Issues of hydrogen consumption and generation in technological processes of oil refineries

RELEVANCE of the study is determined by the implementation of the oil refinery modernization program in the Russian Federation, aimed at increasing the depth of oil refining and improving the quality of petroleum products. The increase in the share of deep processing processes leads to a significant change in the balance of hydrogen at refineries, which requires a comprehensive analysis of its generation and consumption. OBJECTIVE. To improve the energy efficiency of refineries by increasing the depth of oil refining through the use of hydrogen or hydrogen-containing gas (HCG). To analyze the issues of hydrogen consumption and generation in refinery technological processes. To establish the dependence of hydrogen consumption on the depth of oil refining. To evaluate the most effective methods of hydrogen production for use at refineries. METHODS. The study is based on the analysis of standard indicators and technological characteristics of the main oil refining processes (isomerization, hydrotreating, hydrocracking, catalytic reforming). Based on the material balances of these processes, a correlation was established between the depth of oil refining and the volume of hydrogen consumption at refineries. RESULTS. The article presents the specific energy consumption for the main process units. It has been established that achieving a refining depth of over 85% requires a significant increase in hydrogen consumption and the introduction of additional hydroprocessing of residual fuel oil. Catalytic reforming is identified as a key source of hydrogen, while hydrotreating and hydrocracking are its primary consumers. CONCLUSION. With the need to increase refining depth and depleting light crude oil reserves, there is a steady trend toward increasing hydrogen consumption for refinery processes. The development of the oil refining industry requires modernization and the introduction of new, efficient hydrogen generation facilities.

1. Energy Strategy of the Russian Federation for the period up to 2050: Decree of the Government of the Russian Federation dated 04/12/2025 No. 908-R. URL: https://www.garant.ru/products/ipo/prime/doc/411766542//

2. Baykova O.V., Bolshakova O.I., Chebotaeva E.S., Gromyko E.O. Evaluation of the results of modernization and prospects for the development of Russian oil refining in the context of sanctions restrictions//Bulletin of the University. 2023. No. 11. pp. 81-91.

3. Afanasyev V. Ya. Transformation of the fuel and energy complex to ensure Russia's energy security in the era of sanctions restrictions / V. Ya. Afanasyev, O. I. Bolshakova, A. A. Romantsov // Bulletin of the University. – 2023. – No. 9. – pp. 93-102.

4. Tyrtov E. Russian oil refining: the strongest will survive / E. Tyrtov, E. Demidova // Energy policy. – 2021. – № 7(161). – Pp. 38-47.

5. Koroleva A. N. Modeling of the isomerization process of light gasoline fractions in the Aspen Hysys software package and analysis of the results / A. N. Koroleva, V. A. Bakhman, E. L. Tsaregorodtsev // International Scientific Research Journal. – 2023. – № 7(133).

6. Strokin A.V., Cherkasova E.I. The main trends of the isomerization process // Bulletin of the Kazan Technological University. 2014. Vol. 17. No. 8. pp. 66-68.

7. Hidalgo, J. M. Current uses and trends in catalytic isomerization, alkylation and etherification processes to improve gasoline quality / J. M. Hidalgo, M. Zbuzek, R. Cerny, P. Jisa // Central European Journal of Chemistry. 2014. Vol. 12. №. 1. P. 1-13. (Hidalgo, J. M. Current use and trends of catalytic isomerization, alkylation and esterification processes to improve gasoline quality / J. M. Hidalgo, M. Zbuzek, R. Cherni, P. Jisa // Central European Chemical Journal. 2014. Vol. 12. No. 1. pp. 1-13.)

8. Valavarasu, G. Light naphtha isomerization process: A review / G. Valavarasu, B. Sairam // Petroleum Science and Technology. 2013. Vol. 31. №. 6. P. 580-595. Valavarasu, G. The process of isomerization of light naphtha: a review / G. Valavarasu, B. Sairam // Petroleum Science and Technology. 2013. Vol. 31. No. 6. pp. 580-595.

9. Meyers R.A. Basic oil refining processes. Reference book: translated from English. edited by Glagolevoy O.F., Lykova O.P. 3rd ed. St. Petersburg: Profession, 2012. 944 p.

10. Solodova N. L. Hydrogen is an energy carrier and reagent. Technologies for its production / N. L. Solodova, E. I. Cherkasova, I. I. Salakhov, V. P. Tutubalina // News of higher educational institutions. Energy problems. 2017. Vol. 19, No. 11-12. pp. 39-50.

11. The problem of controlling the catalytic reforming process and the method of its solution / V. G. Matveikin, B. S. Dmitrievsky, A. G. Kokuev, A.M. Dzhambekov // Proceedings of Tomsk Polytechnic University. Georesource engineering. – 2019. – Vol. 330, No. 6. – pp. 59-67.

