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REFINERY NEWS ROUNDUP: Runs rise at Russian plants as works finish

Russian refineries processed 23.911 million mt (about 5.6 million b/d) of crude in October, up 12% on the year and 5.1% higher than in September, according to energy ministry data.

The year-on-year increase in throughput was due to run cuts last year, while the monthly increase was due to the gradual end to autumn refinery turnarounds.

The Astrakhan refinery, which had deferred its start-up to October, was gradually restarting over the course of the month. Omsk and Syzran started their maintenance in October, while over the course of the month Ryazan, Taif, Yaisky, Ukhta, Angarsk, Komsomolsk completed their works.

Gasoline production in October was 3.43 million mt, up almost 15% on the year and up 6.2% month on month. Diesel output in October totaled 6.853 million mt, up 20% on the year and up 6.9% from August. Fuel oil production totaled 4.024 million mt in October, up 22% year on year and up 9.7% from September.

Planned sales of oil products on Russia’s St. Petersburg International Mercantile Exchange in November will be higher month on month, despite fewer days, as refinery maintenance is winding down. A number of refineries will restart in November, including Omsk and Syzran.

Separately, a fire occurred at the hydrotreater unit at Russia’s Novoil late Nov. 9, the local emergency ministry said. The fire occurred following depressurization of a pipeline at the unit. Separately, Russia’s crude pipeline operator Transneft said that the Novoil has fully halted crude intake since Nov. 9.

Near-term maintenance
New and revised entries
** Ukraine’s second-largest producer of gasoline and diesel fuel, Shebelinka GPP, which operates under the Shebel brand name, resumed operations after a scheduled 15-day maintenance, national oil and gas company Naftogaz Ukrayiny reported on Oct. 28. The refinery was out of operation between Oct. 10 and Oct. 25. During the maintenance, the refinery conducted checks and repairs to some of its equipment, including pipelines and valves, renovated catalysts at the hydrotreating reactor as well as cleaned columns and heat exchangers. After the maintenance, the refinery will switch on production of winter diesel fuel, adapted for low temperatures. The refinery, owned by UkrGazVydobuvannia, the country’s largest natural gas producer, refines mostly domestically produced gas condensate and produces gasoline and diesel fuel that meets the Euro-5 quality standards, LPG and other kinds of petroleum products. Shebel is one of two operational refineries in Ukraine, along with Kremenchuk-based oil refinery UkrTatNafta. Shebel increased output of A-95 gasoline by 61.7% on the year to 36,200 mt in January-September, while diesel fuel production increased by 7.4% on the year to 58,200 mt, the company said. Shebel also produced 105,900 mt of LPG in the first nine months of the year, up 3.1% on the year. The company refined 343,900 mt of oil and gas condensate in January-September, up 1% on the year. In 2020, Shebel decreased oil and gas condensate processing by 11% on the year to 446,500 mt from around 500,000 mt refined in 2019.

** Kazakhstan’s Pavlodar refinery was restarting late October after completing maintenance ahead of schedule. All production was due to resume from Nov. 1. The turnaround included replacement of columns and other equipment, maintenance of the primary distillation. The refinery has deferred its maintenance three times this year — once from July to September, and then from September to October. The refinery started its maintenance Oct. 1 but deferred the start of works on the primary processing by 10 days in order to secure sufficient diesel supply, S&P Global Platts reported earlier.

** Russia’s Saratov refinery has deferred its planned maintenance to 2022, according to market sources. The refinery was planning works in October and November.

Existing entries
** The predominantly export-oriented Tuapse refinery, located on the Black Sea coast in southern Russia, is expected to carry out works starting around mid-November and lasting until January, according to sources. Previously, traders indicated the works were likely to start in early November.

** Kazakhstan’s Atyrau refinery will defer its planned maintenance to avoid shortages on the domestic market, according to local media reports, citing the refinery. S&P Global Platts reported earlier that the plant was expected to defer its autumn maintenance to the spring of 2022, citing market sources. The refinery was expected to carry out a planned maintenance from mid September to mid October.

Upgrades
New and revised entries
** Russia’s Yaisky refinery is starting the third phase of its upgrade. By 2026, it plans to complete a dewaxing complex with 2.6 million mt/year capacity and a delayed coker with 1.34 million mt/year capacity. The commissioning of those complexes will increase its depth of processing to 93% and enable it to produce diesel with improved cold properties. Earlier this year, it completed the second phase of its upgrade, including a deep processing complex that enabled it to produce over 700,000 mt/year of Euro 5 gasoline. The complex includes a gasoline hydrotreater, isomerization and CCR unit.

