Raw and other materials used in production
In its refining and petrochemical operations, the Group processes various raw materials and semi-finished products. Crude oil is the principal raw material, which at each ORLEN Group company accounts for more than 92% of total feedstock used in production.
Crude oil consumption
| Oil [m tonnes] | 2014 | 2015 |
|---|---|---|
| PKN ORLEN | 14.28 | 15.67 |
| ORLEN Lietuva | 7.50 | 8.49 |
| Unipetrol | 5.13 | 6.50 |
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 purchases 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).
Recycled materials used as input materials
The ORLEN Group recycles effluents and reuses water.
The ORLEN Group companies convert waste materials into raw materials by reprocessing them in production to obtain the original material or a material that can be used for other purposes. By reusing waste materials, the companies reduce the consumption of fresh raw materials, which enhances the efficiency of their processes and helps protect natural resources.
Recycling and reuse of waste materials also reduces the overall amount of generated waste. Efficient energy management involves the use of energy materials or energy carriers. The principal goal of the recycling effort is to maximise the reuse of materials with a minimum energy spending on their processing.
In 2015, PKN ORLEN’s Płock Production Plant recovered 0.05% of slops in the wastewater treatment process and reprocessed them in the distillation unit. Moreover, 9.76% of treated wastewater was used to produce industrial water and water for fire-fighting purposes.
Waste raw materials and heat were also reused at the ORLEN Group companies.
- Basell Orlen Polyolefins reused 2.6% of heat recovered from production (steam) to heat water.
- ANWIL reused in its production processes 6.75% of PVC SX from effluents, 1.38% of natural gas (methane) in the ammonia unit, 1.54% of river water and 1.27% of brine.
- ORLEN Eko reused 2.05% of heat recovered from flue gas to produce steam.
- ORLEN Południe Trzebinia Production Plant reused 57% of heat, 3.8% of condensate from paraffin production, 0.2% of waste from the wastewater treatment plant and 0.2% of slops.
- ORLEN Południe Jedlicze Production Plant reused in production 0.44% of slops in/from the fractional distillation unit and 0.71% of slops in/from the waste oil regeneration unit, 15% of steam condensate in/from the CHP plant, and 16.2% of heat in/from the waste oil regeneration unit.
- ORLEN Lietuva reused 78% of wastewater to produce process water, and also reused 0.15% of slops and 76% of heat from steam.
- Inowrocławskie Kopalnie Soli SOLINO S.A. recovered 10.7% of waste brine in the brine concentration process.
- ORLEN OIL recovered 1.18% of slops.
- Česká rafinérská recovered 0.08% of hydrocarbon slops.
Product and service labelling
Obligations of the ORLEN Group companies to provide information, by means of signs and labels, of potential hazards associated with specific products are prescribed by the relevant provisions of international and EU legislation. The key tool used to determine the required type of labelling are safety data sheets, prepared in accordance with the EU REACH regulation. Safety data sheets contain information on product labelling based on the CLP classification and warning stickers related to hazards involved in transport (if required).
They are mainly a source of information on products used for industrial and professional applications. In the case of products directly placed on the market for use by general consumers, such information is provided by the ORLEN Group companies through labels on product packages.
Labels on product packages prepared in accordance with the CLP regulation contain, in addition to pictograms, certain standard hazard statements and precautionary statements.
Given the wide range of applications of ORLEN Group products, package labels are also consistent with specific legal provisions applicable to detergents, fertilizers, etc.
As the requirement to communicate hazards and safe use instructions is imposed by law, labels included in safety data sheets and placed on product packages are checked for regulatory compliance by competent state authorities (such as the State Sanitary Inspection (SANEPID)).
Benzene, lead and sulfur content in fuels
Benzene, lead and sulfur content in all types of liquid fuels representing final (commercial) products, by company and product
PKN ORLEN S.A.
