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Operation of Primary Crude Oil Processing (OPCOP)

The Operation of primary crude oil processing LK-6U– is the main one, the leading one at the Refinery. Such a key role it plays not only because of scale of operation but also because of output of the main products. The LK-6U Unit is the leading unit of the refinery, it is produced here the components of commercial gasolines of grades AI-92-К4, AI-95-К4, diesel fuel ДТЛ-К4, fuel for jet engines of grade РТ, mazut, household gases.

The PCOP LK-6U Complex has been put into operation in 1978. The crude oil processing capacity is 6 million tons per year.

The design of combined unit LK-6U has been designed by the "Lengiproneftekhim" Institute (Leningrad city) especially for Pavlodar refinery.

lk1.jpgIn 1978-1992 the LK-6U complex processed 7 million tons of crude oil a year. In 1993 2002 the total designed capacity of the complex was not used because of absence of crude oil delivery. Since 2003 the oil processing volume started to increase from year to year, and in 2007 the complex processed 4,3 million tons of oil, and in 2012 it has been already processed 5,0 million tons of crude oil. For 2018 it is scheduled the processing of 5,25 million tons of crude oil. In this complex there have been big scopes of work performed for reconstruction and replacement of process equipment, which nowadays allows producing oil products in compliance with requirements of the Technical Regulation of the Customs Union ТР ТС 013/2011.

The LK-6U Complex consists of the following units:

  • С-100 – ELOU-AT, capacity 6 mln. t/year;
  • С-200/1- Naphtha Hydrotreater, capacity 1,24 mln. t/year;
  • С-200/2 – Catalytic Reformer, capacity 1,0 mln. t/year;
  • С-300/1 – Diesel Fuel Hydrotreater, capacity 2,3 mln. t/year
  • С-300/2 – Kerosene Hydrotreater, capacity 364 thousand t/year;
  • С-400 – Gas Fractionation, capacity 450 thousand t/year;
  • B300S – Naphtha Splitter, capacity 1961 thousand t/year;
  • А100 - Isomerization, capacity 570 thousand t/year;
  • Е-905 – Fuel gas treatment station using LPG, capacity 12039 kg/h;
  • Air-Nitrogen Station (ANS);
  • Air-Nitrogen Station on the basis of air separation unit KDNO-1200.

Characteristic of LK-6U sections

SECTION 100 

Section 100, ELOU-AT is the main one in the combined unit LK-6U and it is designed for processing blend of the West-Siberian crude oil.

The process is conducted by means of the following physicochemical methods: desalting, dehydration, fractionation and heat exchange.

The section 100 consists of two blocks:

  • ELOU block is intended for electric desalting of crude oil coming for processing;
  • AT block where crude oil fractionation takes place, which then becomes feedstock for other subsequent sections of LK-6U unit.

As a result of processing there are separate crude oil fractions which become feedstock for other subsequent sections of LK-6U unit.

SECTION 200/1

Section 200/1 of LK-6U – naphtha hydrotreating is designed for reducing content of sulfurous, nitrogenous, oxygen-containing, metal-organic and unsaturated compounds in crude mixture of gasoline fractions by catalytic transformations and production of stable hydrogenation product which is routed for further fractionation to the naphtha splitter unit.

SECTION 200/2

Section 200/2 Catalytic Reforming of LK-6U unit is designed for producing high-octane component of motor gasolines and technical hydrogen as a result of catalytic transformations of heavy naphtha coming from naphtha splitter of combined unit of isomerization and naphtha splitter (А100/В300S). Hydrogenous gas (technical hydrogen) is used further as a feed for hydrogen production unit or in fuel hydrotreating processes.

SECTION 300/1

Section 300/1 Diesel Fuel Hydrotreating of LK-6U is designed for producing a component of commercial diesel fuel with low content of sulfurous and nitrogenous compounds.

The products of the section are:

  • diesel fuel – a component of commercial diesel fuel corresponding to ecological class К-4;
  • stripped gasoline, used as a component of feed of section 200/1;
  • hydrocarbon gas used as fuel.
SECTION 300/2

Section 300/2 Kerosene Hydrotreating is designed for treatment of straight-run kerosene fraction of section 100 of LK-6U unit (ELOU-AT) from any sulfur-, nitrogen-, oxygen containing compounds for the purpose of producing aviation fuel of type РТ.

SECTION 400

Section 400 of LK-6U unit – the unit of gas fractionation of saturated hydrocarbons, it is designed for producing liquefied hydrocarbon gases of domestic and industrial use, components of motor gasolines by processing of “unstable overhead” (top fraction) of atmospheric distillation of crude oil and catalytic reforming.

B300S NAPHTHA SPLITTER

B300S Naphtha Splitter is designed for separation of hydrotreated fraction of naphtha from naphtha hydrotreating unit into light and heavy naphtha in order to send it as a feed for isomerization unit and catalytic reforming unit.

A100 ISOMERIZATION UNIT

А100 Isomerization Unit (licensed process of UOP) is designed for producing isomerate – high-octane component of gasoline pool with a low content of aromatic hydrocarbons, benzene and olefins. The feedstock for producing this product is light naphtha from naphtha splitter.

Е-905 FUEL GAS TREATMENT STATION USING LIQUIFIED PETROLEUM GAS

Fuel gas treatment station using LPG Е-905 – it is an object intended for production of hydrocarbon (fuel) gas from liquefied technical butane for the main and pilot burners of heaters of LK-6U combined unit sections.

AIR-NITROGEN STATION

Air-nitrogen station with a section for filling balloons 2×АК-0,6 is intended for production of:

- gaseous and liquid nitrogen of ultra-high purity as per GOST 9293;

- gaseous technical oxygen of 1st grade as per GOST 5583, as well as liquid technical oxygen of 1st grade as per GOST 6331.

Air-Nitrogen station 2×АК-0,6 includes two air separation sections АК-0,6 with capacity of 600 m3/hour each for gaseous nitrogen and 85 m3/hour for gaseous oxygen and section of filling balloons with gaseous oxygen and nitrogen, with carrying capacity of 150 m3/hour and 20 m3/hour accordingly.

AIR-NITROGEN STATION ON THE BASIS OF AIR SEPARATION UNIT KDNO-1200

Air-Nitrogen station on the basis of air separation unit KDNO-1200 is intended for production of:

- gaseous and liquid nitrogen of ultra-high purity as per GOST 9293;

- liquid technical oxygen of 1st grade as per GOST 6331.

Air-Nitrogen station includes air separation unit KDNO-1200 with capacity of 1200 m3/hour for gaseous nitrogen, 116 kg/h for liquid nitrogen and 100 kg/h for liquid oxygen.