials and products from oil, the list of which takes up many pages. The higher the degree of oil refining, the less it is required, and the lower the cost of production.

If you liked our article and we were somehow able to answer your questions, we will be very grateful for good review about our site!

LUKOIL includes four refineries in Russia (in Perm, Volgograd, Nizhny Novgorod and Ukhta), three refineries in Europe (Italy, Romania, Bulgaria), and LUKOIL also owns a 45% stake in refineries in the Netherlands. The refinery's total capacity is 84.6 mmt, which is practically the same as the Company's oil production in 2018.

The Company's refineries have modern conversion and refining facilities and produce a wide range of high-quality petroleum products. Russian plants in terms of technological level of capacity and efficiency indicators exceed the average Russian level, and the European plants of the Company are not inferior to competitors and are located close to key markets sales.

Oil refining at own refineries in 2018

Modernization

The company completed a large-scale investment cycle in 2016 with the commissioning of the largest vacuum gas oil deep processing complex in Russia at the Volgograd Refinery.

The implementation of the program made it possible to increase the environmental class of produced motor fuels to Euro-5, as well as to significantly increase the share of high value-added petroleum products in the produced basket.

Russian refineries

Commissioning of new processing units in 2015–2016, optimization of secondary process loading and expansion of the raw material mix allowed to significantly improve the product mix and reduce the share of fuel oil and vacuum gas oil in favor of increasing the share of light oil products.

OIL REFINING AT REFINERS IN RUSSIA IN 2018

In 2018, work continued to increase the depth of processing through the use of alternative raw materials and additional loading of secondary processes, including through deepening inter-factory integration.

Volgograd Refinery

Located in the southern region of Russia

Processes a mixture of light West Siberian and Lower Volga oils

Oil is supplied to the refinery via the Samara-Tikhoretsk oil pipeline

Finished products are shipped by rail, river and by car

The main conversion processes are coking units (2 units with a capacity of 24.0 thousand barrels per day), hydrocracking units (with a capacity of 67.0 thousand barrels per day)

* Excluding unused capacities (1.2 million tons since 2015).

Factory history

The plant was commissioned in 1957 and became part of LUKOIL in 1991. In the early 2000s a gasoline blending station and an oil discharge rack, diesel fuel hydrotreating units, straight-run gasoline stabilization and gas fractionation of saturated hydrocarbon gases were put into operation.

In 2004-2010 the first stage of the coke calcination unit, the isomerization unit, and the catalytic reforming unit were put into operation. The vacuum block of the AVT-6 unit was reconstructed and put into operation. The production of diesel fuel under the EKTO brand has begun.

In 2010-2014 modernization of diesel fuel hydrotreatment was completed, a hydrogen concentration unit, a delayed coking unit, a diesel fuel hydrotreatment unit, and the second line of the coke calcination unit were put into operation.

In 2015, the ELOU-AVT-1 primary oil refining unit was put into operation, which makes it possible to increase the refining efficiency and increase the oil refining capacity to 15.7 million tons per year.

In 2016, a complex for deep processing of vacuum gas oil was put into operation. The capacity of Russia's largest Vacuum Gas Oil Deep Processing Complex is 3.5 million tons per year. It was built in record time - 3 years. The complex also included installations for the production of hydrogen and sulfur, industrial facilities.

In 2017, the hydrocracking unit, built in 2016, was successfully brought to the design mode. This made it possible to significantly improve the refinery's oil product basket by replacing vacuum gas oil with high value-added products, primarily Euro-5 class diesel fuel.

In 2018, the Volgograd Refinery developed a technology for the production of low-sulfur dark marine fuel that meets the promising requirements of MARPOL.

Perm refinery

• Oil refinery of fuel and oil and petrochemical profile

  Located 9 km from the city of Perm

  Processes a mixture of oils from fields in the north of the Perm region and Western Siberia

  Oil is supplied to the refinery via the Surgut-Polotsk and Kholmogory-Klin oil pipelines

  Finished products are shipped by rail, road and river transport, as well as via the Perm-Andreevka-Ufa oil product pipeline

  The main conversion processes are T-Star hydrocracking units (65.2 thousand barrels per day), catalytic cracking (9.3 thousand barrels per day), coking units (56.0 thousand barrels per day)

Factory history

The plant was put into operation in 1958, and in 1991 it became part of LUKOIL. In the 1990s the plant implemented a program for the reconstruction of the coking unit, built a unit for vacuum distillation of fuel oil, created the production of oils, put into operation a unit for the utilization of hydrogen sulfide and the production of sulfuric acid.

