LUKOIL Group integrates four refineries in Russia (in Perm, Volgograd, Nizhny Novgorod and Ukhta) along with three refineries in Europe (in Italy, Romania and Bulgaria) and has a 45% interest in a refinery in the Netherlands.
The total capacity of the Company's refineries as of late 2016 came to 82.1 mln t per year.
The Company's plants have cutting-edge conversion and reforming capacities, and produce a wide range of high quality petroleum products. In terms of the engineering properties of their production capacities and the efficiency indicators, the Russian refineries surpass the average Russian level, while the European plants of the Company are equal to their competitors and are located close to our key target markets.
The 2016 oil refining output at the Group's refineries came to 66.06 mln t.
LUKOIL is continuously upgrading its refining capacities quickly responding to the major market trends. While upgrading its refineries, the Company makes use of the cutting-edge technologies in order to improve the quality of its products and reduce the environmental impact. The European quality standards for engine fuels are being introduced well ahead of schedule at all refineries of the Group. This will enable the Company to gain major competitive advantages, as well as an additional price premium for environmental friendliness and high quality of its products.
2011 witnessed start of a new development stage in the Russian oil refining industry: state institutions and oil companies concluded agreements on refinery upgrade, to switch over to the production of petroleum products with higher quality, and to ensure the necessary petroleum product output to supply it to the domestic market.
The Company completed its large-scale investment cycle in 2016. Russia’s largest vacuum gas oil refining facility was commissioned at the Volgograd Refinery. A large-scale efficiency enhancement program at all refining facilities operated by the Group was implemented.
In addition to the upgrade of its Russian facilities, LUKOIL develops its overseas plants. In the period characterized by low oil prices the Company efficiently makes use of the vertical integration advantages.
In the medium term perspective the Company intends to bring new engineering facilities into production and to optimize the production facilities in view of their commissioning. Efficiency enhancement programs, namely Road Maps were developed for all enterprises of the Group.
The LUKOIL Group’s refineries are included into the lists of Russia’s strategic enterprises. They produce a major impact on GRP generation, employment of population and social stability in the regions.
* Refining depth, light petroleum product yield and Nelson Index exclude mini-refineries and include the impact of cross-supplies of commercial petroleum products between the Group’s refineries.
In 2016, the throughput at Russian refineries remained flat year-on-year at 41.8 million tonnes. Following the output mix improvement driven by the duly completed upgrade program and by optimized utilization of secondary processes, the Group's Russian refineries posted strong financial results in 2016 despite the unfavorable macroeconomic environment.
In the reporting year, light product (excluding products of mini-refineries) yield was 62.9% (2015: 58.9%). The refining depth (excluding mini-refineries) reached 84.7% (2015: 79.9%), mainly driven by the newly commissioned residue refining facility at the Perm Refinery, virtually phasing out fuel oil production.
Capital expenditures of Russian refineries totaled RUB 28 billion in 2016, down 49% year-on-year. The decrease was due to the completion of the major upgrade program at our refineries.
Fuel and lube-petrochemistry production refinery.
Located 9 km away from Perm.
Specializes in refining of blended crudes from northern Perm Oblast and Western Siberia.
The crude is delivered to the refinery via Surgut-Polotsk and Kholmogory-Klin oil pipelines.
Finished products are shipped by railroad, motor and river trucks, as well as via the Perm-Andreevka-Ufa oil product pipeline.
The capacity is 13.1 mln t/year
The Nelson complexity index is 9.4
Key conversion processes: T-Star hydrocracking unit (65.2 th. bbl/d), a catalytic cracking unit (9.3 th. bbl/d), and a coking unit (56.0 th. bbl/d).
The plant was commissioned in 1958, and joined the LUKOIL Group in 1991. In 1990-s the plant implemented a coking unit upgrade program, constructed a fuel oil vacuum distillation unit, a lube refining unit, commissioned a hydrogen sulfide utilization and a sulfuric acid production unit.
In the 2000-s an advanced petroleum refining complex was commissioned, as well as an additive feeding hub at the hydro dearomatization unit, an isomerization unit, AVDU units were reconstructed, an atmospheric block at the AVDU-4 unit was upgraded thus increasing the capacity by 125 th. t/year. In 2008 the refinery capacity was increased up to 12.6 mln t/year.
Between 2011 and 2014 the capacity of the delayed coking unit was increased up to 1 mln t/year, a modern distributed control system was commissioned based on the microprocessor technology at hydro crackers, hydrogen generation units, a crude processing unit, solvent deasphalters and dewaxing units, the diesel fuel hydrotreater was upgraded, and technical re-equipment of the vacuum block at the AVDU-4 unit was completed.
