Caspian Energy (CE): Mr. Ismaylov, how do you evaluate the development path of Heydar Aliyev Baku Oil Refinery? 

Elman Ismaylov, Director, Heydar Aliyev Baku Oil Refinery: Heydar Aliyev Baku Oil Refinery has passed a long way of development and this year we have celebrated the 60th anniversary of the plant which was created in accordance with the former USSR Oil Industry Ministry’s Decree issued on July 29, 1953. 

But the main era of refinery’s development along with the introduction of new technologies and production facilities is inseparably associated with the name of Nationwide Leader of Azerbaijan Heydar Aliyev who personally initiated this work in 1970s.  It is noteworthy that all units currently operating at the refinery were built after 1976. 

Owing to the far-seeing policy of Heydar Aliyev, the 6MTA ELOU-AVT-6 plant was commissioned (in 1976) at the refinery within a short period of time; the process took only 2 years. 

In December 1980, the Nationwide Leader of Azerbaijan initiated construction of the catalytic reforming unit for production of high-octane petroleum on basis of the license of the American UOP Company that is considered to be a global leader in this sphere. The refining capacity of the catalytic reforming unit built in accordance with the project of the French company LITVIN totals 1mln tons. It is noteworthy that the unit was initially planned to be built at Moscow oil refinery, but later owing to personal interference of Heydar Aliyev this unique device was commissioned in Azerbaijan. 

Working in Moscow in 1980s, Heydar Aliyev kept contributing directly to further development of the sphere. Thus, a delayed coking unit was launched at BOR in 1986. Later, the catalytic cracking unit G-43-107M was commissioned in 1993 after Heydar Aliyev’s return to power. 

The Contract of the Century signed on September 20, 1994 owing to a titanic labor of Nationwide Leader Heydar Aliyev gave a new impulse to the development of both oil production and oil refining sectors in Azerbaijan. At present, Heydar Aliyev BOR is fully meeting Azerbaijan’s demand for oil products and even exporting them. 

Nowadays, the production capacity of the refinery totals 6 mln tons of oil per year. Plans aiming at the capacity growth are under development now.  Motor fuel is the main product of the refinery along with all types of petrol, diesel fuel, jet fuel as well as liquid gas, coke, black oil and other oil products. Considering the significant role the Nationwide Leader played in the history and development of BOR it has been named after Heydar Aliyev since 2004.

CE: What technological innovations have been applied and are planned to be introduced at the refinery?

Elman Ismaylov: The work on introduction of advanced technologies in production, modernization and application of automatic control systems over production processes has been carried out at the refinery in order to provide rational oil refining. The main goal for the use of latest technologies in production is to reduce operating costs, energy consumption, increase the depth of processing and produce high-quality products meeting the world standards. 

The final feasibility study of the project on reconstruction of the crude oil distillation plant ED-AVQ-6 is under development now, and whereupon the scope of reconstruction work will be determined. The future plans envisage reconstruction of the catalytic cracking, catalytic reforming and delayed coking units. This work aims at growth of the oil processing depth, reduction of energy expenditures and increase of the output of oil processing units. 

The most important task for now is the shift to the European quality standards. As you know, we produce petrol and diesel fuel meeting Euro-2 standard. Besides, our oil products also conform to Euro-3 standard on many parameters. The main operations are currently carried out in this direction and will find their solution for they are associated with the use of new technologies. We have focused our work mainly on reduction of benzol content in petrol. Its content in euro-standards makes 1%. This figure reaches 5% in our country. The second issue concerns reduction of sulphur content. In this regard, we hold consultations with UOP Company about Meroks units. The work on preparation of the feasibility study of the project is underway now. 

Another big project is the capacity growth of the catalytic cracking unit up to 3 mln tons per year. It is clear that the demand for petrol is increasing because of the growth of the automobile fleet by 50-100,000 vehicles per year. Our task is to meet the growing demand for fuel and bring the quality of oil products to conformity with Euro-3 and Euro-4 standards until the new oil refinery is launched in Garadagh which shall produce petrol meeting Euro-5 standards. 

CE: What kind of work is carried out to provide dry gas supply to SOCAR enterprises in Sumgayit?

Elman Ismaylov: In view of SOCAR management’s order to provide additional raw materials to the Ethylene-Polyethylene plant of Azerikimya PA the decision on supply of dry gas, coming out of the catalytic cracking unit, and supply of naphtha, produced by our refinery, was made. A gas pipeline and a petrol line, each, 60km long, were laid  from the Heydar Aliyev Oil Refinery towards the Ethylene-Polyethylene plant of Azerikimya PA for transportation of dry gas and naphtha respectively. 