| Commercial name | Average content in 2015 | Basis of regulatory requirements | |||
|---|---|---|---|---|---|
| Sulfur | Benzene | Lead | |||
| Petrol | |||||
| Regulatory quality requirements | max. 10.0 | max. 15.0 | max. 1.00 | max. 5.0 | |
| mg/kg | mg/kg | %(V/V) | mg/l | ||
| EuroSuper 95 | 8.8 | ─ | 0.69 | <2.50 | Minister of Economy’s Regulation of October 9th 2015 concerning the quality requirements for liquid fuels (Dz.U. of October 25th 2015, item 1680) and PN-EN 228:2013-04 standard: ‘Automotive fuels’ Unleaded petrol Requirements and test methods |
| Eurosuper 95 with Ethanol and ETBE content | 8.6 | ─ | 0.57 | <2.50 | |
| Super Plus 98 with ETBE content | 7.8 | ─ | 0.45 | <2.50 | |
| Super Plus 98 with Ethanol and ETBE content | 8.0 | ─ | 0.59 | <2.50 | |
| VERVA 98 with Ethanol and ETBE content | 8.0 | ─ | 0.59 | <2.50 | |
| Diesel oil | |||||
| Regulatory quality requirements | max. 10.0 | max. 10.0 | none | none | |
| mg/kg | |||||
| Ekodiesel Ultra | 7.9 | ─ | not specified | not specified | Minister of Economy’s Regulation of October 9th 2015 concerning the quality requirements for liquid fuels (Dz.U. of October 25th 2015, item 1680) and PN-EN 228:2013-04 standard: ‘Automotive fuels -- Diesel oils -- Requirements and test methods’ |
| Class 2 Ekodiesel Ultra | 7.5 | ─ | not specified | not specified | |
| Verva ON | 9.0 | ─ | not specified | not specified | |
| Fuel oil | |||||
| Regulatory quality requirements | max. 0.1 | ─ | none | none | |
| %(m/m) | |||||
| Ekoterm Plus fuel oil | 0.1 | ─ | not specified | not specified | Minister of Economy’s Regulation of November 3rd 2014 concerning quality requirements related to sulfur content in oils as well as types of installations and conditions in which heavy fuel oils are to be used (Dz.U. 2014, item 1547) and PN-C-96024:2001 standard ‘Petroleum products. Fuel oils’ |
| Regulatory quality requirements | max. 3.5 | ─ | none | none | |
| %(m/m) | |||||
| OOC3 | 2.1 | ─ | not specified | not specified | Minister of Economy’s Regulation of October 22nd 2015 concerning requirements for sulfur content in marine fuel, including method of its labelling (Dz.U. 2015, item 1665) and PN-C-96024:2001 standard ‘Petroleum products. Fuel oils’ |
| Aviation turbine fuel | |||||
| Regulatory quality requirements | max. 0.30 | ─ | |||
| mg/kg [%(m/m)] |
|||||
| Jet A-1 | 600 (0.06) | ─ | not specified | not specified | In-house standard ZN-ORLEN-18 ‘Aviation turbine fuel Jet A-1’, detailed requirements consistent with Aviation Fuel Quality Requirements for Jointly Operated System – AFQRJOS, Bulletin 76., issue of March 28th 2015 Joint Inspection Group (JIG), which contains requirements set out in: (a) British Ministry of Defence, Defence Standard 91-91 (DEF STAN 91-91), issue 7. of February 18th 2011, incorporating Amendment 3. of February 2nd 2015 ‘Turbine Fuel, Kerosene Type, Jet A-1. NATO Code: F-35’, Joint Service Designation AVTUR. (b) ASTM D 1655-15de1 Standard Specification for Aviation Turbine Fuels |
not specified - not measured; no limit prescribed
none - no limit prescribed
ORLEN POŁUDNIE
| Commercial name | Average content in 2015 | Basis of regulatory requirements | |||
|---|---|---|---|---|---|
| Sulfur | Benzene | Lead | |||
| Diesel oil | |||||
| Regulatory quality requirements | max. 10.0 | ─ | none | none | |
| mg/kg | |||||
| Biodiesel RME/FAME (B100) | 4.38 | ─ | not specified | not specified | Minister of Economy’s Regulation of January 22nd 2009 concerning the quality requirements for liquid biofuels (Dz.U. 2009, No. 18, item 98), the Minister of Economy’s Regulation concerning the quality requirements for biocomponents, as well as methods of testing biocomponent quality and taking biocomponent samples (Dz.U. of December 17th 2010, item), the Minister of Economy’s Regulation of May 14th 2015 amending the regulation concerning the quality requirements for biocomponents, as well as methods of testing biocomponent quality and taking biocomponent samples (Dz.U. of June 11th 2015, item 780) and PN-EN 14214+A1:2014-04/AC:2014-11 standard ‘Automotive fuels. Fatty acid methyl esters (FAME) for compression-ignition (Diesel) engines. Requirements and test methods’ |
