| www.eJournalnet.com | Issue 3 - 2002/03 | ISSN 1311-8978 |
organization the production of fuels in “lukoil neftochim bourgas” ad in accordance of the european envinronmetal standards Stefan G. Petrov, Lukoil Neftochim Bourgas AD Antony M. Donov , Lukoil Neftochim Bourgas AD Dicho S. Stratiev , Lukoil Neftochim Bourgas AD Received: 25.10.03; Cited: 05.12.03
Abstract The “lukoil neftochim bourgas” politics is closely connected to the state strategy in the area of commercial and environmental safety and the rational use of the natural resources.The most important targets of “lukoil neftochim bourgas” in the field of environmental protection are:Complying the existing methodological basis with the international standards – EN, ISO, ENISO, ASTM, API Introduction of the world quality certification systems ISO 9001:9001 Stabilization and consequential reduction of the quantity and the toxicness of the detrimental substances by applying of new progressive technologies and processes. Reduction of the load on the environment during introduction of new objects by implementation of environmental expertise.
The atmosphere protection from pollution is an environmental approach, which will be dominating one in the policy of EC during present century. This approach will also impact the policy in fields of distribution of energy, transportation and development of different countries. The activities of the Society for atmosphere protection are related to different problems as: limitation of process of ozone reduction in stratosphere, control of acidification and other pollutants, as well as climatic conditions changes. During the last decade in this direction some very important steps have been made, but still there is no considerable environmental improvement regardless of emissions reduction to atmosphere and water of quite high number pollutants as sulphur dioxide (50 % reduction, compared to the level of 1980), lead (60 % reduction, compared to the level of 1980). The air pollutants, coming from different sources can be divided in three large categories: emissions from different sources - transportation vehicles; · emissions from stationary sources - industrial, public services, agricultural and waste disposal sites; · emissions from heating and power stations; The high concentrations of these gases, resulting from the emissions are dangerous for human health and vegetable kingdom; they have aggravating effect on the agricultural production and are provoking the "green house effect". Besides this they are cause for materials corrosion. The sulphur issue in gasoline and diesel fuels, connected to the market and in particular to the evaluation of gasoline and diesel motors and different technologies for reduction of their emissions are suggesting that it is possible to achieve positive results by use of fuels with sulphur content below 50 ppm. In May 2001 were finalized the suggestions for Auto Oil II. These directives lay the beginning point for the requirement, stating that in year 2005 the sulphur content in gasolines and diesel fuel should be 50 ppm, with some categories even to 10 ppm. The limit of 10 ppm will be mandatory in year 2011. During 90's in Europe there was quick reduction in the production of lead-containing gasolines. In 1990 in EC countries the share of leaded gasolines was 85 % , and in 1997 this portion dropped to 35 %. According present expectations in year of 2005 the production of leaded gasolines will drop to 5 % and in 2010 will become 1-2 %. At the same time the problem with reduction of sulphur content in fuels became subject of higher consideration. The European Commission laid down limits for sulphur content in gasolines and diesel fuels. In 2000 the sulphur content can not be higher than 150 ppm. For 2005 this limit for the gasoline will be 50 ppm. For diesel fuels the values are 350 and 50 ppm respectively (Table 1).
Pertinent specifications for gasoline and diesel fuels - limits
The trends in Europe for the demands of primary light products, gasoline and diesel are closely related. The higher market share of diesel fuel in Europe is due to the smaller portion of passenger vehicles per capita of the population, lack of very large machines, using gasoline and the high percentage of commercial auto transportation, realized by large machines with diesel fuel. From historical point of view, the diesel machines are with higher emission values of particles and hydrocarbonates, which cause pollution, very typical for residential regions. During the previous years a lot of efforts were made in purpose to improve the environmental aspect of diesel motors employment and other characteristics as low acceleration, high noise level and higher initial costs. All these characteristics make those motors unattractive for the user. It is generally accepted that the distribution of diesel cars is already competed and in the period up to year 2010 there will be slight change in he ratio of diesel / gasoline automobiles. In general the retail prices of diesel fuel are 15 - 30 % lower, compared to the one of lead-free premium gasoline. Furthermore, the taxes portion in the general price of diesel fuel is about 10 % lower than the portion in gasolines. Both factors are with favourable effect on the dynamics for development of automobile park with diesel motors. The dynamics of consumption of motor gasolines for different regions shows drop in the demand for motor gasolines in Western Europeans countries. This drop is dependent on the higher number of diesel automobiles and relative rise in the consumption of diesel fuel. Having in mind the total intensive economical development, the expansion of automobile and tractor park with diesel motors is expected to continue in the period of 2005 - 2010 .
