Product responsibility

We seek to consistently reduce the energy consumption of PKN ORLEN's production units, thus fostering operational excellence.

Raw materials and products – Płock Production Plant

Raw materials and products – Płock Production Plant

The main objective of our refining operations for the next three years is to strengthen PKN ORLEN’s position as a downstream segment leader in the region through maximising production competitiveness, which is expected to result in:

  • High-margin product yield increase to 77% by 2017;
  • Energy intensity index reduction to below 88 points (based on Solomon’s methodology) by 2017;
  • Operational availability increase to 97% in 2016;
  • Efficient use of capital expenditure, which will involve reducing replacement and maintenance expenditure while stepping up capex on growth and upgrade projects (construction and launch of a Visbreaker Vacuum Flasher in Płock with a view to increasing the depth of processing and white product yields – in 2018);
  • Reduction of the refinery’s own consumption by 1.4 pp in 2017 relative to 2013.

In the area of petrochemical production, our plans for the next three years provide for operational efficiency improvement, to be achieved through increased energy efficiency and adaptation of the asset base for future investment needs. This will be made possible through:

  • Reduction in the energy intensity of key units: Olefins at the Group by at least 7%, Fertilizers by 4%, Plastics by 12%, and PX/PTA by 10% by 2017;
  • Cutting down losses and own consumption by an average of 0.02 pp pa;
  • Implementation of numerous efficiency-oriented initiatives, mainly proposed by the production staff;
  • Maintenance of the operational availability of Olefin production capacities at the Group at 95% (while adjusting the availability at BOP) and of Anwil plastics production capacities at 95.7%;
  • Larger volumes of high-margin products to be achieved through the construction of new and intensification of the existing production units.

In 2014, no new gasoline types were added to our product range, but the production volume of alcohol-containing gasolines was increased. PKN ORLEN continued the production of gasolines containing biocomponents: EuroSuper 95 gasoline with alcohol and ether, Super Plus 98 gasoline with alcohol and ether, and Super Plus 98 and VERVA 98 gasolines, which meet the requirements of the Minister of the Economy’s Regulations on the quality requirements applicable to liquid fuels.

Motor gasolines produced at PKN ORLEN S.A. in 2014 by quality and type

ProductsOutputAverage sulfur contentAverage benzene contentAverage ethanol contentAverage ETBE contentAverage alcohol content restated to include EETB content
 Mgmg/kg % (V/V)% (V/V)% (m/m)% (V/V)
Quality requirements 1)   - max. 10  max. 1.0 max. 5 max. 15
[max. 0.001 max 15 (ethers with five or more carbon atoms)
 % (m/m)]  
EuroSuper 95 245,512 8.5 0.6
(0.000852)
Super Plus 98 with ETBE content  58,936 8.0 0.4 13.52 6.1
(0.000847)
Eurosuper 95 with ethanol and ETBE content  2,016,970 8.7 0.5 4.9 3.9 1.8
(0.000874)
Super Plus 98 with Ethanol and ETBE content  101,119 7.8 0.5 4.9 5.1 2.4
(0.000781)
VERVA 98  155,843 8.0 0.3 3.0 8.3 3.8
(0.000787)

1) In accordance with the Minister of Economy’s Announcement dated May 10th 2013, concerning publication of the consolidated text of the Minister of Economy’s Regulation on the quality requirements applicable to liquid fuels (Dz.U. of September 11th 2013, item 1058), and the Minister of Economy’s Regulation of November 3rd 2014, amending the Regulation on the quality requirements applicable to liquid fuels (Dz.U. of November 6th 2014, item 1532).

Diesel oils in 2014 by quality and type

No.ProductOutput [Mg]Average sulfur content [wt %]
Quality requirements for sulfur content in diesel oil 1)-Max 0.001
1 Ekodiesel Ultra 2) (excluding diesel oil intended for storage in salt caverns) 5,701,316 0.00081
2 ON A-2 38,187 0.00081

1) In accordance with the Minister of Economy’s Regulation of May 10th 2013, concerning publication of the consolidated text of the Minister of Economy’s Regulation on the quality requirements applicable to liquid fuels (Dz.U. of September 11th 2013, item 1058).

2) Including VERVA diesel oil.

The coming years will be a sort of ‘survival test’ for Heavy Fuel Oil C-3. A step change in the quality requirements for bunker fuel is to be implemented by the International Maritime Organization (IMO), to be effected in accordance with the adopted schedule in two stages:

Stage 1 − reduction in sulfur content to wt 0.1% as of January 1st 2015 in the Sulfur Emission Control Areas (SECAs), with sulfur content for other water bodies maintained at maximum wt 3.5%;

Stage 2 − reduction of sulfur content to wt 0.5% in bunker fuel for non-SECA areas as of January 1st 2025.

Production volumes of selected refining products (‘000 tonnes)

 20132014 Change 2014/2013
Crude processed 15,182 14,278 -6%
Total gasolines 2,593 2,327 -10%
Total diesel oils 6,131 5,763 -6%
Light fuel oil 510 321 -37%
Aviation (jet) fuel 388 442 14%
Total fuels 9,798 9,020 -8%
Heavy fuel oil 3% S 1,604 1,611 0%
Ethylene 487 471 -3%
Propylene 352 340 -3%
Butadiene 53 56 7%
Benzene 193 187 -3%
PTA 566 562 -1%
Energy intensity of the Refining segment [GJ]  36,619,875 33,168,387 -9%
Energy intensity of the Petrochemical segment [GJ]  28,420,372 27,255,622 -4%

Fuel yield including flow of products between ORLEN Group production companies

It is worth mentioning that in 2014 energy intensity dropped year on year, which is attributable to a number of initiatives and process-related actions improving the efficiency of the production segment. For the coming years, energy intensity of production facilities is planned to be gradually reduced through Operational Excellence projects. The change in output volumes reflects maintenance shutdowns at the majority of Petrochemical production units.