not specified - not measured; no limit prescribed
none - no limit prescribed
ORLEN Lietuva
| Commercial name | Average content in 2015 | Basis of regulatory requirements | |||
|---|---|---|---|---|---|
| Sulfur | Benzene | Lead | |||
| Petrol | |||||
| Regulatory quality requirements | max. 10.0 | max. 15.0 | max. 1.00 | max. 5.0 | |
| mg/kg | mg/kg | %(V/V) | mg/l | ||
| US92 petrol | ─ | 12.86 | 0.81 | not specified | US specification (Colonial pipeline company section 3.4 quality assurance) |
| A92 petrol | 8.21 | ─ | 0.80 | <2.5 | In-house standard ORLEN Lietuva ĮST 166451720-3:2009 ‘Automotive fuels. Basic unleaded petrol for compounding with bioethanol. Requirements and test methods’ |
| 95 petrol | 7.30 | ─ | 0.83 | <2.5 | EN 228:2012 ‘Automotive. Unleaded petrol. Requirements and test method’ |
| 95 Bio petrol | 6.79 | ─ | 0.90 | <2.5 | EN 228:2012 ‘Automotive. Unleaded petrol. Requirements and test method’ |
| 95 petrol E33 | 8.45 | ─ | 0.48 | <2.5 | In-house standard ORLEN Lietuva ĮST 166451720-8:2015 ‘Automotive fuels. Basic unleaded petrol for compounding with bioethanol. Requirements and test methods’ |
| 98 petrol | 5.08 | ─ | 0.94 | <2.5 | EN 228:2012 ‘Automotive. Unleaded petrol. Requirements and test method’ |
| Diesel oil | |||||
| Regulatory quality requirements | max. 1000 | max. 10.0 | none | none | |
| mg/kg | mg/kg | ||||
| Marine gasoil | 900 | ─ | not specified | not specified | EN 590:2013 ‘Automotive. Diesel. Requirements and test method’ |
| Arctic diesel | ─ | 6.24 | not specified | not specified | |
| Diesel F | ─ | 6.97 | not specified | not specified | |
| Diesel E | ─ | 7.56 | not specified | not specified | |
| Diesel C | ─ | 8.11 | not specified | not specified | |
| Diesel E BIO | ─ | 6.00 | not specified | not specified | |
| Diesel C BIO | ─ | 7.99 | not specified | not specified | |
| Heating Oil | ─ | 7.31 | not specified | not specified | |
| Diesel Agro | ─ | 7.45 | not specified | not specified | |
| Fuel oil | |||||
| Regulatory quality requirements | max. 250, 000 | ─ | none | none | |
| mg/kg | |||||
| Fuel oil | 23 000 | ─ | not specified | not specified | LST 1956:2004 (Lithuanian standard) ‘Liquid fuel. Fuel oil. Requirements and test methods’ |
| Aviation turbine fuel | |||||
| Regulatory quality requirements | max. 3,000 | ─ | |||
| mg/kg | |||||
| JET A-1 | 2.19 | ─ | not specified | not specified | ASTM D 1655-15de1 ‘Standard Specification for Aviation Turbine Fuels’ |
not specified - not measured; no limit prescribed
none - no limit prescribed
Česká Rafinérská a.s.
| Commercial name | Average content in 2015 | Basis of regulatory requirements | |||
|---|---|---|---|---|---|
| Sulfur | Benzene | Lead | |||
| Petrol | |||||
| Regulatory quality requirements | max. 10.0 | max. 15.0 | max. 1.00 | max. 5.0 | |
| mg/kg | mg/kg | %(V/V) | mg/l | ||
| Natural 95 Super (BIO-E5) | 3.2 | ─ | 0.72 | 0 | ČSN-EN 228:2013 (65 6505) ‘Motorová paliwa. Bezolovnaté automobilové benziny.Technické požadavky a metody zkoušeni’ (‘Automotive. Unleaded petrol. Requirements and test method’) |
| Natural 95 Super (BIO-E10) | 3.1 | ─ | 0.74 | 0 | |
| Natural 95 Super (BioETBE-exp.) | 3.2 | ─ | 0.71 | 0 | |
| Natural 95 Preblend without biocomponents bioalcohol | 2.8 | ─ | 0.78 | 0 | |
| Diesel oil | |||||
| Regulatory quality requirements | max. 10 | max. 10.0 | none | none | |
| mg/kg | |||||
| Motorová nafta třídy B, D, F (MN tř. B,D,F) | 7.6 | ─ | not specified | not specified | ČSN EN 590 (65 6506) ‘Motorová paliva. Motorové nafty. Technické požadavky a metody zkoušení’ (‘Automotive. Diesel. Requirements and test method’) |
| Motorová nafta třídy 2 | 4.0 | ─ | not specified | not specified | |
| NM třída B,D,F (NBF-preblend) | 8.1 | ─ | not specified | not specified | |
| Fuel oil | |||||
| Regulatory quality requirements | max. 0.1 | ─ | none | none | |
| %(m/m) | |||||
| ETO | 8.0 | ─ | not specified | not specified | In-house standard PN 10 CRC ‘Topný olej extralehký (TOEL, ETO) Technické požadavky a metody zkoušení’ |
