Atyrau refinery –the first Kazakhstan refinery – is known for its remarkable traditions and achievements.
The construction of the plant started in 1943 in difficult condition of the post –war period, and in September 1945 the plant was put into operation.
Nowadays, Atyrau refinery is a major modern plant which is located in the oldest oil producing region of the country.
Atyrau refinery processes heavy crude oil with high paraffin content from oil deposits in the Western regions of Kazakhstan. The period from mid-60-s to mid 80-s of the last century saw a major technical updating of all refinery technological equipment , which enabled to increase the capacity up to 4,3 million tons per year.
Atyrau refinery reconstruction was aimed at the replacement of the old equipment, reduction of the adverse effect on the environment by means of producing high-quality products conforming to the European Union specification, production increase of light petroleum products with high added value, and creation of new jobs.
To implement these tasks, there were constructed new gasoline hydro- treatment facilities, diesel hydro-treatment/dewaxing, isomerisation, amine gas treatment, hydrogen formation, biological sewage treatment and sulfur recovery.
Early 2007 saw the first release of petrol conforming to Eurostandard (with sulfur content no more than 150 ppm) and diesel oil conforming to Eurostandard (with sulfur content up to 50 ppm and freezing point 35 OC). The production of leaded petrol, harmful for the environment, was discontinued which improved the quality of petrol grades Mp-80 to Mp-93/96.
Currently, in terms of Atyrau refinery development, the following projects are under way::
1. CDU/VDU crude vacuum unit reconstruction and delayed coker unit installation»
The project is under construction.
Implementation time: 2008-2010
2. «Aromatics plant construction»
Project feasibility study and design and estimate documentation were developed and approved by the RoK state expertise. Feasibility study and design and estimate documentation were compiled on the basis of process technologies of Axens licensor (France).
Implementation time: 2008 - 2013
3. «Deep conversion plant construction»
«Omskneftkhimproekt» OJS is developing the design and estimate documentation on the basis of process technologies of Axens licensor (France).
Implementation time: 2008-2014
The project’s objectives::
Balanced capacity increase up to 5 million tons per year;
Refining depth increase by 84%;
Light petroleum products production increase;
Increase of product range including benzol and paraxylene;
Motor fuel quality improvement to Euro-4 standard.
Shymkent refinery
Shymkent refinery was put into operation in 1985. The estimated capacity of the plant amounted to 6 million tons per year. In 2000, as the plant began processing Kumkol deposits’ oil, the diesel petrol and kerosene hydro-treatment sections were reconstructed.
At present, the plant’s installed capacity is 5, 25 million tenge per year. The processed oil is a combination of Kumkol deposit’ oil (80%) and purchased oil from Western-Siberian deposits (20%).
The production capacity of the plant consists of the following facilities: combination unit LK-6U (atmospheric distillation, catalytic reforming, diesel fuel hydro-treatment, kerosene hydro treatment, gas fractioning plant), residual fuel vacuum distillation and visbreaking.
In order to increase the refining depth and motor fuel volume production, in 1998 the construction of residual fuel catalytic cracking unit with capacity of 1, 8 million tons per year was started. The construction was suspended due to lack of financing. Up to 57% of incomplete construction can be used for further reconstruction.
In July 6, 2007, 50% share of «PetroKazakhstan Oil Products» (Shymkent refinery) was purchased and transferred to «KazMunayGas» JSC.
In 2009, in terms of Shymkent refinery reconstruction and modernization project, «Honeywell-UOP» (the USA) developed the project’s feasibility study.
The project’s objectives:
Increasing oil refinery estimated capacity up to 6 million tons per year;
Refining depth increase up to 90%;
Light petroleum products production increase up to 83%;
Motor fuel quality improvement to Euro-4 standard.
The term of implementation of the project: 2008-2014
Key areas of reconstruction: Catalytic cracking plant construction completion, catalytic reforming new facilities construction, hydrogen recovery, sulphur recovery, diesel fuel, avia fuel, HFC hydraulic treatment set reconstruction. Reconstruction of the existing set of catalytic reforming for isomerisation.
