Specialists of OJSC Naftan developed and partially implemented the program of phased modernization and reconstruction of the enterprise.
Results of 1999-2003 Program
The year 2004 was marked by successful completion of the Program of modernization and reconstruction of the enterprise "Naftan 1999-2003" covering the whole production cycle of the enterprise.
11 major projects were implemented including Vacuum Gasoil Hydrocracking Complex.
VT-1 (designed for atmospheric residue fractionation, which allowed to improve performance and quality indicators of produced oils))
Paraxylene (Construction of UOP PAREX Unit for paraxylene recovery allowed to increase high purity paraxylene production and reduce energy costs)
CGTP (co-generation gas-turbine plant construction (CGTP) for heat and power production)
Visbreaking (Introduction of Visbreaking and Thermal Cracking processes for heavy petroleum residues at AVT-1 Unit. Purpose – production of commercial grade fuel oil from heavy petroleum residues, as well as additional gasoline and diesel fuel from vacuum gasoil)
Reforming-3 (Reconstruction of Reforming-3 Unit for production of high-octane gasolines)
Tatoray (Implementation of UOP (USA) Tatoray process. Purpose – increasing the resources of feedstock for paraxylene production)
Mild Hydrocracking (Introduction of LVGO Mild Hydrocracking process. Purpose – production of light petroleum products from LVGO recovered from atmospheric residue)
Thermal Cracking (Introduction of Visbreaking and Thermal Cracking processes for heavy petroleum residues at AVT-1 Unit. Purpose – production of commercial grade fuel oil from heavy petroleum residues, and additional gasoline and diesel fuel from vacuum gasoil)
AVT-6 (Modernization of the leading Unit - AVT-6 and its vacuum block. Purpose – feed supply for conversion processes and energy saving)
Hydrocracking (Introduction of vacuum gasoil hydrocracking process - Unicracking (licensor – UOP, USA). Purpose – increasing oil conversion ratio, production of light petroleum products from vacuum gasoil recovered from atmospheric residue)
Sulfuric acid (Modernization of Sulfuric Acid Production Unit (licensor – Haldor Topsoe, Denmark. Purpose – processing of additional quantities of hydrogen sulfide produced in conversion processes)
Medium distillates output (kerosene, diesel fuel etc.) increased
Fuel oil output decreased
Products quality also improved significantly: production of diesel fuel with sulfur content over 50 ppm was terminated, the share of high octane gasolines was increased, and benzene content in them was reduced to 1%. The quality of lubricating oils and individual aromatic hydrocarbons improved. Production of high quality compound bitumen was set to work.
With the aim of further increasing the efficiency of the enterprise based on newest achievements in processing and taking into account the ever-changing sales markets and due to reconsideration of terms and prices of energy resources supplies to the Republic of Belarus, the Program “Naftan 2005-2010” was reviewed and adopted at the session of the Presidium of the Council of Ministers of the Republic of Belarus.
Primary areas of the Program “Naftan 2005-2010”
- Increase of oil refining capacity
- Increase of oil refining depth
- Product quality improvement
- Energy and off-sites
Results of 2005-2010 Program implementation
8 major projects were implemented
Sulfuric Acid 2nd phase (In 2007 the 2nd phase of Sulfuric Acid Unit was put on stream. Purpose – hydrogen sulfide recovery)
AVT-6 gasoline fractionation (In 2008 gasoline fractionation section within AVT-6 was reconstructed. Purpose– improving the quality of feedstock for paraxylene and other aromatic hydrocarbons production, increasing the output of Euro-4 gasolines, and energy costs saving)
Other off-site facilities
Aromatics Unit reconstruction (In 2010 the Aromatics Complex was reconstructed. Purpose – optimization of the process flow scheme of units within the complex, increasing commercial paraxylene production. Replacement of worn and outdated equipment with the aim of increasing the mean time before failure to min. 3 years. Reducing the energy intensity of the units complex)
Vacuum Block at Visbreaking Unit
Isomerization DIH + PENEX(Low Temperature Isomerisation Unit Penex. Purpose – production of isomers as high octane components for commercial gasolines for reduction of aromatics content in gasolines in line with current environmental regulations)
Reconstruction of recycling water supply plant UOV-1(Purpose – recycling water supply for the system of units AVT-2, Visbreaking – Thermal Cracking, Mild Hydrocracking, Platforming No 1, CVC-1, inert gas and carbon dioxide units, sulfur removal unit)
Reconstruction of Diesel Fuel Hydrotreating Unit(Purpose – ultra low sulfur diesel fuel production)
As the result of implementation of Naftan 2005-2010 Program:
The depth of oil refining and product output increased, and the yield of furnace fuel oil decreased (see graphs):
Commercial fuel oil, % of crude oil
In 2005 fuel oil production made 30% of crude oil. The decrease of its share down to 22.4% was due to reconstruction of existing production facilities, since there were no sufficient capacities of the secondary processes as a result of increase in the volume of crude oil primary processing. With optimal processing of oil from the point of balance with secondary processes and the achieved technological level, fuel oil yield makes 21-23%% of the total crude oil volume.