** Russia’s Rosneft and Italy’s Maire Tecnimont have signed an agreement for building a VGO hydrocracker at the Ryazan refinery. The project involves the planning, equipment supply, construction and commissioning of the hydrocracker complex. It will enable the refinery to improve its margins through the conversion of heavy products into light products. The complex includes a hydrocracker, hydrogen and sulfur units. Separately, Ryazan is building a gas fractionation unit. The new unit will produce household LPG, isobutane, butane, and other products.

** The testing of the new FCC unit at Russia’s Salavat has entered the final stage. It said previously it planned to launch the newly constructed unit in the second half of this year. The unit will enable the refinery to increase production of Euro 5 gasoline. It will replace two outdated units — catalytic crackers 1 and 2 built in the 1950s.

Existing entries
** Russia’s Orsk continues with its upgrades, including the construction of the delayed coker complex. It is currently receiving the equipment for the delayed coker complex. The refinery started building the delayed coker in Q3 2020 and plans completion in Q3 2023. Safmar plans to build new deep processing complexes at the Orsk refinery. They include a 1.2 million mt/year delayed coker and a gasoline dewaxer with 600,000 mt/year capacity. It also plans an upgrade of the hydrocracker complex and the isomerization unit which would increase their productivity by more than 15%. The hydrocracker is set for launch in Q3 2022. The refinery’s depth of processing will increase from 76.7% to 98.1% by 2022-2023. Separately the refinery is building a new unit for hydrotreatment of distillate products from the delayed coker unit. The unit can also be used for hydrodesulfurization of diesel from the primary processing units.

** Russia’s Angarsk has started assembling the main column at the catalytic cracker complex. The assembly of the column is part of the refinery’s upgrade. The GK-3 unit is aimed to process 130 mt/hr vacuum gasoil and 520 mt/hr desalted crude oil will produce over 43 components.

** Lummus Technology has been awarded a contract for two proprietary heaters that will be part of Russia’s Kirishi upgrade. The heaters will be used “in the conversion of heavy oil residues, which would otherwise end up in fuels, to valuable lighter products,” it said in a statement. The company’s delayed coking heaters “can handle a wide range of feedstocks in refineries and upgraders for both fuel and specialty coke production.” The award is complimentary to a delayed coking technology license awarded by the KINEF refinery in Kirishi to CLG, a joint venture between Chevron and Lummus, in 2018.

** Belarus Naftan refinery reported a fire at the new delayed coker, the refinery said. The fire occurred in the week ended Oct. 1, due to a diesel leak during testing of the delayed coker. The delayed coker at Belarus Naftan was expected to be launched and produce its first batch of product by the end of this year. The complex was previously expected to come online in 2020. Tests are underway at the new hydrocracker at Belarus Mozyr refinery. The hydrocracker, along with a hydrogen and sulfur units, is part of the H-Oil complex. The completion of the hydrocracker H-Oil complex at Mozyr will cut fuel oil output and increase light products. The complex, with feedstock capacity of 3 million mt/year, will increase its light products yield to 70% and depth of processing to 90%.

** Russia’s Afipsky refinery has started to assemble the pressure pipelines in its hydrocracker complex. The deadline for completion of that part of the work is March 2022. Work is underway on the two most important parts of the complex — the hydrocracking unit and the sulfur production unit. According to the Krasnodar regional administration, the hydrocracker is due for completion in 2023. Separately, the Afipsky refinery is planning the construction of a 1.6 million mt/year delayed coker. Safmar Group is reorganizing two of its refineries by merging the Krasnodar refinery to the Afipsky refinery in southern Russia. It aims to complete the process by the end of summer 2021 and will thereby retain the name Afipsky refinery. The Krasnodar refinery will specialize in primary processing and the Afipsky refinery in secondary processing.

** Gazprom Neft has completed the construction of the diesel hydrotreater and dewaxer at its Omsk refinery and has started testing the unit. The new unit, with 2.5 million mt/year feedstock capacity, will replace two outdated units. Gazprom Neft said it had successfully completed the construction of a delayed coker at Omsk. The delayed coker, along with a hydrocracker, will form part of the deep crude oil processing complex of the Omsk refining complex. The finalizing of the works in the deep processing complex in 2021 will increase the depth of processing up to 100%, the company said. The 2 million mt/year complex will enable the refinery to increase the depth of processing and regulate the yields of gasoline, jet fuel and lubricants feedstock. The company has started assembly of electricity equipment at the catalytic cracker at Omsk refinery as part of the unit’s upgrade which aims at increasing the output of high octane components. The company had completed installation of the upgraded L 35/11-600 catalytic reformer. Two new compressors have been installed and three have been upgraded. Work had been due for completion in 2020. Omsk has also completed the installation of the main equipment at the primary CDU-VDU processing complex. The complex, with 8.4 million mt/year capacity, will be completed in 2021, and will allow the refinery to take six outdated units out of service. The refinery also started a project to upgrade the AVT-10 primary processing complex, which has a capacity of 8.6 million mt/year. The project is due to be completed by the end of 2021.