2014 saw continued implementation of the energy efficiency improvement programme at the Płock Production Plant. Further efficiency-oriented initiatives were identified, to be carried out by 2018. They are expected to reduce the volume of steam fed to production units by approximately 135 tonnes/h, which will directly translate into reduced demand for energy generated at the Company CHP plant and lower noxious air emissions. The energy efficiency improvement programme was continued at the refinery units, with the efficiency measured with the Energy Intensity Index according to Solomon’s methodology. In 2014, the index fell by approximately 0.8 pp year on year, from 87.84 to 87.08, and is planned to be further reduced in next years. At the Petrochemical segment, work continued on improving and maintaining high energy efficiency of the key units, including the Olefins II unit, the largest energy consumer among all petrochemical units segment of the Płock Production Plant. Despite the maintenance shutdown, during which energy requirement is not offset by production, the unit recorded a year-on-year decrease in energy intensity to 23.41 GJ/Mg (C2+C3) due to the implementation of certain initiatives and process-oriented actions. The intensity was measured according to Solomon’s methodology as net energy consumption (in GJ) per one tonne of produced monomers: ethylene + propylene. Further reduction, to 21.5 GJ/Mg (C2+C3), is planned for subsequent years.

In 2014, a number of projects and initiatives were executed to mitigate our environmental impact, including:

  • Upgrade of the pyrolysis furnace BA 108 at the Olefins II unit, which made it possible to reduce natural gas consumption and CO2 air emissions by approximately 11,000 tonnes in 2014;
  • Use of gas discharged from the Ether unit in low-pressure fuel gas network; this project made it possible to reduce natural gas consumption and CO2 emissions by directing flare gas from the Benzene, Butadiene and Ether Unit (in a daily amount of approximately 11 tonnes) to the low-pressure fuel gas network, instead of directing it for combustion on flare stacks, and resulted in a decrease in CO2 air emissions by approximately 10,000 tonnes in 2014;
  • Reduction of steam consumption at process furnace air pre-heaters; with this initiative, the consumption of 0.6 MPa steam (used to pre-heat air fed to process furnaces at the Refinery units) was reduced by approximately 43,000 tonnes, and CO2 air emissions went down by approximately 10,000 tonnes;
  • Adaptation of B5-B6-B7 handling tanks, enabling post-pyrolysis oil remaining after stopping and emptying of the Olefins II unit (approximately 1,750 tonnes) to be collected and then reused during the unit start-up (earlier, the oil was directed to the discharge network for disposal/combustion or processing at the Slop Distillation unit).

Numerous investment and other initiatives enabled CO2 air emissions to be reduced by a total of approximately 63,000 tonnes in 2014.

Direct energy consumption at the Płock Production Plant and the Włocławek PTA Plant in 2014 by primary energy source

 Measurement unitDirectly purchased energyDirectly produced energyDirectly sold energyTotal direct energy consumption
Natural gas1)  GJ 29,001,087 0 0 29,001,087
Fuel gas2)  GJ 0 25,492,985 878,225 24,614,760
Fuel oil  GJ 0 2,664,770 0 2,664,770
Electricity  GJ 1,683,109 6,104,948 1,676,897 6,111,160
Heat3)  GJ 381,514 49,034,107 3,757,576 45,658,045

1) Gas purchased from PGNiG for the Płock Production Plant and the Włocławek PTA Plant.

2) Low-pressure and high-pressure fuel gas at the Płock Production Plant.

3) Heat in the form of steam and hot water at the Płock Production Plant and the Włocławek PTA Plant.

Płock Production Plant

 Measurement unitDirectly purchased energyDirectly produced energyDirectly sold energyTotal direct energy consumption
Natural gas1)  GJ 28,123,419 0 0 28,123,419
Fuel gas2)  GJ 0 25,492,985 878,225 24,614,760
Fuel oil  GJ 0 2,664,770 0 2,664,770
Electricity  GJ 1,295,321 6,040,868 1,676,897 5,659,292
Heat3)  GJ 200,838 44,747,849 3,757,576 41,191,111

1) Gas purchased from PGNiG for the Płock Production Plant and the Włocławek PTA Plant.

2) Low-pressure and high-pressure fuel gas at the Płock Production Plant.

3) Heat in the form of steam and hot water at the Płock Production Plant and the Włocławek PTA Plant.

Włocławek PTA Plant

 Measurement unitDirectly purchased energyDirectly produced energyDirectly sold energyTotal direct energy consumption
Natural gas1)  GJ 877,668 0 0 877,668
Fuel gas2)  GJ 0 0 0 0
Fuel oil  GJ 0 0 0 0
Electricity  GJ 387,788 64,079 0 451,868
Heat3)  GJ 180,676 4,286,258 0 4,466,934

1) Gas purchased from PGNiG for the Płock Production Plant and the Włocławek PTA Plant.

2) Low-pressure and high-pressure fuel gas at the Płock Production Plant.

3) Heat in the form of steam and hot water at the Płock Production Plant and the Włocławek PTA Plant.