Short introduction of MOL Duna Refinery

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Short introduction of MOL Duna Refinery

• 30th October, 2004 Százhalombatta
• László Lázár
• Chief Engineer (HU)

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An evergreen question...
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Refining from very technical point of view
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Another way of presentation...

• From Crude Oil to Gasoline
• Chemistry for non chemical engineers
• How Oil Refining works?
• Basic terms, main processes
• Danube Refinery
• Simplified schema
• Units, hazards
• Recent projects
• Logistics
• Production slate, margin
• Organizational chart

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The beginning Crude Oil

• Currently the majority of
• energy consumed by humans
• is produced by fossil fuels.
• 35 of this consumed energy comes from crude oil.
  It is also the main ingredient for many products
  such as plastics, paints, medicines, lubricants,
  etc
• However, crude oil in the unrefined state has
  very limited uses.
• Consequently crude oil must be refined to obtain
  salable products with the desired quality and
  quantity.

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Some chemistry
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From Crude Oil to Products
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The Refining Process

• Physical process (separation)
• desalting
• fractional distillation
• extraction
• blending
• Chemical process
• cracking (thermal or catalytic)
• alteration (reforming)
• unification (alkylation)
• modification (isomerisation)
• treatments (hydrotreating)

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Cracking
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Reforming
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Conclusion

• It is necessary to refine crude oil to attain
  marketable products desired by the public.
• This can be accomplished by using an integrated
  group of manufacturing plants .
• There are many configurations, as well as
  equipment and process variations that have not
  been covered.

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Duna Refinery, Százhalombatta

• Established in 1960
• Commissioning of its first distillation unit
  (AV-1) 1965
• Present distillation capacity 8,3 Mt/year
• At present, the only crude processing refinery in
  Hungary
• Production of fuels and base oils

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Simplified schema of Duna fuel Refinery
Fuel gas
Gas fractionation
Iso- merisation

CCR
Hydro- treater
Components of gasoline and naphtha, aromatics
Alkylation
HDS, MIC
FCC
ETBE
MTBE
Atmospheric and Vacuum Distillation
Crude
Components of Diesel
HDS, HDA
Hydro- treaters
DC
Coke
Fuel oil, S lt 1
New projects
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Processing Units at MOL's Duna Refinery
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Processing Units at MOL's Duna Refinery
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Processing Units at MOL's Duna Refinery
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Processing Units at MOL's Duna Refinery
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Processing Units at MOL's Duna Refinery
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The most up-to-date unit of the refinery Delayed
Coker with a processing capacity of 1 million t
heavy fuel oil
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Economical effect of DC commisioning
The Change in Product Slate Resulted in about HUF
10 Billion Profit Increase
Refinery margin increased from USD/bbl 1.92 to
2.86
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Why is oil refining a hazardous industry?

• Hydrocarbon gases liquids, and solid materials
• Total volume of Tank Farm appr. 2.5 million m3
  (348 tanks)!
• Stocks inside battery limits is much more lower
  appr. 0.03 million m3
• Conditions of processing
• Temperature till 800 oC
• Pressure till 80 barg
• but no (or only controlled) access to oxygene

• Fire conditions
• Flammables Combustibles
• Ignition temperature
• Oxygen

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Equipment numbers at production plants
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Complexity and hydrotreating ability of European
refineries
Source based on OilGas Journal capacity figures
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Position of the Hungarian Oil Industry in Quality
Improvement

• Hungarian Government follows development
  tendencies in the World and Europe- undertook
  compliance with EU 2005 air pollution
  directives- did not apply for derogation in
  fulfilment of fuel quality requirements,
  either
• MOL's development strategy compliance with EU
  2005 quality requirements necessary refinery
  investments - gasoil desulphurisation plant
  (2200 kt/y) - gasoil blender - hydrogen
  plant (44 kt/y) - gasoline desulphurisation
  plant (820 kt/y)

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Gasoil Blending Unit after revamp
ANDERES 0.1 S
SULPHUR AN. 500-2000 ppm
PIC
LLSG
BLEND HEADER II
DIN 0,2 S
P362 I/II
P305/6
ADDITIONING CFPP WASA CETANE HFRR CONDUCT DEHAZE
LLSP
PIC
ETO
P358/359
LSGO
FTNIR CFPP CLOUD P. FLASH P. DENSITY DESTILL. CET
ANE HFRR POLYAROM.
VGO
P351/352
HSP
P360/359
HSGO
P357 I/II
HDS
P353/354
LCO
PIC
DIESEL 10 ppm
P356 I/II
SULPHUR AN. 0-15 ppm
BLEND HEADER I
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Actual quality of DIESEL in Duna Refinery
From the beginning of September Danube Refinery
is producing DIESEL below 50 ppm S
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Crude oil pipeline system
Barátság I.
Barátság II.
Eger
TF
DF
Hajdúszoboszló
ZF
Füzesgyarmat
Gellénháza
Zalakomár
Szank
Kardoskút
Sávoly
Szokedencs
Bázakerettye
Algyo
Kiskunhalas
Adria
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MOL refineries, depots and product pipelines
NA300
Nyírbogdány
NA200
Tiszaújváros
Komárom
Füzesabony
NA200
NA300
Gyõr
Ebes
NA150
NA200
NA300
NA300
NA150
Csepel
Szhbatta
Ferihegy
NA150
Vép
Székesfehérvár
Szajol
NA300
NA150
NA200
Kecskemét
Zalaegerszeg
NA300
Algyõ
pipeline
Dombóvár
depot
NA200
refinery
Pécs
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Product slate of MOL refineries in 2000-2003
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Net Cash Margin in MOL's Peer Group (2002)
Assesment on cost of crude, crude delivery costs,
configuration and location, MOL is the best in
Peer Group
European Refining - Wood Mackenzie, May 2003
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MOL Group organizational chart
Executive Chairman CEO
GCEO
Strategy business development
Finance
Exploration and production
Refining and marketing
Retail services
Natural gas
Internal audit
Corporate center
MOL Romania srl.
Lubes
Petchem
Slovnaft Polska s.a.
Legal
Enterprise relations
Slovnaft Ceská republiká, s.r.o.
Health, safety and environmental protection
MOL Slovenija
Security and protection
Human resources
MOL Agram
INTERMOL
Corporate communication
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Refining
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Thank You for the Attention!