12. Yarullin R.S., Salikhov I.Z., Cherezov D.S., Nurislamova A.R. Prospects of hydrogen technologies in the energy and chemical industries // News of higher educational institutions. PROBLEMS OF ENERGY. 2021. Vol. 23. No. 2. pp.70-83

13. The concept of development of hydrogen energy in the Russian Federation [Electronic resource] : approved by Decree of the Government of the Russian Federation dated 12.10.2021 No. 2812-R. — URL: http://static.government.ru/media/files/5JFns1CDAKqYKzZ0mnRADAw2NqcVsexl.pdf

14. Geopolitics of the Energy Transformation: The Hydrogen Factor. — Abu Dhabi : International Renewable Energy Agency (IRENA), 2022. — 140 p. — URL: https://www.irena.org//media/Files/IRENA/Agency/Publication/2022/Jan/IRENA_Geopolitics_Hydrogen_2022.pdf

15. Methods for producing hydrogen on an industrial scale. Comparative analysis / D. R. Shafiev, A. N. Trapeznikov, A. A. Khokhonov // Advances in chemistry and chemical technology. — 2020. — Vol. XXXIV, No. 12 (235). — pp. 53-57. — URL: https://cyberleninka.ru/article/n/metody-polucheniya-vodoroda-v-promyshlennom-masshtabe-sravnitelnyy-analiz/viewer

16. Semenova, I. V. Production of electrolytic hydrogen. Physico-chemical patterns, current state and development prospects / I. V. Semenova // Energy saving and water treatment. 2010. — No. 3. — pp. 15-21. — URL: https://www.elibrary.ru/item.asp?id=15223310

17. Hydrogen Production: State of Technology / S. Li, Q. Kang, J. Baeyens, H. L. Zhang, Y. M. Deng // IOP Conference Series: Earth and Environmental Science. — 2020. — Vol. 544. — P. 012011. — DOI 10.1088/1755-1315/544/1/012011

18. Comparison of various technologies for the production of hydrogen from natural gas / N. A. Mezaal, A. A. Kalyutik, A. S. Salman, L. M. Abdali // Intelligent systems in production. — 2023. — Vol. 21, No. 4. — pp. 101-108. — DOI 10.22213/2410-9304-2023-4-101-108

19. Development of hydrogen energy in Russia and the world [Electronic resource] : analytical report / Analytical Center under the Government of the Russian Federation. — Moscow, 2021. — 64 p. — URL: https://delprof.ru/upload/iblock/eef/DelProf_Analitika_Vodorodnaya-energetika.pdf

20. Parkes, R. ‘Too much green hydrogen’ | Is China is heading for an oversupply of renewable H2 / R. Parkes // Hydrogen Insight. — 2023. — 24 August. — URL: https://www.hydrogeninsight.com/production/-too-much-green-hydrogen-is-china-is-heading-for-an-oversupply-of-renewable-h2-/2-1-1505821

21. Kessler, R. Texas has industrial makings for $100bn hydrogen superhub with 180k jobs by 2050: report / R. Kessler // Recharge. — 2022. — 23 June. — URL: https://www.rechargenews.com/energy-transition/texas-has-industrial-makings-for-100bn-hydrogen-superhub-with-180k-jobs-by-2050-report/2-1-1243998

22. Ghilotti, D. Spain will be Europe’s ‘first green hydrogen hub’ and export millions of tonnes a year to the rest of the continent, says Enagas / D. Ghilotti // Hydrogen Insight. — 2023. — 25 January. — URL: https://www.hydrogeninsight.com/policy/spain-will-be-europe-s-first-green-hydrogen-hub-and-export-millions-of-tonnes-a-year-to-the-rest-of-the-continent-says-enagas/2-1-1393472

23. Economics of hydrogen production, taking into account exports and the Russian market / F. Veselov, A. Solyanik // Energy policy. – 2022. – № 4(170). – Pp. 58-67. – DOI 10.46920/2409-5516_2022_4170_58.

24. IEA. The future of hydrogen. July 2019.

25. Hydrogen Council. Path to hydrogen competitiveness: a cost perspective. January 2020. URL: httpsV/hydrogencouncil.com/wp-content/upioads/2020/Ol/Path-to-Hydrogen-Competitiveness_Full-Study-l.pdf.

26. Bekirov E. A., Development of energy complexes for hydrogen production in the territory of the Republic of Crimea / E. A. Bekirov, M. M. Asanov, S. Sh. Nusretova // News of higher educational institutions. Energy problems. – 2021. – Vol. 23, No. 2. – pp. 161-172. – DOI 10.30724/1998-9903-2021-23-2-161-172.

27. Nikolaev, Yu. E. Evaluation of the efficiency of energy complexes with the production of hydrogen, oxygen, heat and electricity / Yu. E. Nikolaev, M. A. Aidarov // News of higher educational institutions. Energy problems. – 2024. – Vol. 26, No. 2. – pp. 114-127. – DOI 10.30724/1998-9903-2024-26-2-114-127.

28. Hydrogen fuel as an alternative to traditional fuels / E. R. Zvereva, G. E. Maryin, I. G. Akhmetova [et al.] // News of higher educational institutions. Energy problems. – 2025. – Vol. 27, No. 3. – pp. 187-197. – DOI 10.30724/1998-9903-2025-27-3-187-197.

29. Pletnev M. A. Socio-economic problems of the development of hydrogen energy / M. A. Pletnev, A. N. Kopysov // News of higher educational institutions. Energy problems. – 2021. – Vol. 23, No. 2. – pp. 36-45. – DOI 10.30724/1998-9903-2021-23-2-36-45.