An oil residue refining complex was commissioned in 2015, which makes it possible to switch over to the mazute-free plan and enhance the light petroleum output, and construction of a power block with a 200 MW rated capacity was completed.
In 2016 LUKOIL completed reconstruction of the diesel fuel hydrodearomatization block of the hydrocracker. This modernization will allow the Company to increase production volumes of EURO 5 winter diesel. A record refining depth of 97% was achieved.
- Enterprise website
Fuel and lube production refinery.
Located in Kstovo, Nizhny Novgorod Oblast.
Specializes in refining of the blended crudes from West Siberia and Tatarstan.
The crude is delivered to the refinery via Almetyevsk-Nizhny Novgorod and Surgut-Polotsk oil pipelines.
Finished products are shipped by railroad, motor and river trucks, as well as via the pipeline.
The capacity is 17.0 mln t/year
The Nelson complexity index is 7.1.
Key conversion processes include a catalytic cracking unit (80.0 th. bbl/d) and a visbreaking unit (42.2 th. bbl/d)
The plant was commissioned in 1958, and joined the LUKOIL Group in 2001.
AVDU-5 and lube hydrotreating units were reconstructed in 2000. Highly purified food paraffin production, a catalytic reforming unit and a gasoline isomerization unit were commissioned, the AVDU-6 atmospheric block and hydrotreatment units were upgraded, which made it possible to start Euro-5 compliant diesel fuel manufacturing. A tar visbreaking unit with a capacity of 2.4 mln. tn/year was commissioned in 2008, which increased the vacuum gasoil output and reduced the fuel oil output. A vacuum gasoil catalytic cracking unit was commissioned in 2010, which made it possible to enhance the plant’s production of high octane automobile gasolines by 1.4 mln t/year, diesel fuel by 400 th. t/year, light petroleum product output by 12%. The diesel fuel hydrotreater was reconstructed.
Between 2011 and 2014 a hydrogen fluoride alkylation unit was commissioned, the AVDU-5 reconstruction was completed, and a modern distributed control system was introduced at the AVDU-1 unit. The oil and petroleum product storage plants were expanded, which created an oil reserve and optimized the fuel oil logistics. Operations were conducted to supply equipment and commission the infrastructure facilities to prepare for bringing Catalytic Cracking Complex No.2 and Vacuum Block VT-2 into production. The facilities were commissioned in 2015.
In 2016 the feedstock mix was expanded, thus increasing the output of diesel fuel and gasoline with no incremental fuel oil production.
- Enterprise website
Fuel and lube production refinery.
Located in southern Russia.
Specializes in refining of the blended light West-Siberian and Lower Volga oils.
The crude is delivered to the refinery via the Samara-Tikhoretsk oil pipeline.
Finished products are shipped by railroad, river and motor trucks.
The capacity is 14.5 mln t/year.
The Nelson complexity index is 6.9.
Key conversion processes include coker units (2 units with a capacity of 24.0 th. bbl/d), hydrocracking unit (with capacity of 67.0 th.bbl/d).
The plant was commissioned in 1957, and joined the LUKOIL Group in 1991. Mid 2000-s witnessed commissioning of a gasoline blending unit and an oil discharge rack, as well as a diesel fuel hydrotreater, a straight-run gasoline stabilization unit, and a saturated hydrocarbon gas fractionation unit.
Between 2004 and 2010 the first stage of the coke calcination unit was commissioned, as well as the isomerization unit with a capacity of 380 th. t/year; a catalytic reforming unit was constructed. A vacuum block of the AVDU-6 unit was reconstructed and commissioned. An automated gasoline blending station was commissioned, as well as an inert gas production unit and a vapor recovery unit at the loading rack. Production of ECTO-branded diesel fuel was launched.
Between 2010 and 2014 the diesel fuel hydrotreater was upgraded, a PSA block was commissioned, as well as a new delayed coking unit with a capacity of 1 mln t/year, a diesel fuel hydrotreater with a capacity of 3.0 mln t/year, the second string of the coke calcination unit with increased calcination capacity of up to 280 th. t/year. Delivery and assembly of the core equipment for hydro crackers and a hydrogen generation unit of the Vacuum Gasoil Deep Conversion Complex was completed in 2014. The project implementation will considerably enhance EURO-5 compliant diesel fuel production.
AVDU-1 desalter primary crude processing unit was commissioned in 2015. It helps enhance the oil refining efficiency and capacity up to 15.7 mln t/year.
A vacuum gasoil deep conversion complex was commissioned in 2016. The capacity of the Russian Vacuum Gasoil Deep Conversion Complex comes to 3.5 mln t/year. It was constructed in record-breaking time, i. e., 3 years. The complex also comprises hydrogen and elementary sulfur generation units, plant economic facilities.