Considering the economic importance of the project, the Heydar Aliyev Baku Oil Refinery mobilized all internal capacities. As a purchase and delivery of new equipment takes rather long time, the compressor RK-102-2 placed on the catalytic cracking unit #55 (section #100) was reconstructed for transportation of dry gas. According to the project, 92,000 tons of dry gas shall be transported to the Ethylene-Polyethylene plant. Thus, the first stage of the big project has been completed successfully. 

The second stage of the project work has been commenced after completion of the first one. It is necessary to clean dry gas from sulfur and CO2 compounds at this stage. The necessity for commissioning the monoethanolamine (MEA) treatment unit as well as designing and construction of the unit for regeneration of the saturated solution of MEA arose. The analysis of internal resources showed that regeneration of the saturated solution of MEA can be carried out on the base of the unit #54 of BOR (Baku Oil Refinery). Assembling operations of this unit are already underway. Certain equipment is bought whereupon this unit will be commissioned. All this will enable to broadly improve quality of dry gas transported to EP-300 plant in Sumgayit, and save certain reagents like caustic soda. 

During the event involving SOCAR management in July of this year that was dedicated to the 60th anniversary of the refinery, a new compressor machine on delayed coking unit #43 was commissioned. This unit will enable to change the supply direction of gas produced in this unit and used as fuel gas for furnaces. As I have already mentioned, it has already been for 2 years since the gas produced on catalytic cracking unit is supplied as a raw material to Azerikimya PA. As it showed positive results, the similar dry gas produced at delayed coking unit will also become a raw material for Azerikimya PA. We have already commissioned the unit but the adjustment work is still underway. We soon plan to start the transportation of this gas. Dry gas transportation point has already been prepared for operation. 

CE: What have been the main performance results of the oil refinery since the beginning of 2013? 

Elman Ismaylov: All production processes of the catalytic cracking, delayed coking units and other sections of the refinery have been computerized so far. Overall renovation has been carried out at workshops and production sections. All necessary conditions have been created for employees including provision of special summer, winter clothes, footwear and jackets. Milk is supplied for employees engaged in jobs with harmful working conditions. All safety regulations, quality of products and ecological requirements meet international standards at the refinery. 

The work of specialists of the refinery enables to ensure high level control over production process that also leads to achievement of positive results. The control over waste of energy, reagents and water meant for chemical purification has been increased. The percentage rate growth of output of light products after primary processing has been ensured. I.e. it is considerably higher than the plan. All production processes ensuring development of the refinery have been thoroughly analyzed. Appropriate organizational-technical measures have been worked out and introduced for solution of arising problems. 

According to the outcomes of 7 months of 2013, the management and the staff of the refinery have successfully fulfilled all the tasks and assignments of SOCAR. As the result, high performance indicators were fixed owing to maximal use of human and technical resources in implementation of the production program. 

The refinery processed 3518.5 thousand tons of crude during January-July 2013. Of this total, 2602.1 thousand tons, 907.3 thousand tons, 9.1 thousand tons fell to the share of oil, external semi-finished products and heavy pyrolysis tar respectively. Refining of raw materials grew by 10% within 7 months of 2013 compared to the figures from the same period of last year. 

Owing to optimization of work associated with the operation of the refinery, rational usage of capacities of processing units, especially catalytic cracking unit that refers to reprocessing and delayed coking processes, created were conditions for production of expensive oil products out of bright stock of heavy and light fuel oil resources obtained during refining. 

Visiting the refinery in 2004, President of Azerbaijan Ilham Aliyev highly evaluated to the work of oil refinery workers and said: “You know perfectly well that the depth of oil processing is the main indicator for workers engaged in this sphere. I am pleased to note that this indicator has exceeded 60% since 2003”. 

Fulfilling President’s recommendations, the staff of the refinery increased the processing depth up to the highest rate in 2013. Thus, following the order given by the head of the state for maintenance of the high rate processing depth as it plays an important role in oil refining industry, we raised the processing depth up to 92% in 2013. This indicator was achieved owing to the optimization of operation of production units, especially due to the growth of efficiency of oil recycling units (catalytic cracking and delayed coking). 

In general, the Oil Refinery fulfilled the production plan by 102.8% during January-July 2013. 

The fact that the refinery, named after Nationwide Leader Heydar Aliyev, has been actively developing is clear. All of it promotes further fruitful work of the personnel this year and fulfillment of all tasks assigned by the management of SOCAR.