Gasoline Taking into consideration the above mentioned, there are reasonable expectations that the treatment units of FCC plants will be modernized in a way, that will permit higher sulphur removal in production of cracking gasoline. As in treatment of cracking gasoline, it will be necessary to modify the processes for LPG removal from the streams. This will be done in purpose to remove the sulphur in the butane and components of LPG gasoline as alkylate and MTBE and to reach sulphur content of 20-30 ppm. After performing these comparatively inexpensive modifications, it will be necessary to make hydrodesulphurization of the gasolines, remaining fromFCC. This technology is still under development, but it can be assumed that one process like that will be used for production of gasolines with sulphur content of 50 ppm. Sulphur reduction to 10 ppm will demand utilization of more severe hydrotreatment process, which is related to a certain decrease of octane number. The capital investment costs for preliminary treatment of FCC feedstock are considerably higher, but in many cases the results of such treatment are better yields. These improved yields can make the investment costs quite attractive from economical point of view.
Diesel fuel There are already existing diesel fuels hydrotreating units, operating at medium pressure in the range of 50 - 60 bars. The refineries, that are generally accepted as a measure for production of high quality product will require only additional catalyst volume , employment of high activity catalyst and some improvements in hydrogen treatment units. Many experts believe that production of gasoline and diesel fuel with sulphur content below 10 ppm is technically possible by use of proven processes. The focal point of gasoline desulphurization is the components, produced in FCC and Steam Cracking where the sulphur removal is 99 %. Contrariwise, all diesel components contain sulphur and require hydrodesulphurization treatment. This can create a problem with satisfying market demands, in case that there would be earlier legislation of 10 ppm sulphur limit. The main question, arising when there is sulphur reduction in gasoline is the possibility for octane number decrease, which is minor as a value, but important from quality point of view. In configuration of refineries the only component with sufficient volume, which could compensate this decrease is the reformate. This reformate could increase the aromatic content. This is against the existing fuels standards, which require reduction of aromatics from 42 % in year 2000 to 35 % in 2005. One alternative approach to solve the problem with the decrease of octane number would be the addition of alternative oxygen containing components. This alternative could become source of problems, related to pollution of environment in case of spill and contamination of underground waters. If the employment of aromatics and alternative oxygen containing components will be excluded, in purpose to recover the octane rating for gasolines with low sulphur content a substantive capital costs will be required for installation of akylating units. The sulphur reduction in diesel fuel could change the cetane number, polyaromatic hydrocarbon content, lubricating properties and density. The reduced density and cetane number could cause lower motor power. The reduced greasing ability will provoke quick wearing out of the combustion systems. An estimation was made of planning of the production and research activities of new projects for crude oil processing. The companies, engaged in crude oil processing will continue to use modern technologies and to revamp existing units in purpose to increase the capacity, which will cover the future demands. Some experts believe that very soon in purpose to reduce sulphur content in gasoline and diesel fuel it will be necessary to install additional equipment for desulphurization in each refinery. It will be required to repair or to provide equipment for processing, blending and distribution.
Environment monitoring in East Europe In East Europe, particularly in Sofia, the Local Air Quality Group (SILAQ) activity is of vital importance. The management of the working group is in Bulgaria, with representatives of Czech Republic, Hungary, Poland, Rumania and Slovenia. The SILAQ initiative is aiming to improve quality of atmospheric air, considering two issues of great significance : - expertise in use of unleaded gasolines. - reduction of emissions of sulphur and solid particles . For implementation and stringent applying of the required procedures for improvement of population exposure to the impact of lead emissions is indispensable to keep one severe politics for observation of responsibilities. One of this responsibility is the harmonization of legislative framework in the countries of SILAQ with those, applicable for EC. One of the most important priority in the countries-members of SILAQ is the harmonization of legislative frame work with the one in EC. Most of the countries had already accepted the EC specifications. The acceleration of this procedure in the stage of lead removal, as a part of the harmonization process will simplify the acceptance of this countries in EC. In each country, member of SILAQ , the limit, defined by EC for lead content of 0,15 g/l in leaded gasoline and 0.013 g/l in unleaded one have been already accepted or will be accepted in near future. In purpose to fulfill this task, a long period of time will be required, applying an approach, based on new technologies because of the high number of old automobiles. All countries - members of SILAQ are intending to suspend the use of leaded gasoline not later than year 2003. The shortage of cash resources is significant obstacle in the countries - members of SILAQ, especially in Bulgaria and Rumania. The modernization of existing refineries, aiming production of unleaded gasoline is technically possible, but this procedure requires substantial capital investments. In case of implementation of appropriate stimulating combinations and more stringent legislation the refiners will be in more active search for financing sources. At present time LUKOJL NEFTOCHIM BOURGAS - AD processes about 5.5 millions tons of crude oil. This quantity is determined on the basis of optimum capabilities of deep processing complex, having in purpose maximum yield of light products like gasolines, jet fuels and diesel fuels. The units loading is directly related to the consumption of gasolines, diesel and other fuels - local and for export and for supplying of petrochemical and polymer plants with necessary feedstocks. The refinery's general process diagram contains units for production gasolines, diesel fuels, jet fuels gasoil for industrial and public purposes, boiler and marine fuels, bitumens and corresponding units (Gas Treatment, Hydrogen Unit, Sulphur Recovery). The produced fuels are with qualities in accordance to the international standards.
