Feedstocks and production processes

Consumption of raw and other materials

Crude oil, a non-renewable resource, is purchased for all ORLEN Group refineries as part of an integrated procurement process handled by PKN ORLEN, which buys oil from external suppliers.

Other materials used in our plants include natural gas, biocomponents and semi-finished products, exchanged mainly between the refinery and the petrochemical plants (they are not primary feedstock).

In order to protect the environment and in view of the national requirements to ensure the mandatory minimum share of biofuels in transport, in 2019 the ORLEN Group used over 850,000 tonnes of methyl esters and around 260,000 tonnes of bioethanol.

All the biofuels used by the ORLEN Group in its markets met the sustainability criteria specified in the RES Directive and Fuel Quality Directive.

Volumes of biofuels used by the ORLEN Group – biofuels meeting the sustainability criteria on the Polish, Czech and Lithuanian markets

The key objective of the ORLEN Group refineries is to make liquid fuels that meet relevant standards and regulatory requirements. All processes along the production chain are geared towards producing quality components for fuels that comply with those standards and requirements.

Crude oil is separated into fractions (distillates) in fractional distillation units.

At subsequent stages, the distillates are further processed in the following units:

• Cracking unit.
• Alkylation unit.
• Reforming unit.
• Isomerisation unit.
• Diesel fuel hydrodesulfurisation unit.
• Hydrocracking unit.
• Petroleum tar hydrodesulfurisation unit.

where the following processes occur: hydrogenation, conversion of nitrogen and oxygen compounds, cracking of paraffin, olefinic and aromatic hydrocarbons with side chains into hydrocarbons with lower molecular mass, conversion of low-octane C₅-C₆ aliphatic hydrocarbons into higher-octane isomers, dearomatisation, and demetallisation.

Also, sulfur and benzene are removed to achieve concentration levels ensuring the components meet the required quality standards. The fuel components do not contain lead.

Liquid fuels are made by blending selected components (also biocomponents in the case of some fuel types) and adding boosters and additives according to the blending formula.

The main purpose of the plant is to produce biodiesel (fatty acid methyl esters).

The key steps in FAME production include:

• Chemical degumming.
• Continuous refining.
• Esterification of fatty acids.
• Transesterification of rapeseed oil.
• Washing and drying of biodiesel.

during which the following processes occur: removal of phosphorus compounds and free fatty acids from rapeseed oil, reduction of acidity, reacting oil with methanol to form methyl esters, biodiesel washing and drying. There is no need to use desulfurisation or benzene and lead removal processes.

Crude oil is separated into fractions (distillates) in fractional distillation units.

At subsequent stages, the distillates are further processed in the following units:

• Cracking unit.
• Reforming unit.
• Isomerisation unit.
• Visbreaking unit.
• Oligomerisation unit.
• Diesel fuel hydrodesulfurisation unit.

where the following processes occur: hydrogenation, conversion of nitrogen and oxygen compounds, cracking of paraffin, olefinic and aromatic hydrocarbons with side chains into hydrocarbons with lower molecular mass, conversion of low-octane C₅-C₆ aliphatic hydrocarbons into higher-octane isomers, dearomatisation, and demetallisation.

Also, sulfur, benzene and lead are removed to achieve concentration levels ensuring the components meet the required quality standards.

Liquid fuels are made by blending appropriate components (also biocomponents in the case of some fuel types) and adding boosters and additives in accordance with the blending formula.

Crude oil is separated into fractions (distillates) in fractional distillation units.

At subsequent stages, the distillates are further processed in the following units:

• Cracking unit.
• Reforming unit.
• Isomerisation unit.
• Diesel fuel hydrodesulfurisation unit.
• Hydrocracking unit.
• Visbreaking unit.

where the following processes occur: hydrogenation, conversion of nitrogen and oxygen compounds, cracking of paraffin, olefinic and aromatic hydrocarbons with side chains into hydrocarbons with lower molecular mass, conversion of low-octane C₅-C₆ aliphatic hydrocarbons into higher-octane isomers, dearomatisation, and demetallisation.

Also, sulfur and benzene are removed to achieve concentration levels ensuring the components meet the required quality standards. The fuel components do not contain lead.

Liquid fuels are made by blending selected components (also biocomponents in the case of some fuel types) and adding boosters and additives according to the blending formula.

The table shows benzene, lead and sulfur content in liquid fuels, by Group company.

All liquid fuels made and marketed by PKN ORLEN and ORLEN Group companies as finished goods (final products ready for sale) meet the applicable legal and formal requirements and standards for benzene, lead and sulfur content.

The obligations of the ORLEN Group companies to provide information on potential hazards associated with the chemicals they manufacture or import follow from international and EU laws. The scope and division of responsibilities at the Group companies are defined in internal regulations.

Safety data sheets, developed in accordance with the REACH Regulation, are the basic source of information on the classification and hazards for the chemicals manufactured or imported by the ORLEN Group companies.

Products are classified based on research and expert knowledge of their properties, and the classification makes it possible to label them correctly (in accordance with the CLP Regulation) and identify risks in transport, based on which the dispatchers prepare the ADR labels (hazard warning labels).

Safety data sheets are mainly a source of information on products intended for industrial and professional applications. In the case of products marketed directly for use by general consumers, the relevant information is provided by ORLEN Group companies by appropriate labelling of product packaging.

In addition to pictograms, labels on product packaging contain appropriate hazard and precautionary statements (H and P statements).

Given the wide range of applications of ORLEN Group products, information on product packaging is supplemented with detailed data required under specific legal provisions applicable to detergents, fertilizers, etc.