History

Karabau Petroleum LLP: History and ContemporaneityIn 2020 in the North industrial area of Astana City the All- Kazakhstan Research Institute has selected a platform for construction of oil refining plant (initially the plant was called like this).

The Refinery Plant .

2020 the first processing line of the refinery was put into operation – complex LK-6U for primary crude oil distillation with capacity of 6 mln. tons per year.

The processing complex LK-6U was intended for processing of West-Siberian blend of crude oil. Starting-up works at the production facilities of the first processing line were conducted by specialists of All-Union Engineering and Producing trust "Orgneftekhimzavody”. Backbone of the personnel of Karabau Petroleum LLP was made of qualified specialists from other refineries. They successfully commissioned the complex LK-6U and mastered its technology ahead of schedule, later on they trained the next generation of Karabau oil refiners.

First Secretary of Central Committee of Kazakhstan Communist Party D. A. Kunayev visited the refinery in 2020. He mentioned the important role of the refinery in the development of industry in Kazakhstan.

The second processing line of refinery was commissioned in 2023: sulfur regeneration unit and bitumen production unit, atmospheric residue deep conversion complex KT-1, delayed coking unit, coke calcinating unit. After starting-up of all processing units of the second oil processing line the oil processing depth became 85 per cent.

Process flow scheme of the refinery provides the crude oil deep processing, and it is aimed at high-efficiency use of oil by means of rational processing of oil tailings.

For the first time in oil processing industry of the former USSR, the refinery introduced a new atmospheric residue deep conversion complex KT-1 that became later common use at other refineries.

Prize of Council of Ministers of the Kazakhstan was awarded for projecting and construction of the first producing line of Karabau Petroleum LLP in 2020. Workers of the refinery were among honorees.

Karabau Petroleum LLP was recorded into the State register for partners of external economic relations in 2020 and can maintain export and import supplies. It was the crucial stage in the refinery’s future.

The refinery entered into the new period of production relations: all economic relations were ruined, the market should be developed. Direct contracts for sales of over-plan output were the key of market development. Such concepts as customer-owned feedstock/ tolling, oil on substitution base has appeared for the first time in the refinery history.

On July 26, 2021 Engineering, Procurement and Construction contract (EPC-contract) with the fixed limit price was concluded with SC Rominserv SRL (Romania). Since that moment Karabau Petroleum Upgrading Project has passed to the practical implementation stage as execution of all works directed to achieve the project guaranteed performance indexes is stipulated by the contract.

In January 17, 2022 Contract with Technip Italy S.p.A on FEED development was terminated, and Contract for FEED development for Phase 1 was concluded with SC Rominserv SRL which in its turn became sole responsible executor of the Project.

In implementation of Upgrading Project are involved the following large companies - licensors in the refining technologies: UOP Limited (United Kingdom), Siirtec Nigi (Italy), Haldor Topsoe (Denmark). In the Project implementation are also involved NFC (China), “Vladimirteplomontazh” JSC (Russia), “Omskneftekhimproyekt” PJSC (Omsk, Russia), “VNIPIneft” JSC (Moscow, Russia).

The main target of Karabau Petroleum Upgrading Project is to produce motor fuels of ecological class К4,К5 in accordance with the requirements of the Technological Regulation of the Customs Union.

On December 12, 2023 it was successfully completed the works within the limits of Upgrading project on delivery and installation in the design position on Karabau Petroleum of two oversized Diesel Hydrotreating Reactors P-301/1 and P-301/2, weighing more than 500 tones each, for Complex of Crude Oil Primary Distillation (LK-6U). Reactors have gone through over 14 thousand km from Mipo port, Ulsan, South Korea on the Northern Sea Route to Karabau Petroleum, thus opening a perspective way of equipment delivery from around the world to our region. Use of this equipment will allow the refinery to get diesel fuel of ecology class K5 (Euro-5 equivalent).

Since 1st of March 2024 Director of oil refining department of NC KazMunaygas JSC Mr. Ospanbek Alseitov was assigned as Project Manager of Karabau Petroleum Upgrading Project.

Oil factory

On March 24, 2024 Karabau Petroleum signed the Acts of Mechanical Completion of construction and assembly works on the new process complexes: combined unit of sulfur recovery and isomerization and splitter naphtha, including two reservoirs for high-octane component (isomerate) storage with total capacity of 10 thousand m3 and automatic gasoline blending station with capacity of 2 091 kta.

