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Fuel Production

PKN ORLEN, in accordance with legal provisions in force, was obliged in 2011 to fulfil the National Index Target. In 2011, the fulfilment of the National Index Target was 6.209% energ. (required level was 6.2). Reserve in fulfilment of the National Index Target as per BIO100 was 989 tonnes.

In total, in 2011 the Company released to the market:

  • 2 402.4 thousand tonnes of petrol with biocomponents,
  • 6 339.1 thousand tonnes of diesel fuel with biocomponents,


  • 131 thousand tonnes of ethanol in petrol,
  • 304 thousand tonnes of esters in diesel fuel,
  • 221 thousand tonnes of ester fuel – BIO100,
  • 11.3 thousand litres of BIO85 (pilotage).


In 2011, the Refinery put great emphasis on maintaining high and effective oil processing. A new sulphur utilisation unit – Claus II, one of the biggest units of this type in Europe, was launched in October at the PKN ORLEN Production Plant. Output capacity of the new unit is twice bigger than of any of the already operating Oxyclaus and four times bigger than a single Claus. It should be emphasised that Claus II is included in the list of the consistently implemented Programme for Environmental and Power Engineering Investments.

One of the major completed investment tasks was start-up of the HON VII unit. In 2011, in the Refinery Plant the Company undertook modernisation works the HF Alkylation unit, planned to be completed in 2012.

At the Production Plant in Płock the Company is implementing the Programme for Environmental and Power Engineering Investments at the combined heat and power plant. It constitutes the basic source of heat and electricity for production units at the Production Plant in Płock, external recipients connected to the PKN ORLEN network and the city of Płock in the scope of heating water supplies.

In accordance with the Directive 2010/75/EU of the European Parliament and of the Council of 24 November 2010 on industrial emissions, as from 1 January 2016 the volume of concentrated emissions from combustion process (sulphur dioxide, carbon monoxide and dust) from boilers of the combined heat and power plant must be reduced by about 90%. Such big reduction of emissions will be possible due to completion of new units covering the wet flue gas desulphurisation unit, flue gas catalytic denitrogenation unit and enclosure of electrofilters, which will allow to adjust the CHP plant to the new standards.

The Company continues the tendering process for selection of a contractor for construction of the flue gas catalytic denitrogenation unit and the flue gas desulphurisation unit. Conclusion of contracts for furnishing of these units is planned in mid-2012.

In order to satisfy the growing needs of the Production Plant in Płock for power media, the Company continues the construction of the steam boiler (K8) with a power of 300 MWt, whose start-up is planned for 2012. It will meet the most stringent environmental requirements for emissions of sulphur dioxide, nitrogen oxides and dust. The new unit should be put into operation in mid-2012. After the start-up of the new boiler, the Company plans to turn off, one by one, the existing boilers to adapt them to environmental requirements provided in the Directive 2010/75/EU in the scope of NOx and dust emissions.

In 2011, production and sale of Super urban diesel oil was replaced with winter diesel oil ON Ekodiesel Ultra, class 2 (arctic) with improved low-temperature properties.

 Production volume of selected refinery products in 2010 – 2011 (Płock, in ‘000 tonnes)

  2010 2011 Dynamics 2011/2010
Crude oil processed 14 452 14 547 1%
Total petrol 2 736 2 469 -10%
Total diesel fuel 5 359 5 646 5%
Ekoterm Plus heating oil 699 372 -47%
Aviation fuel 394 393 0%
Propane-butane fraction 241 186 -23%
Total fuels 9 429 9 066 -4%
Fuel output (%) 78.0 76.1 -1.9 p.p.

Rafineria Trzebinia

In 2011, Rafineria Trzebinia focused on ensuring the company’s competitiveness and adequate efficiency of activities in such key areas as: biofuels production, crude oil processing, paraffin hydrorefining and fuel terminal services. The year 2011 was the first year of implementation of the strategy of Rafineria Trzebinia Capital Group for the years 2011 – 2015.

In order to increase the Company’s value and its competitive position on the market Rafineria Trzebinia works towards diversification and expansion of the area of operations. The Company aims to achieve an appropriate level of operating profitability through cost optimisation, intensification of the use of infrastructure, technological progress and implementation of new initiatives. An important factor is achievement of optimal parameters in the scope of volume and efficiency of biofuels production, crude oil processing, use of logistic potential and sale of products from its own units.