MAIN OBJECTIVES for organization of fuels production in LUKOIL NEFTOCHIM BOURGAS AD in accordance with European Environmental Standards : · Production of high quality fuels in a safe way with minimum negative impact on the environment during their production and use; · To ensure competitive capabilities of the produced motor fuels in the conditions of the European and international markets;
MAIN TASKS · Revamp of Catalytic Reformer Unit with continuos catalyst regeneration (CCR) and capacity increase up to 600 000 metric tons per year; · Revamp of complex Catalytic Cracking by implementation of moderate hydrocracking and capacity increase up to 2,0 millions tons per year; · Planning of quality parameters of the produced fuels on the basis of careful consideration of European market requirements; · Increase of high octane gasolines shares; · Reduction of low octane gasolines; · Introduction and maintenance of quality control system according requirements of ISO 9001:2000; · Implementation of laboratories and test methods in accordance with requirements of European and International Standards.
ANTICIPATED RESULTS · The motor gasolines will be compatible with quality requirements of EC; · The whole gasoline pool will be with octane rating over 95 by research method (RM); · Suspending of leaded gasoline production; · Flexibility of gasolines and diesel fuels production, depending on the market demands; · Increase of fuel gas production.
QUALITY POLICY OF LUKOIL NEFTOCHIM BOURGAS - AD The priorities Lukoil Neftochim Bourgas AD in respect to the management of the products quality and improvement of the reputation are as follows:
· modification of existing methodological basis for quality determination of final products in accordance with requirements of International Standards - EN, ISO, EN ISO, ASTM, IP; · meeting the requirements of world certification systems ISO 9001:2000 and ISO 14 000 (ISO certificate 9001:2000 was awarded on April 21st, 20020); · improvement of prevention philosophy for reduction of second quality products and prevention of claims;
Motor gasoline production Alternative 6000 tons crude oil
(Catalytic reformer 500000 tons, 90 - 170° C, benzene in reformate 4 %,; 105 -170 benzene in reformate 2.6 %) Catalytic cracking 1500 thousands tons - benzene 0,6 % )
Components Quantity, tons IBP 180 102535 C5 from xylenes 9747 Reformate 354200 MTBE 46793 Alkylate 153331 Naphtha from FCC 736911 Extraction gasoline 4000 Stock motor gasolines 1407519 Quality parameters of gasoline pool
Research Octane 94.46 Benzene 1.341 Aromatic Hydrocarbons 34.2 Unsaturated Hydrocarbons 19.2 Sulphur 0.03032
1 - 0.86 % in benzene level in reformate of 2.6% 2-50 ppm after desulphurization of naphta from Topping Unit and FCC
Parameters of components for stock diesel fuels and light heating oil (LHO) (existing capacities) Alternative 6000 thousand tons crude oil
Technical and Environmental Requirements for Diesel Fuels 98/70/EC - 13.10.1998
At present Lukoil Neftochim Bourgas AD produces for export diesel fuel with sulphur content of 350 ppm, which is corresponding to EN 590. On April 27th, 1998 by Directive N173 of the Council of Ministers was accepted National Program for gradual suspension of production and use of leaded gasolines in Republic of Bulgaria. This directive determines responsibilities of Lukoil Neftochim Bourgas AD as follows: - not later than 31.12.2002 to ensure production of 80 % unleaded gasolines from the total production; - not later than 31.12.2003 to suspend the production of leaded gasolines. Lukoil Neftochim Bourgas AD produces unleaded gasolines ahead of timing requirements of the National Program. It can be stated that Lukoil Neftochim Bourgas AD meets the requirements of Bulgaria for unleaded gasolines and diesel fuels and exorcize persisting efforts in improvement the quality by implementation of new process solutions for increase the octane rating and reduction of sulphur content. As a conclusion we can remark that the production of motor gasolines and diesel fuels is very dynamic process and is strongly affected by factors like price, market, environment and etc. This, of course, reflects on the quality and product range. The continuous increase of the requirements for fuels quality, dictated by European Directives for protection of environment from toxic components creates serious problems for the refiners and their profit. Taking in consideration the persisting stringent environmental legislation for limitation of the emissions it will be required considerable capital investments. Regardless of the fact, that there are available ready-to-use commercial technologies for production of diesel fuel with ultra-low sulphur content, the final selection of the approach or combinations to reach this will be very specific, which is due to the unique combinations of feedstocks, operating units and market demands.
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