On completion of the project, it is planned to process 75% of Aktobe and 25% of Kumkol oil.
Pavlodar Petrochemical Plant
Pavlodar Petrochemical Plant was put into operation in 1978. The estimated capacity of the refinery plant comprises 6 million tons per year. In 1978, bitumen production unit was put into operation. 1983 saw a major expansion of the refinery, it included putting into operation a deep conversion plant, which was followed by the delayed coker plant installation. The plant processes a combination of Western-Siberian oil coming through the pipeline Omsk-Pavlodar.
At present the installed capacity of the plant comprises 5,0 million of crude oil per year.
The main technological equipment of the refinery consists of two complexes. The first one is LK-6U (atmospheric rectification, catalytic reforming, gasoil hydraulic treatment set, gas fractioning set), and the second one is KT-1 complex (vacuum distillation unit, vacuum gasoil hydraulic treatment unit, catalytic cracking and gas fractioning unit).
In September 2008, hydrogen production unit was put into operation. It enables to manage the lack of hydrogen-bearing gas for hydro-refining processes and considerably improves qualitative characteristics of finished products.
2009 saw finalising of the transaction on buying controlling stock of Pavlodar refinery.
On the basis of» Memorandum of Cooperation and Understanding concerning investments in industrial infrastructure objects in the Republic of Kazakhstan between NC «KazMunayGas» JSC ( hereinafter –KMG) and Italian Company «Eni s.p.a.» (hereinafter referred to as Eni), October 2009 marked the beginning of working-out the Development Program of Pavlodar refinery. The first stage of the Program includes development and selection of the optimal scheme of the plant modernization. The feasibility study development and the general plan of modernization are planned to be finished in 2010. Volume of investments will be determined on the basis of these documents.
Together with KMG and ENI representatives, there has been created a joint Modernization project management committee in charge of the project monitoring.
The project’s objectives::
Oil processing capacity increase up to 7,5 million tons per year;
Refining depth increase up to 90%;
Light petroleum products production increase;
Motor fuel quality improvement to Euro-4 standard.
Implementation time: 2008-2014
KazMunayGas Brand
Upon results of marketing researches of fuel retail and consumer opinion a decision was made to re-brand the gas filling stations. New design of KazMunayGas filling stations reflects innovative style and the company’s aspiration to meet the best world standards.
The first modular filling stations with the new corporate design have already come into disposal of subsidiaries of KazMunayGas-refining and marketing JSC.
The first stage of the pilot project on introduction of automation system at the filling stations was successfully completed. It will allow increasing labor productivity by 9%, decreasing losses when accepting oil products at the filling stations from fuel trucks.
New technologies will enable enhancing quality of service, oil products, decreasing consumer service time. Integrated management system meeting the requirements of ISO 9001:2000, ISO 14001:2004 and OHSAS 18001:1999 was introduced at KazMunayGas-refining and marketing JSC.
Quality walkthrough system was created from production of oil products to their sale at filling stations with the help of mobile quality laboratories (MQL) on the basis of specially equipped motor vehicles «Gazel».
Three stationary laboratories in Almaty, Atyrau and Astana are fit with equipment by well-known European and American producers (Petrotest Instruments, Grabner Instruments, Phase Technology, PSL, Varian, Mettler –Toledo and others).
Nine mobile quality laboratories are equipped with all the necessary instruments for prompt revelation of fuel quality. The laboratories can confirm or overturn ecological qualities of fuel in short time (from 20 minutes to 1 hour) such as existence of benzol, sulfut, aromatic compounds, hydrocarbons (it total over 30 parameters). All the data obtained will be the indicator of fuel safety.
Regular quality control of fuel is provided by the laboratories at all filling stations to check all quality indicators 1-2 times a month.
Free hot-line for consumer support service was introduced: 8-800-080-2222, 8-727-259-6161 (in Almaty). Any client of KazMunayGas filling stations who is not satisfied with gasoline quality, level of service, can express his wishes and proposals. The Call-center also works as information desk where one can get information about the company.
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