** Lukoil will build a catalytic cracker complex at its Perm refinery in Russia. The complex will have 1.8 million mt/year feedstock capacity. It will include a catalytic cracker, as well as a high-octane gasoline components unit. The complex is expected to be launched in 2026 and will increase the output of high-octane gasoline. It will also allow the refinery to produce propylene to be used as petrochemical feedstock. Perm is also working on a deep processing complex which will increase the refinery’s depth of processing. The project’s timeline is 2020-25. The complex includes a catalytic cracker, diesel hydrotreater, hydrogen unit and alkylation unit.

** Russia’s Moscow refinery has started the construction of a deep processing complex, set to be completed in 2025, which will enable it to reach almost 100% depth of processing and halt production of fuel oil. The refinery will be able to produce additional volumes of gasoline, diesel and jet fuel. Gazprom Neft’s refinery has chosen Spanish engineering company Tecnicas Reunidas to construct the new delayed coker which is part of the complex. It has also selected South Korean company DL E&C Co to participate in the hydrocracker construction. The delayed coker, which will have a 2.4 million mt/year capacity, will enable the refinery to increase production of motor fuel and start producing petroleum coke. The 2 million mt/year hydrocracker, a sulfur production unit and a hydrogen unit are also part of the complex.

** Russia’s Glavgosexpertiza, the state construction and engineering auditor, has approved the upgrade project for the Novoshakhtinsky refinery, clearing the way for launching its new gasoline complex in 2024. The complex will produce 92 RON and 95 RON Euro 5 gasoline and Euro 5 diesel. It aims to produce around 670,000-680,000 mt/year and construction is due to start in 2021. Separately, the refinery plans to launch in December 2024 a 1.8 million mt/year diesel hydrotreater. At the end of 2026 it expects to launch a deep-processing complex, which includes a hydrocracker and delayed coker. Following the completion of all upgrades, the refinery will be able to produce up to 3.2 million mt/year of diesel and 400,000 mt of petroleum coke. The refinery completed a bitumen unit in 2014 and a second CDU in 2015, Glavgosexpertiza said.

** Russian oil company Lukoil started the construction of a polypropylene unit at its refinery near Nizhny Novgorod, also known as Norsi and Kstovo. The unit will use feedstock from the two upgraded FCC units with 4 million mt/year capacity. Nizhny Novgorod is completing the construction of a deep processing complex. It is due to be launched in the autumn and will allow the refinery to reduce fuel oil output by 2.6 million mt/year and increase 10 ppm diesel output by 700,000 mt/year. The refinery’s depth of processing will reach 97% and the light products yield 74%. As a result of the launch, Lukoil’s refineries’ fuel oil output will be less than 4% and light products yield 75%. The deep processing complex includes a 2.110 million mt/year delayed coker; a diesel and gasoline hydrotreater, with 1.5 million mt/yr capacity; a hydrogen unit, with 50,000 Nm3/hour capacity; a gas fractionation unit, with 425,000 mt/year capacity; and a sulfur unit, with 81,000 mt/year capacity.

** Russian oil company Tatneft will use the technology of Hungarian oil company MOL to build a unit for the production of resin-modified bitumen. The unit, with 25,000 mt/year capacity, will be commissioned around mid-2023. Taneco refinery is building a second delayed coker with 2 million mt/year capacity, residue hydroconversion and diesel hydrodewaxing.

** Russia’s Yanos refinery in Yaroslavl has started building a delayed coker complex. As a result it will fully halt fuel oil output. Its depth of processing will exceed 99% and light products yield — 70%. Construction is scheduled for completion in 2024. The complex will be built in two stages — initially a delayed coker will be built which will enable the processing of more than 3.4 million mt heavy fractions, followed by a naphtha hydrotreater and light gasoil coker. They will provide feedstock for gasoline and diesel.

** Russia’s Komsomolsk refinery is planning to upgrade the ELOU AVT-3 primary processing complex. The refinery is building a hydrocracker complex which will increase its depth of processing to over 92%. The complex has 3.5 million mt/year capacity.

** Russia’s Achinsk refinery will increase its depth of processing to over 95% and the light products yield to 88% upon completion of its upgrades, which will lead to the almost complete halt of fuel oil output. It is building a hydrocracker with integrated hydrotreater. Its launch will enable it to almost double the output of motor fuel aimed at covering domestic demand predominantly in Siberia and the Far East. It is also building a delayed coker complex.

