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HPCL Mumbai Refinery
ContentsContents ContentsContents
• Refinery growthRefinery growth• ProductsProducts• Refinery location & layoutRefinery location & layout• Crude receiving and product dispatching facilitiesCrude receiving and product dispatching facilities• Refinery process unitsRefinery process units• Refinery Block diagrams Refinery Block diagrams • Physical performancePhysical performance• Commitment to EnvironmentCommitment to Environment• Major Projects under implementationMajor Projects under implementation
Refinery GrowthRefinery GrowthRefinery GrowthRefinery Growth
FUELS BLOCK FUELS BLOCK LUBE BLOCKLUBE BLOCK
ErstwhileErstwhile Standard VacuumStandard Vacuum Lube IndiaLube India
CommissionedCommissioned Year 1954Year 1954 Year 1969Year 1969
Capacity expansion Capacity expansion
ORIGINALORIGINAL 1.25 MMTPA1.25 MMTPAIN 1969IN 1969 3.5 ...3.5 ... 165,000 T165,000 TIN 1983IN 1983 225,000 T225,000 TIN 1985IN 1985 5.5 …5.5 …IN 1995IN 1995 335, 000 T *335, 000 T *
* Largest In India* Largest In India
Crudes processed = 43 Crudes processed = 43 Crudes processed = 43 Crudes processed = 43
GippslandHarriet
AnkleshwarMum High
Arab LtArab MixBasrah
Upp ZakumOman
Iran Lt+HyKuwaitDubai
Suez mix
EscravosForcadosQua Iboe
Bonny Light
MiriLabuanTapisLirik
Soviet export Blend
Fuel Products = 13Fuel Products = 13
1.1. PropanePropane
2.2. LPGLPG
3.3. Motor GasolineMotor Gasoline
4.4. Low Aromatic NaphthaLow Aromatic Naphtha
5.5. High Aromatic NaphthaHigh Aromatic Naphtha
6.6. Special Cut NaphthaSpecial Cut Naphtha
7.7. Aviation Turbo FuelAviation Turbo Fuel
8.8. Superior Kerosene OilSuperior Kerosene Oil
9.9. Special cut KeroseneSpecial cut Kerosene
10.10. High Speed Diesel (3 Grades)High Speed Diesel (3 Grades)
11.11. Light Diesel OilLight Diesel Oil
12.12. Fuel Oil ( 2 grades)Fuel Oil ( 2 grades)
13.13. LSHSLSHS
Lube Products = 91. Neutral Oils = 32. Turbine Oils = 23. Industrial Oils = 24. Spindle Oil5. Bright Stock
Specialties = 7Specialties = 71. Hexane2. Solvent 14253. MTO4. CBFS5. RPO6. Bitumen (3 Grades)7. Sulfur
Total Products = 29Total Products = 29Total Products = 29Total Products = 29
Product MixProduct MixProduct MixProduct Mix
LPG
3%Petrol
5%Naphtha
13%
ATF
9%
SKO
6%
HSD
27%
LDO
4%
Lubes
4%
Bitumen
6%
IFO/LSHS
20%
Others
3%
Refinery Location Refinery Location
Refinery Layout Refinery Layout Refinery Layout Refinery Layout
Crude receiving and Product shipment facilitiesCrude receiving and Product shipment facilities
Vashi / Loni / Sewri
/Wadala Mazagaon
RCFRCF
JAWAHER JAWAHER DWEEPDWEEP
PRIPAUPRIPAU
MANIFOLDMANIFOLD
ONGC URANONGC URAN
42”
24”
36”
HP REFINERYHP REFINERY
24”
BH Gas
Nap./IFO/SKO/LSHS/HSD LPG
A T
F
SAHAR / SANTACRUZSAHAR / SANTACRUZ MahulMahulTerminalTerminal
Hex/Sol/M
TO/RPO/
CBFS
MS/HSD/SKO/LDO
IFO / Lubes
BPCLBPCL
LSHS
Naphtha
Bitumen
Refinery Process Units Refinery Process Units Refinery Process Units Refinery Process Units
Fuels BlockFuels Block
Crude Distillation - 2
Vacuum Distillation - 2
Naphtha stabilizers - 2
Fluidized Catalytic Cracking
Diesel Hydro De Sulfurization
Hexane
Propane
Lube BlockLube BlockVacuum DistillationSolvent Extraction - 3Propane De-waxingPropane De-AsphaltingIndustrial Oil Hydrofiner
UtilitiesUtilitiesCaptive Power Plant - 5 GTG’sEffluent Treatment Plants - 2Boiler House Cooling Towers Instrument/utility air system Tankage
Mumbai Refinery Process unitsMumbai Refinery Process unitsMumbai Refinery Process unitsMumbai Refinery Process unitsLPG
LS
HS
Stabilizer
Treating
NaphthaATF
DHDSHSDSKO/MTOSulfur
LDO
FR
CDU
VDUs
SEUs
PDA
IOH
PDU
FRE
CDU
VDU
FCC
Spindle Oil150 N500 N1300 NBright StockIO-100IO-1600
Bitumen
Gasoline
LSHS
HMU
IFO
Hexane Hexane /Solvent/Solvent
Physical PerformancePhysical PerformancePhysical PerformancePhysical Performance
AchievementsAchievementsAchievementsAchievements
• ISO 14001 Certified Environmental Friendly RefineryISO 14001 Certified Environmental Friendly Refinery
• ISRS Safety rating of 8 – A comparative safety level with International ISRS Safety rating of 8 – A comparative safety level with International RefineriesRefineries
• First Refinery to implement complete OM&S Automation First Refinery to implement complete OM&S Automation
• Computerized Maintenance Management System (CMMS) implemented Computerized Maintenance Management System (CMMS) implemented
• Oil Industry Safety Award 2002-2003 for 1Oil Industry Safety Award 2002-2003 for 1stst Best overall Safety Best overall Safety
Performance amongst Refineries.Performance amongst Refineries.