In the 2000s a complex for deep oil refining, an isomerization unit were commissioned, the AVT units were reconstructed and the atmospheric unit of the AVT-4 unit was upgraded. In 2008, the refinery's capacity was increased to 12.6 million tons per year.

In 2011-2014 the capacity of the delayed coking unit was increased to 1 million tons per year, the diesel fuel hydrotreatment unit was modernized, and the technical re-equipment of the vacuum unit of the AVT-4 unit was completed.

In 2015, the Oil Residue Processing Complex was put into operation, which made it possible to switch to an oil-free scheme and increase the yield of light oil products, and the construction of a power unit with an installed capacity of 200 MW was also completed. In 2016, the reconstruction of the Diesel Fuel Hydrodearomatization Unit of the Hydrocracking Unit was completed.

In 2017, a fuel oil discharge rack with a capacity of up to 1 million tons per year was put into operation. The overpass increased inter-factory integration and made it possible to provide the oil residue processing complex and the bitumen production unit of the Perm Refinery with heavy oil feedstock from the Nizhny Novgorod Refinery.

In 2018, the Perm Refinery commissioned an infrastructure for receiving fuel oil, which made it possible to increase the load on delayed coker units and improve inter-factory optimization within the Group.

Nizhny Novgorod Refinery

Oil refinery fuel and oil profile

Located in Kstovo, Nizhny Novgorod Region

Processes a mixture of oils from Western Siberia and Tatarstan

Oil is supplied to the refinery via the Almetyevsk-Nizhny Novgorod and Surgut-Polotsk oil pipelines

Finished products are shipped by rail, road and river transport, as well as by pipeline

The main conversion processes are a catalytic cracking unit (80.0 thousand barrels per day), a visbreaking unit (42.2 thousand barrels per day)

Factory history

The plant was commissioned in 1958 and became part of LUKOIL in 2001.

In the 2000s AVT-5 units and oil hydrotreating units were reconstructed. A catalytic reforming unit and a gasoline isomerization unit were put into operation, and the AVT-6 atmospheric unit was upgraded. The hydrotreating unit was reconstructed, which made it possible to start producing diesel fuel according to the Euro-5 standard. In 2008, a tar visbreaking unit with a capacity of 2.4 million tons/year was put into operation, which contributed to an increase in the production of vacuum gas oil and a decrease in the production of heating oil. In 2010, a catalytic cracking complex for vacuum gas oil was put into operation, thanks to which the production of high-octane gasoline and diesel fuel was increased. The diesel fuel hydrotreating unit was reconstructed.

In 2011-2014 a hydrofluoric alkylation unit was put into operation, the reconstruction of AVT-5 was completed. In 2015, Catalytic Cracking Complex 2 and Vacuum Unit VT-2 were put into operation. In 2016, the commodity basket was expanded.

In 2017, the production of EKTO 100 premium gasoline with improved performance properties began. Also adopted the final investment decision on the construction of a delayed coking complex with a capacity of 2.1 million tons per year in terms of raw materials. The raw material for the complex will be heavy oil refining residues, and the main types of products will be diesel fuel, straight-run gasoline and gas fractions, as well as dark oil products - vacuum gas oil and coke. The construction of the complex and related optimization measures will increase the yield of light oil products at the Nizhny Novgorod Refinery by more than 10%. The increase in recycling capacity, along with optimization of the plant's load, will significantly reduce the output of fuel oil.

In 2018, the Nizhny Novgorod Refinery began construction of a delayed coking complex, signed EPC contracts with contractors, and began preparing the pile field and foundations for the complex’s units. The increase in recycling capacity, along with optimization of the plant's load, will reduce the production of fuel oil by 2.7 million tons per year.

Ukhta refinery

Located in the central part of the Komi Republic

Processes a mixture of oils from the fields of the Komi Republic

Oil is supplied to the refinery via the Usa-Ukhta oil pipeline

Main conversion processes - visbreaking unit (14.1 thousand barrels per day)

* Excluding unused capacity (2.0 mmt).

Factory history

The plant was commissioned in 1934 and became part of LUKOIL in 1999.

In the 2000s, the AT-1 unit was reconstructed, a unit for hydrodewaxing of diesel fuel, an overpass for draining oil and loading dark oil products were put into operation. The first stage of reconstruction of the catalytic reforming complex was completed, which increased the capacity of the process by 35,000 tons per year. A block was commissioned to increase the hydrogen concentration at the hydrodewaxing unit, the second stage of the oil and oil products loading and unloading complex was built, the catalytic reforming unit was re-equipped, and a tar visbreaking unit with a capacity of 800,000 tons per year was launched, which made it possible to increase the production of vacuum gas oil. In 2009, the construction of the isomerization unit was completed.

