LUKOIL Group integrates four refineries in Russia (in Perm, Volgograd, Nizhny Novgorod, and Ukhta), along with two refineries in Europe (in Romania and Bulgaria), and has a 45% interest in a refinery in the Netherlands. The aggregate capacity of these refineries is 66.2 million tonnes.
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.
In 2016, LUKOIL completed a large-scale upgrade program worth around USD 12 billion to build 12 units for secondary processing and treatment of the feedstock (11 in Russia and one in Bulgaria). The program helped LUKOIL become the first company in Russia to produce motor fuels compliant with Euro 5 standards. Furthermore, the Company was able to boost manufacturing efficiency and increase the share of high value-added petroleum products in its mix.
Since 2017, LUKOIL has been implementing selective projects to upgrade its Russian facilities.
In 2022, the Group completed the following projects:
The Nizhny Novgorod Refinery completed the largest selective project within the Company’s refinery modernization program, launching a 2.1 million tonne residue conversion complex. The new facility includes a delayed coker, a combined diesel fuel and gasoline hydrotreater, a gas fractionator, and hydrogen and sulfur production units. The project will increase the refinery’s annual Euro 5 diesel fuel production by 1.1 million tonnes while reducing the share of fuel oil in its product mix and driving synergies with the refinery’s existing process facilities. Following the facility launch, the light product yield at the Nizhny Novgorod Refinery reached an all-time high of 70 percent in December 2022, compared with 63 percent in 2021.
The Volgograd Refinery completed a large-scale revamp of its 3.5 million tonne CDU-VDU-5 crude distillation unit and the solvent extraction unit with an annual production capacity of 300 thousand tonnes. The CDU-VDU-5 project will increase crude refining by 400 thousand tonnes per year while growing the output of kerosene and diesel fuel fractions. The rollout of advanced technologies and digital solutions will boost the energy efficiency of operations and reduce per unit carbon dioxide emissions.
| 2018 | 2019 | 2020 | 2021 | 2022 | |
|---|---|---|---|---|---|
| Feedstock processing, mln t | 67.316 | 68.746 | 58.608 | 62.959 | 70.056 |
| Petroleum products output, mln t | 63.774 | 65.081 | 54.964 | 60.015 | 65.766 |
| Light product yield, % | 71 | 73 | 72 | 73 | 72 |
| Refining depth, % | 88 | 89 | 93 | 92 | 90 |
| Nelson Index | 8.6 | 8.6 | 8.6 | 8.7 | 9.0 |
REFINERIES IN RUSSIA
| 2018 | 2019 | 2020 | 2021 | 2022 | |
|---|---|---|---|---|---|
| Feedstock processing, mln t | 43.189 | 44.154 | 40.109 | 42.616 | 44.040 |
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Light product yield (excluding mini-refineries), % | 69.3 | 69.9 | 69.8 | 70.4 | 71.2 |
| Refining depth, (excluding mini-refineries), % | 88.0 | 88.7 | 91.4 | 89.4 | 90.1 |
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
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)
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Plant’s History
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. 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.
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 sulfur generation units, plant economic facilities.
In 2017 hydrocracker built in 2016 successfully reached the design capacity. This significantly improved the refinery's petroleum product slate by replacing the vacuum gas oil with higher value-added products, primarily Euro-5 diesel fuel.
In 2019, the Volgograd Refinery launched production of low-sulfur bunker fuel (fuel oil) compliant with MARPOL requirements.
In 2020, the Volgograd Refinery completed construction of a de-asphalting unit and a fractionation unit for unconverted oil as parts of a high-viscosity index lubricants production complex.
In 2022, the Volgograd Refinery completed a large-scale revamp of its 3.5 million tonne CDU-VDU-5 crude distillation unit and the solvent extraction unit with an annual production capacity of 300 thousand tonnes.
- Enterprise website
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
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)
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Plant’s History
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, 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.
In 2017, a rail trestle for the fuel oil discharge with a capacity of up to 1 million tonnes per year was commissioned. The rail trestle enhanced inter-plant integration and ensured the supply of heavy petroleum feedstock from Nizhny Novgorod Refinery to the petroleum residue processing complex and bitumen production unit of Perm Refinery.
The fuel oil loading infrastructure was also brought on stream at Perm Refinery in 2018, improving delayed coker utilization rate and strengthening inter-plant optimization across the Group.
- 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
Key conversion processes include a catalytic cracking unit (80.0 th. bbl/d) and a visbreaking unit (42.2 th. bbl/d)
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Plant’s History
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 t/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.
In 2017, Nizhny Novgorod Refinery started producing ECTO 100, a premium gasoline with improved performance properties. Also LUKOIL took the final investment decision on the construction of a delayed coker complex with a feedstock capacity of 2.1 million tonnes per year at its Nizhny Novgorod Refinery. The complex will use heavy residuals from the refining process as feedstock, and produce mainly diesel fuel, straight-run gasoline, and gas fractions, as well as dark products – vacuum gas oil and coke. The launch of the delayed coker complex and related optimization measures will increase the output of light products at Nizhny Novgorod Refinery by more than 10%. Increased secondary refining capacity and optimized refinery utilization will help reduce fuel oil output by 2.7 million tonnes per year.
Construction of a delayed coker complex and an isomerization unit was launched in 2018.
In 2021, PENEX isomerisation unit was commissioned. The unit will allow to apply low temperature isomerisation to light naphtha in order to produce high-octane blending component to gasoline. The annual feed rate amounts to 800 thousand tonnes.
In 2022, the Nizhny Novgorod Refinery completed the largest selective project within the Company’s refinery modernization program, launching a 2.1 million tonne residue conversion complex. The new facility includes a delayed coker, a combined diesel fuel and gasoline hydrotreater, a gas fractionator, and hydrogen and sulfur production units.
- 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
Key conversion processes include a visbreaking unit (14.1 th. bbl/d)
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Plant’s History
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
Urai Mini-Refinery
Fuel production refinery
Located in Urai
Specializes in refining of the local blended crudes
Commissioned by the LUKOIL Group in 1995
- Enterprise website
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Kogalym Mini-Refinery
Fuel production refinery
Located in Kogalym
Specializes in refining of the local blended crudes
Commissioned by the LUKOIL Group in 1997
REFINERIES IN EUROPE
| 2018 | 2019 | 2020 | 2021 | 2022 | |
|---|---|---|---|---|---|
| Feedstock processing, mln t | 24.127 | 24.592 | 18.499 | 20.343 | 26.016 |
| Refining depth, % | 88.0 | 90.8 | 95.3 | 98.0 | 90.8 |