| TOT R2 vysokosirný | 2.6 | ─ | ČSN 65 7991/Z1:2005 'Ropné výrobky. Topné oleje. Technické požadavky' | ||
| TOT R2 málosirný | 1,0 | ─ | not specified | not specified | ČSN 65 7991/Z1:2005 ‘Ropné výrobky. Topné oleje. Technické požadavky’ |
| Aviation turbine fuel | |||||
| Regulatory quality requirements | max. 0.30 | ─ | |||
| mg/kg | |||||
| JET A1 | 4.0 | ─ | not specified | not specified | British Ministry of Defence, Defence Standard 91-91 (DEF STAN 91-91), issue 7. of February 18th 2011 incorporating Amendment 3. of February 2nd 2015 ‘Turbine Fuel, Kerosene Type, Jet A-1. NATO Code: F-35’, Join Service Designation AVTUR. (British Ministry of Defence, Defence Standard 91-91 (DEF STAN 91-91), issue 7. of February 18th 2011 incorporating Amendment 3. of February 2nd 2015 ‘Turbine Fuel, Kerosene Type, Jet A-1. NATO Code: F-35’, Join Service Designation AVTUR.) |
not specified - not measured; no limit prescribed
none - no limit prescribed
Volumes of biofuels produced and purchased meeting the sustainability criteria
In order to protect the environment, and in view of the national requirements to ensure a minimum share of biofuels in transport, the ORLEN Group used over 640 thousand tonnes of methyl esters and 234 thousand tonnes of bioethanol. All biofuels used by the ORLEN Group on all 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
| [tt] | Poland | Czech Republic | Lithuania | TOTAL |
|---|---|---|---|---|
| Fatty acid methyl esters | 505.621 | 90.000 | 45.088 | 640.709 |
| Bioethanol | 168.119 | 50.500 | 15.749 | 234.368 |
| [M3] | Poland | Czech Republic | Lithuania | TOTAL |
|---|---|---|---|---|
| Fatty acid methyl esters | 566.908 | 101.925 | 51.062 | 719.895 |
| Bioethanol | 216.153 | 63.843 | 19.910 | 299.906 |
The volumes include biofuels produced by Orlen Południe.
Management approach to the Energy aspect
In 2015, the ORLEN Group reduced its energy intensity by nearly 3pp (yoy). The reduction was achieved on the back of energy efficiency improvement initiatives, increased capacity utilisation at PKN ORLEN and ORLEN Lietuva, and a lower volume of crude oil processed at Unipetrol due to the Steam Cracker’s temporary shutdown following a fire in Litvínov.
Our strategy for the Energy area is to create value through operational synergies with the Refining and Petrochemical business of the Downstream segment. The key focus is on developing modern industrial cogeneration as a source of electricity and heat for production assets, as well as pursuit of new projects based on innovative technologies, including Renewable Energy Sources. At the ORLEN Group, we are committed to continuous efforts towards operational excellence, within such areas as production process optimisation, distribution losses and improved efficiency of process units. Our strategic vision in the Energy area is to transform the ORLEN Group from an energy consumer to an energy producer. All activities to achieve the stated objectives are carried out with due regard for the environment and local communities. The key success driver in that area are our Employees − a team of strongly motivated and dynamic professionals.
Key projects:
- CCGT Włocławek – construction
- CCGT Płock – construction
- FGD (flue gas desulfurisation unit) – commissioned on December 31st 2015
- PKN ORLEN’s first application for project co-funding under the EU Horizon 2020 and MSC programmes
-
Conclusion of contracts for pilot photovoltaic panels at service stations, and pilot LED installation at the CHP plant in Płock
-
Implementation of ISO 50001-compliant Energy Management System
-
Implementation of REMIT system
- GAHE (Active Energy Trading Platform) – implementation work on the Czech and Lithuanian markets.
In 2015, the energy saving measures led to the following reductions in energy consumption:
Electricity – 6.132 MWh
Heat in steam – 73.297 GJ
Compressed air for pneumatic devices – 41.942.880 m3
The savings were calculated based on data from PKN ORLEN, Unipetrol and Anwil. The main criterion in selecting the reporting companies was their business materiality for the Energy area.