In 2012, the technical re-equipment of the reactor block of the GDS-850 diesel fuel hydrotreatment unit was completed. In 2013, the AVT plant was put into operation after reconstruction, and the capacity of the vacuum unit was increased to 2 million tons per year. The project for the construction of a gas condensate discharge unit was completed. In 2014-2015 the technical re-equipment of the enterprise continued.

mini refinery

European refineries

OIL REFINING AT EUROPEAN REFINERS IN 2018

Refinery in Ploiesti, Romania

Oil refinery fuel profile

Located in Ploiesti (in the central part of Romania), 55 km from Bucharest

Processes Urals oil (Russian export blend) and oil from Romanian fields

Oil is supplied to the refinery via an oil pipeline from the port of Constanta on the Black Sea. Romanian oil also comes by rail

Finished products are shipped by rail and road

The main conversion processes are the catalytic cracking unit (18.9 thousand barrels per day) and coking unit (12.5 thousand barrels per day)

Factory history

The plant was commissioned in 1904 and became part of LUKOIL in 1999.

In the 2000s the production of AI-98 gasoline and low-sulphur diesel fuel was mastered. In the early 2000s installations for primary oil refining, hydrotreatment, reforming, coking, catalytic cracking, gas fractionation and isomerization were upgraded, catalytic cracking gasoline hydrotreatment units and hydrogen production units were built. In 2004 the plant was put into operation. Later, a unit for the production of MTBE/TAME additives was put into operation, a 25 MW turbine generator was launched, the reconstruction of units for hydrotreatment of diesel fuel, catalytic cracking, hydrotreatment of catalytically cracked gasoline and production of MTBE/TAME, as well as the vacuum unit of the AVT-1 unit, was completed. The construction of a hydrogen production unit was completed, which made it possible to produce fuels of the Euro-5 standard.

In 2010-2014 2 new coking chambers of the delayed coking unit were installed, the production of propylene with a sulfur content of less than 5 ppm was organized, the reconstruction of the amine block was completed, an improved control system was introduced at the AVT-3 unit, which makes it possible to increase the output marketable products. In 2013, projects were completed to increase the degree of recovery of C3+ from dry gas from catalytic cracking, and upgrade treatment facilities. A major overhaul of the enterprise was carried out, a transition to an oil-free production scheme was carried out, the depth of processing and the yield of light oil products were increased.

In 2015, a catalytic cracking flue gas cleaning unit was put into operation.

Oil refinery in Burgas, Bulgaria

Oil refinery of fuel and petrochemical profile


Located on the Black Sea coast, 15 km from Burgas


Processes oil of various grades (including Russian export grades), fuel oil


Oil is supplied to the refinery via a pipeline from the Rosenets oil terminal


Finished products are shipped by rail, sea and road transport, as well as through an oil product pipeline to the central regions of the country


The main conversion processes are a catalytic cracking unit (37.1 thousand barrels per day), a visbreaking unit (26.4 thousand barrels per day) and a tar hydrocracking unit (39.0 thousand barrels per day)

* Excluding unused capacities (2.8 mmt).

An industrial enterprise whose main function is the processing of oil into gasoline, aviation kerosene, fuel oil, etc.

refinery - industrial enterprise, whose main function 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 availability 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 yield of gasoline during the primary distillation of oil is negligible, 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 more 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 hydrotreating reactions comes from catalytic reformers or is produced in special plants.

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 an oven 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 during the hydrotreatment of vacuum gas oil, 6-8% of the diesel fraction is also formed. In the purified diesel fraction, the sulfur content can decrease from 1.0% to 0.005% and below. Process gases are subjected to purification in order to extract hydrogen sulfide, which is supplied 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 of finished products

Gasoline, kerosene, diesel fuel and technical 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)

The locations of the largest oil refineries in the world in 2007 are shown in Fig. 1. Most big power(47 million tons / year) has a refinery in Venezuela (Paraguana Refining Center, Cardon / Judibana, Falcon state), and similar in capacity to it are located in the Asia-Pacific region ( South Korea, Japan), 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)

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 / year, which moved the first stage of the refinery in Jamnagar from 4th place.

3. Reduced capacity at large ExxonMobil Refining&Supply plants 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.