The project implementation will enhance EURO-5 diesel fuel production by 1.8 mln t/year, automobile gasoline components by 0.6 mln t/year and liquefied gases by 0.1 mln t/year. The manufactured products will be in demand above all in southern Russia.
- Enterprise website
Fuel production refinery.
Located in the central part of the Komi Republic.
Specializes in refining of the blended crudes from the fields of the Komi Republic.
The crude is delivered to the refinery via the Usa-Ukhta oil pipeline.
Finished products are shipped by railroad and motor trucks.
The capacity net of that of the AVDU vacuum block is 4.0 mln t/year.
The Nelson complexity index is 3.9.
Key conversion processes include a visbreaking unit (14.1 th. bbl/d).
The plant was commissioned in 1934, and joined the LUKOIL Group in 1999.
The AT-1 unit was reconstructed in the 2000-s, a diesel fuel hydrodewaxing unit, an oil discharge rack and a dark petroleum product loading rack were commissioned. The first reconstruction stage of the catalytic reforming complex was completed, which enhanced the respective capacity by 35 th. t/year. A block was commissioned to enhance hydrogen density at the hydrodewaxing unit, the second stage of the oil and petroleum product discharge and loading rack was completed, as well as the catalytic reforming unit re-equipment, a tar visbreaking unit with a capacity of 800 th. t/year was commissioned, which enhanced vacuum gasoil production. Construction of an isomerization block was completed in 2009.
Technical re-equipment of the reactor block of the GDS-850 diesel fuel hydrotreater was completed in 2012. The AVDU unit was commissioned after reconstruction in 2013, the vacuum block capacity was enhanced up to 2 mln t/year. Construction of a gas condensate discharge block was completed. Technical re-equipment of the enterprise continued in 2014—2015.
- Enterprise website
In 2016, the throughput at the Group's European refineries increased by 7.4% to 24.3 million tonnes, following an increase in the capacity utilization rates driven by high refining margins, as well as the implementation of operational excellence programs. The hydrocracker of the Heavy Residue Refining Facility at the Burgas Refinery (Bulgaria) reached its design capacity, bringing the yield of light petroleum products at the Group's European refineries to 72.7% (72.1% in 2015) and the refining depth to 86.0% (84.5% in 2015).
In 2016, the capital expenditures of the Group's European refineries totaled RUB 10.1 billion, down 45.0% year-on-year.
Fuel production refinery.
Located in Ploiești (central part of Romania), 55 km away from Bucharest.
Processes Urals oil (Russian exported blend) and the oil produced at Romanian fields.
The crude is delivered to the refinery via an oil pipeline from the Black Sea port of Constanta. The Romanian oil is also delivered by railway.
Finished products are shipped by railroad and motor trucks. The capacity is 2.7 mln t/year.
The Nelson complexity index is 10.0.
Key conversion processes include a catalytic cracking unit (18.5 th. bbl/d) and a coking unit (10.5 th. bbl/d).
The plant was commissioned in 1904, and joined the LUKOIL Group in 1999.
Manufacturing of AI-98 gasoline and low-sulfur diesel fuel started in the 2000-s. In 2001 the plant was shut down for reconstruction (primary oil processing units, hydrotreaters, reforming units, cokers, catalytic cracking units, gas fractionation and isomerization units were upgraded; cat-cracked gasoline hydrotreaters, hydrogen generation units were constructed). The plant was commissioned in 2004. A MTBE/TAME additive manufacturing unit was commissioned afterwards, as well as a 25 MW turbine generator; reconstruction of diesel fuel hydrotreaters, catalytic cracking units, cat-cracked gasoline hydrotreaters and MTBE/TAME manufacturing units was completed, as well as that of the vacuum block at AVDU-1. Construction of the hydrogen generation unit was completed, which enabled the Company to manufacture Euro-5 compliant fuels.
Between 2010 and 2014 two new coke drums at a delayed coking unit were assembled, propylene manufacturing with the sulfur content of less than 5 ppm was launched, the amine block was reconstructed, an improved control system was introduced to the AVDU-3 unit, thus increasing commercial output. 2013 witnessed completion of projects aimed at C3+ recovery rate enhancement out of the cat-cracked dry gas, upgrade of the treatment facilities. Total overhaul of the enterprise was completed along with reconstruction of the catalytic cracking unit, replacement of the catalyst system at the diesel fuel hydrotreater, which enabled the Company to switch over to the mazute-free production plan and considerably enhance the conversion rate and light petroleum product output.
A unit for the treatment of flue gas generated by the catalytic cracking process was commissioned in 2015.
Fuel and petrochemistry production refinery.
Located at the Black Sea coast, 15 km away from Burgas.
Processes different branded oils (incl. Russian export oils) and fuel oil.