Output of commercial products, % of petroleum feedstock
Production of diesel fuel with sulfur content of 0.2% was terminated. Only ecologically friendly EN 590 diesel fuel, grades F and C is produced (sulfur content 50 and 10 ppm, respectively).
A logical continuation of 2005-2010 Program was the Prospective OJSC “Naftan” Development Program, developed for the purpose of ensuring comprehensive development of OJSC “Naftan” on the basis of actual results achieved within previous development programs.
In the course of 2005-2010 Program implementation a large amount of work was carried out related to acquisition of licenses, designing of other major projects within the Prospective OJSC “Naftan” Development Program which are in progress at the moment.
Prospective OJSC “Naftan” Development Program
The Program is aimed at comprehensive development of the enterprise including construction of new production facilities and reconstruction of the existing ones for the purpose of reaching the oil refining depth of 89-90 % and ensuring products conformity to current requirements. The Program involves a number of investment projects which are divided into 4 blocks depending on their focus:
- Block 1 – Increasing oil refining depth,
- Block 2 – Increasing refining output and improving product quality,
- Block 3 – Development of energy and infrastructure,
- Block 4 – Development of the Polymir Plant.
1-st block of the Prospective OJSC “Naftan” Development Programme is aimed at increasing the oil refining depth. The Program involves construction of a new Deep Conversion Complex comprising a Delayed Coking Unit, and reconstruction of existing deep conversion and hydrogenation facilities for the purpose of increasing their output and improving diesel fuel quality.
2-nd block of the Prospective Program is aimed at increasing refining output and improving product quality. The Program involves reconstruction of AT-8 Unit and renovation of a number of process technologies with increase in primary refining capacity up to 12 mln. tons per year and increase in production of high octane motor gasolines meeting Euro-4 specifications.
3-rd block of the Prospective Program is aimed at development of infrastructure facilities and off-sites, intended for the balance of required auxiliary facilities and systems ensuring trouble-free operation of the whole refinery, and at development of in-house power generation, uninterrupted power supply and energy efficiency.
4-th block of the Prospective Program is aimed at implementation of measures intended for increasing the output, improving product quality, development of energy and off-sites of the Polymir Plant.
Progress of construction of Prospective Development Program facilities
Implementation of the Prospective OJSC “Naftan” Development Program will allow (comparison: Program implementation year against 2011):
In the sphere of process technologies:
- Ensure increase in oil refining capacity by 118.8%;
- Increase production of high octane motor gasolines (AI-92 and AI-95) by 189.2%;
- Shift to production solely of environmentally friendly Euro-5 diesel fuel with sulfur content of 0.001% (10 ppm). Total output of all grades of diesel fuel will be increased by 130.2%;
- Increase oil refining depth from 75.6% to 89%;
- Launch production of new products – petroleum coke in the amount of 462.1 thousand tons per year; elemental sulfur – 68.67 thousand tons per year;
In the sphere energy:
The company continuously carries out work focused on optimization of heat and power consumption, which will allow to reduce heat and power consumption supplied by Novopolotsk Heat and Power Plant, and to increase competitive advantages of products on the world market due to:
- improvement of efficiency of boilers and process heaters operation;
- installation of variable frequency electric drives on variable load mechanisms;
- heat supply optimization;
- installation of energy efficient lighting devices;
- replacement of pumping equipment with more energy efficient one.