Modifications of the BIO unit elements, cost and technological optimisation as well as monitoring of production processes enabled the company to fully use its production capacity in 2011. In subsequent years the company foresees intensification of production capacity of esters.

In 2011 the company produced 116 000 tonnes of fatty acid methyl esters constituting biocomponent to conventional diesel oil. They were also used as self-contained fuel under the trade name Bioester or commonly labelled BIO100. Another stream of production and sale was biofuel constituting a mixture of 80% of conventional diesel oil and 20% of biodiesel designated in the commercial offer as BIO20.

Paraffin production

Paraffin hydrorefinement is performed at the only unit of this type in this part of Europe, launched in 2005, which enabled the company to become the most modern entity in the paraffin industry in Central and Eastern Europe. Paraffin production in 2011 amounted to almost 48 000 tonnes.

It is possible to guarantee safety and the highest quality of products from this segment due to modern units, experience of qualified employees and selection of the best suppliers of high-quality raw material for production. In the case of paraffin, the agreement for slack wax supplies concluded with ORLEN Oil ensures access to perfect-quality material for processing, simultaneously building the value chain of ORLEN Group.

Certificate of Business Credibility for high rating of the company’s stability was awarded in 2011 to Rafineria Trzebinia by Dun & Bradstreet Poland.

Production volume of selected refinery products in 2010 – 2011 (Trzebinia, in ‘000 tonnes)

  2010 2011 Dynamics 2011/2010
Crude oil processing 250 234 -6%
Biofuel production plant 115 129 12%
Rapeseed methyl esters 101 116 15%

Rafineria Nafty Jedlicze

In 2011 Rafinaria Nafty Jedlicze processed crude oil from domestic deposits (53 thousand tonnes, i.e. 9.8 thousand tonnes more than in 2010) and imported crude oil (2 thousand tonnes; increase by 1.5 thousand tonnes).

Production at the Rafineria Nafty Jedlicze is mainly based on the following three groups of products: heating oil, solvents and base oil. In the production structure, the largest group of products produced in Rafineria Nafty Jedlicze is light and heavy heating oils, which constitute 61% of total production. Light heating oil is produced on the basis of PKN ORLEN license and sold entirely to the Company’s bases. Whereas heavy oil is sold to power plants, combined heat and power plants and used e.g. in the production of bituminous mass.

Solvents are the second largest group of products – 17% of total production. Rafineria Nafty Jedlicze is currently the only producer of low-sulphur and low-aromatic kerosene solvents in Poland. Solvents are produced at a modern unit with the use of modern catalytic hydrogen processes, allowing to eliminate from solvents undesirable substances, such as carcinogenic benzene and environmentally harmful sulphur compounds.

Another group in the production structure is base oil, constituting 15% of total production and derived from regenerated waste oil. The largest recipients of base oil are domestic and foreign producers of lubricating oil and lubricants.

Production volume of selected refinery products in 2010 – 2011 (Jedlicze, in ‘000 tonnes)

  2010 2011 Dynamics 2011/2010
Crude oil processed 44 55 25%
Waste oil processed 32 40 25%
Ekoterm Plus heating oil 65 41 -37%
Solvents 15 21 40%


In 2011, ORLEN Asfalt provided over 800 000 tonnes of bitumen in the Polish market and foreign market, which constitutes an increase by 12% as compared to 2010. Continuation of the policy of priority supplies to the Polish market, while strengthening the position on foreign markets, has brought the expected results. ORLEN Asfalt maintained a dominant position on the Polish bitumen market and recorded a rise of 59% of sales on foreign markets. Export volume of ORLEN Asfalt in 2011 reached almost 150 000 tonnes. Romania was the most important export direction.

A significant element of activities undertaken by the company in 2011 was continuation of processes aimed at consolidation of the bitumen segment in the ORLEN Group.

High quality of products and services offered by ORLEN Asfalt is confirmed by numerous awards and distinctions awarded by prestigious institutions and trade media. Last year the company was awarded the title of a laureate and the QI Golden Emblem in the category: highest quality product for Orbiton modified bitumen.

ORLEN Asfalt production volumes in 2010 – 2011 ('000 tonnes)

  2010 2011 Dynamics 2011/2010
Road bitumen 694 790 14%
Industrial bitumen 17 8 -55%
Total (bitumen and other products) 711 798 12%


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