Refining Process & Technology

Overview

At KNPZ, petroleum refining is not simply a mechanical process — it is a disciplined engineering system in which every stage is monitored, measured, and certified. Our refinery operates on a continuous basis, applying industry-standard refining technologies to produce a certified range of petroleum products that meet both Kazakhstani regulatory requirements and the performance expectations of demanding commercial buyers.

Stage 1 — Crude Oil Receipt & Pre-Treatment

All incoming crude feedstock is received and quality-tested before entering the refinery system. Our accredited laboratory analyses samples for density, water content, salt content, sulphur concentration, and viscosity. Only crude meeting our intake specifications proceeds to the primary distillation stage, ensuring consistent feedstock quality and protecting downstream process units.

Receipt via pipeline connection and road tanker unloading stations
Automated desalting and dewatering (electrostatic desalter unit)
Feedstock blending for optimised cut yield
Real-time quality data logged to process control system

Stage 2 — Atmospheric Distillation (Primary Processing Unit)

The atmospheric distillation unit (ADU) forms the core of our primary processing complex. Preheated crude is separated by boiling point into distinct hydrocarbon fractions in a continuously operated distillation column. This stage produces the initial cuts that form the basis of our product slate:

Light naphtha — gasoline blending component
Heavy naphtha — reforming feedstock
Kerosene fraction
Diesel distillate
Atmospheric residue — fed to vacuum distillation unit

Stage 3 — Vacuum Distillation

The atmospheric residue is further processed under reduced pressure in our vacuum distillation unit (VDU), yielding vacuum gas oil (VGO) and bituminous vacuum residue. This stage significantly increases overall refining depth and product recovery, minimising the proportion of low-value heavy residuals.

Stage 4 — Product Blending & Compounding

Our dedicated product blending complex allows precise formulation of finished petroleum products to exact specification. Using a combination of primary distillation cuts and additive dosing systems, our blending operators produce:

Seasonal diesel fuel formulations (summer, winter, arctic grades)
RON-92 and RON-95 motor gasoline to stable octane specification
Mazut M-100 to GOST viscosity and flash point requirements
Bitumen grades meeting GOST 22245-90 penetration and softening point criteria

Stage 5 — Quality Control & Laboratory Certification

Our in-house Chemical Analytical Laboratory (CAL) is accredited by the Federal Agency on Technical Regulating and Metrology. Laboratory personnel conduct testing at every stage of production — from crude intake to finished product loading — using certified analytical instruments and established GOST test methods. Product release is contingent on laboratory approval. No product is dispatched without a conformity certificate.

Density, viscosity, flash point, pour point, cloud point testing
Sulphur content analysis (X-ray fluorescence and ASTM D4294)
Octane number determination (CFR engine method)
Cetane number testing for diesel grades
Full bitumen characterisation (penetration, softening point, ductility)

Stage 6 — Storage & Dispatch

Finished products are transferred to our dedicated tank farm for storage prior to dispatch. Our tank farm is equipped with calibrated metering systems, temperature monitoring for heated-product storage, and safety systems meeting Kazakhstan industrial safety requirements. Products are dispatched by road tanker or rail cistern, with all volumes measured through certified custody-transfer meters.