** Russia’s Ilsky is planning to launch a new gasoline complex, including a 1.5 million mt/year CCR and isomerization units, around the second half of 2023 which will enable it to produce high-octane gasoline components and gasoline meeting Euro 5 standards, LPG and xylenes. After launching the gasoline complex, it aims to start building a diesel hydrotreater, with construction likely to be completed in 2024.

** Uzbekistan’s Bukhara will use Honeywell UOP technology to increase crude conversion and produce Euro-5 standard gasoline and diesel. Honeywell will provide “licensing and basic engineering design services” for a new naphtha hydrotreating, RFCC, SelectFining and Merox units. The existing diesel hydrotreater will be revamped. Uzbekneftegaz has decided to proceed with an upgrade of its Bukhara and Fergan refineries and put on hold building a new refinery in the Jizzakh region. Uzbekistan’s Fergan refinery between 2020-2023 aims to commission hydrocracking process in a staggered way which will allow it to produce Euro-5 regular gasoline 92 RON as well as diesel.

** Renovation and rebuilding work on Azerbaijan’s Heydar Aliyev refinery was delayed by the COVID-19 pandemic. Production of Euro 5 diesel and Euro-5 standard A-92/95/98 gasoline was originally planned by the end of 2021, and prior to that the end of 2020 for Euro-5 diesel and early 2021 for Euro-5 standard A-92/95/98. These dates were later pushed back to the start of 2022 due to the effects of the pandemic, with all work on the plant slated to be completed by 2025. The ongoing work includes replacing all the units of the refinery except one and in the process increasing the capacity to 7.5 million mt/year from 6 million mt/year. Work on the Azerkimya facility, which is supplied with feedstock by the Heydar Aliyev refinery, will raise production from 60,000 mt/year previously to around 175,000 mt/year.

** Russia’s Rosneft is working towards launching the hydrocrackers that it has built at four of its refineries — Achinsk, Komsomolsk, Novokuybishev and Tuapse. Russia’s largest refiner is also completing the reconstruction of the hydrocracker at Ufaneftekhim, which was damaged in a fire in July 2016. Rosneft is expanding the capacity of its existing delayed coker at Novokuybishev. Rosneft plans to complete its refinery modernization program by 2025. The program includes construction and reconstruction of over 50 units, with work on more than 30 of the units having been finished.

** Kyrgyzneftegaz plans to upgrade its Jalal-Abad refinery. Its strategy involves a unit for secondary processing of fuel oil.

** Kazakhstan’s Pavlodar refinery is looking to build a unit for the purification of LPG and has selected a Merox technology.

** The launch of four secondary units at the Mariisky refinery has been delayed. As per plans, after upgrades it expects to increase the AT-2’s capacity to 1.4 million mt/year from 900,000 mt/year and the VDU capacity to 1 million mt/year from 476,000 mt/year.

** The next stage of upgrades at the Antipinsky refinery in Russia involves increasing the capacity of crude and refined product pipelines. Antipinsky, which can process 9 million-9.5 million mt/year of crude, currently receives 7.5 million mt/year of crude.

** A delayed coker will be installed at the Turkmenbashi refining complex in Turkmenistan.

Launches
Existing entries
** Russia’s Rosneft could launch a planned new refinery as part of its VNHK (East petrochemical complex) in the Far East in 2029 and a petrochemical plant in 2026. In August 2020, Rosneft CEO Igor Sechin told Russian President Vladimir Putin that Rosneft has shelved a plan to build a new refinery and petrochemical complex in the Far East due to changes in taxation, but can resume the project provided profitability can be guaranteed. Meanwhile, at a new meeting with Russia’s President, Sechin said that one of the factors for carrying out the Far East project would be taking measures for stimulating the production of ethane and LPG. The Far East refinery is planned to process 12 million mt/year of crude, while the petrochemical plant will have 3.4 million mt capacity. The production will include 1.8 million mt gasoline, 6.3 million mt diesel and 4.5 million petrochemical products annually.

** A new refinery is planned to be launched in Georgia, at the Black Sea port of Kulevi, in 2024. Construction of the 4 million mt/year plant is due to start in 2021. The refinery is expected to have 98% depth of processing and produce Euro 5 and 6 gasoline and diesel and thus reduce Georgia’s import needs for oil products by 15%-20%.

** Russia’s Khabarovsk refinery plans to build a second phase to the plant close to the existing site. The second phase would double the refinery’s capacity to 10 million mt/year, and aims to cover gasoline demand in the far east of Russia. The company is seeking an investor in the Asia-Pacific for the second phase, which includes an FCC, hydrotreater and delayed coker.
Source: Platts

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