The crude is delivered to the refinery via the pipeline from the Rosenets oil terminal.
Finished products are shipped by railroad, sea and motor trucks, as well as via the oil product pipeline to central regions of the country.
The capacity is 9.8 mln t/year
The Nelson complexity index is 13.0 (the highest one among the LUKOIL Group’s refineries).
Key conversion processes include a catalytic cracking unit (37.1 th. bbl/d), a visbreaking unit (26.4 th. bbl/d) and a tar hydrocracking unit (39.0 th. bbl/d).
The plant was commissioned in 1964, and joined the LUKOIL Group in 1999.
The 2000-s witnessed start of high octane gasoline manufacturing characterized by light fractional composition, manufacturing of 5 kinds of products compliant with the European standards; a catalytic reforming unit was constructed, as well as a catalytic cracking unit, a regenerator of the catalytic cracking unit; a system was commissioned to change the TPP fuel structure in view of the market prices for boiler fuel and gas; a gas sulfur manufacturing unit was constructed with a capacity of 30 th. t/year. Between 2006 and 2007 a project was completed to reduce atmospheric emissions, and an n-butane isomerization unit was constructed with a capacity of 50 th. t/year. In 2009 a diesel fuel hydrotreater was upgraded to manufacture Euro-5 compliant fuel, a new sulfuric acid alkylation unit was commissioned.
Between 2010 and 2014 diesel fuel hydrotreaters were commissioned, as well as cat-cracked gasoline hydrotreaters, and a sulfuric acid regeneration unit. Projects were completed to optimize boiler fuel shipment schemes at the Rosenets oil terminal in order to bring the metering stations in compliance with the national tax law requirements. Construction and assembly work of a gas sulfur manufacturing unit was completed in 2014. A natural gas pipeline was commissioned, as well as a waste heat boiler at the catalytic cracking unit, and systems for treatment of flue gases at waste incinerators. A Heavy Residue Processing Complex was commissioned in 2015.
- Enterprise website
Located in the east of Sicily in the vicinity of Priolo.
Processes different branded oils and straight-run fuel oil.
Major feed stock suppliers include countries of the Black Sea region, North and West Africa, the Persian Gulf.
Finished products are shipped by sea and motor trucks.
The capacity is 16.0 mln t/year.
The Nelson complexity index is 9.3.
Key conversion processes include catalytic cracking units (38 th. bbl/d), hydrocracking units (90 th. bbl/day), visbreaking and thermal cracking units (99 th. bbl/d), hydrocracking unit (90 th. bbl/d).
Commissioned in 1964 (Northern site) and 1975 (Southern site). A comprehensive upgrade of the enterprise was completed in 2003. In 2008 the LUKOIL Group acquired a 49% stake in the joint venture to control ISAB Scientific Design Complex from ERG S.p.A. In 2011 the Company’s stake was increased from 49 to 60%, in 2012 from 60 to 80%, while in 2013 the Company’s stake was brought up to 100%. The Group’s stake in the refining volume of the Scientific Design Complex reached 8.23 mln t The IGCC power block was acquired in 2014. Measures were implemented in 2015 to enhance the economic efficiency of the enterprise.
- Enterprise website
Located at the major refining and trading hub of Northwest Europe ARA (Amsterdam-Rotterdam-Antwerp).
Around 90% of the plant’s products are sold in Belgium, the Netherlands, Germany and Switzerland.
Finished products are shipped by water and motor trucks.
Connected via own pipeline with the Maasvlakte Oil Terminal (total capacity of 4 mln. tn).
The plant’s own tank battery includes 54 reservoirs for oil and petroleum product storage.
The capacity is 3.6 mln t/year as part of the Group’s share as of 2016.
The Nelson complexity index is 8.4.
Key conversion processes include a hydrocracking unit (74 th. bbl/d).
Commissioned by TOTAL S.A. in 1973. In 1980 Dow acquired a 20%-stake in the refinery. Early 1980-s saw refinery upgrade, as a result of which a hydrocracking unit was commissioned in 1986. The Dow’s stake in the plant’s equity capital reached 45%. Starting from 1990, constant upgrades took place at the plant, while it remained one of the most hi-tech plants in Europe (kerosene cut treatment and sulfur recovery units were commissioned, capacities of the medium distillate hydro treaters were expanded to ensure diesel fuel manufacturing with the sulfur content of 50 ppm). The hydro cracking unit reconstruction with its capacities expanded is one of the recent large-scale upgrade projects (completed in 2004). In 2009 the LUKOIL Group acquired a 45% stake in the joint venture to control the TRN refinery from TOTAL S.A. In 2011 the TRN refinery (the Netherlands) changed its name into Zeeland Reﬁnery.