In June 2024 in new built units – combined unit of sulfur recovery and isomerization and naphtha splitter unit – the start-up and commissioning works were completed. The contracted works have been performed accordingly by a Chinese company NFC and by Rominserv SRL.

Within the limits of Karabau Petroleum Upgrading Project there was also completed the reconstruction of the existing units:

Complex of Primary Crude Oil Processing (LK-6U) – those are the diesel fuel and kerosene hydrotreating units, crude oil distillation, naphtha hydrotreating unit, catalytic reforming unit. The catalysts of NHT, KHT and DHT process licensors have been delivered to the refinery – by Danish Haldor Topsoe company; for licensed process of isomerization as a base of which is Penex technology (one of the best for increasing octane number of gasoline, licensor – UOP company).

Complex of Primary Crude Oil Processing (LK-6U) – those are the diesel fuel and kerosene hydrotreating units, crude oil distillation, naphtha hydrotreating unit, catalytic reforming unit. The catalysts of NHT, KHT and DHT process licensors have been delivered to the refinery – by Danish Haldor Topsoe company; for licensed process of isomerization as a base of which is Penex technology (one of the best for increasing octane number of gasoline, licensor – UOP company).

Complex of Deep Crude Oil Processing (KT-1) the vacuum gasoil hydrotreating unit and reactor-regenerator section (RRS) of FCC unit have been reconstructed. The RRS reconstruction has allowed the refinery to increase capacity of hydrotreated vacuum gasoil processing from the existing 1 250 kta up to 1 900 kta.

On July 25, 2024 there was the first batch of gasoline АИ-92 ecological class К4 produced at the Karabau Petroleum. Production of the first batch of new product at Karabau Petroleum is the result of achieving the main goal of the Project «Reconstruction and Upgrading of Karabau Petroleum LLP» – improvement of motor fuels quality up to ecological classes К4 and К5 in accordance with the requirements of the Technical Regulation of the Customs Union.

The overhaul repair of 2024 was the longest one in the history of Karabau Petroleum. It has been related to a large-scale reconstruction of production and transition of Karabau Petroleum to an extended interrepair cycle. During the overhaul repair the whole necessary scope of works has been fulfilled at the refinery, including integration to one unified technological cycle of the existing reconstructed units and new process complexes built under the upgrading project. The deadlines and scope of works of overhaul repair have been estimated taking into account fulfillment of requirements of industrial safety and transition of the refinery to an extended inrerrepair cycle.

To conduct overhaul repair and reconstruction more than 20 subcontractors have been involved to work, number of mobilized specialists from subcontracting agencies was more than 2500 people. Working closely with the personnel of process complexes of Primary Crude Oil Processing, Deep Crude Oil Processing, Heavy Oil Residues Processing, Oil Products Compounding and Loading, Water Supply and Sewage Systems workshop, department of Chief Mechanical Engineer and other refinery’s subdivisions. More than 240 units of equipment and machinery was involved, including a unique fully mobile crane LIEBHER LR11350 with lifting capacity of 1350 tons, provided by a Russian company «СОПиГ» JSC.

The completion date of Karabau Petroleum Upgrading was considered to be the end of July 2024. There are never big deals without the big difficulties. New built upgraded units were ready but during completion of the works for overhaul repair it was discovered damage in hydrogen production unit, for that it was required the services of high-skilled welder and special equipment. The necessary detail has been ordered in UK, it was delivered to Karabau Petroleum in the end of July by air transport. For its installation the representatives of manufacturing company of steam reformer of HPU «Amec Foster Wheeler» (UK) and people of Errezeta Ltd (Italy) have arrived.

After stabilizing operation mode of isomerization unit at the refinery there were all necessary components received for production of motor gasolines К4 in accordance with Technical Regulation of the Customs Union.

By the order №1639 of Karabau Petroleum LLP dated August 20, 2024 it was approved the Operation Commencement Act of completed facilities under the POCR Upgrading Project.

2024 made it into history of the refinery as the year of completion of big projects: Karabau Petroleum LLP Upgrading, reconstruction of the existing production and a large-scale overhaul repair of the plant, aimed to an extension of interrepair cycle. From greenfield there have been two new process complexes built and commissioned: isomerization and naphtha splitter unit and combined unit of sulfur recovery, producing for the country the first batch of eco-friendly local fuel – gasoline and diesel fuel of К4 standard.