• DG FASLI (Director General Factory Advice & Labour Institute) awards DG FASLI (Director General Factory Advice & Labour Institute) awards
during 2004-04during 2004-04
– Lowest avg. weighted accident frequency rate for 3Lowest avg. weighted accident frequency rate for 3rdrd consecutive year consecutive year
– Largest number of manhours worked without a fatal/non-fatal accidentLargest number of manhours worked without a fatal/non-fatal accident
• Green-Tech Gold Safety award 2002-03 and 2003-04 for outstanding Green-Tech Gold Safety award 2002-03 and 2003-04 for outstanding
achievement in the field of industrial safety and environment achievement in the field of industrial safety and environment
management.management.
• National Safety Council - Maharashtra Chapter Award: Two Safety awards National Safety Council - Maharashtra Chapter Award: Two Safety awards
for 2002 received from NSC-MC for Longest Accident Free Period & for 2002 received from NSC-MC for Longest Accident Free Period &
Lowest Accident Frequency Rate. Lowest Accident Frequency Rate.
Safety Awards Safety Awards Safety Awards Safety Awards
AwardsAwardsAwardsAwards
• Awards for NMP treating Technology:Awards for NMP treating Technology:
• CSIR Technology awardCSIR Technology award
• Golden Peacock awardGolden Peacock award
• Award for successful implementation of CMMSAward for successful implementation of CMMS
• National Petroleum Management Program (NPMP) award for National Petroleum Management Program (NPMP) award for
excellence, under the enterprise category for creativity and excellence, under the enterprise category for creativity and
innovationinnovation
• Green-Tech Gold award for excellence in maintaining environment for 3 Green-Tech Gold award for excellence in maintaining environment for 3
consecutive years 2002, 2003 and 2004consecutive years 2002, 2003 and 2004
Crude ThruputCrude ThruputCrude ThruputCrude Thruput
5.6 5.6
6.1 6.16.2
5
6
7
2000-01 2001-02 2002-03 2003-04 2004-05
ALL FIG. IN MMTALL FIG. IN MMT
Consistently Achieved more than 100% capacity utilisation
Major ProductsMajor ProductsMajor ProductsMajor Products
0
100
200
300
400
500
600
2000-01 2001-02 2002-03 2003-04 2004-05
0
200
400
600
800
1000
1200
1400
1600
1800
LPG Petrol ATF Diesel
ALL FIG. IN Thou MTALL FIG. IN Thou MT
Consistently maximizing high value, high demand products
Commitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment Protection
• Major environmental projects Major environmental projects
– Implemented over past 2 decades : Rs 935 Cr. (208 Million USD)Implemented over past 2 decades : Rs 935 Cr. (208 Million USD)
– Under implementation (GFECP ): Rs 1152 Cr. ( 256 Million USD)Under implementation (GFECP ): Rs 1152 Cr. ( 256 Million USD)
• Refinery meets stipulations set by MPCB & CPCBRefinery meets stipulations set by MPCB & CPCB
• Extensive green cover in the Refinery & residential complex. Extensive green cover in the Refinery & residential complex.
• Initiated Tank sludge treatment process to recovery oil from sludgeInitiated Tank sludge treatment process to recovery oil from sludge
Commitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment ProtectionCommitment to Environment Protection
Environment Protection Projects ImplementedEnvironment Protection Projects ImplementedEnvironment Protection Projects ImplementedEnvironment Protection Projects Implemented
ProjectsProjects Cost (Rs C r.)Cost (Rs C r.) Year of Commsng.Year of Commsng.
Reduced Air PollutionReduced Air Pollution• Mumbai Pune PipelineMumbai Pune Pipeline 61.361.3 19851985• Ambient air Monitoring stations Ambient air Monitoring stations 1.41.4 19891989• Cooling TowersCooling Towers 18.018.0 19851985• CO BoilerCO Boiler 7.07.0 19871987• Lube Oil pipelineLube Oil pipeline 13.013.0 19921992• Continuous stack MonitoringContinuous stack Monitoring 2.52.5 19991999• Diesel Hydro DesulfurizationDiesel Hydro Desulfurization 758.7758.7 2000 2000
Reduced effluent dischargeReduced effluent discharge• Cooling TowersCooling Towers 18.018.0 19851985• MINAS plantsMINAS plants 15.015.0 19921992
Eco friendly SolventsEco friendly Solvents• NMP treating in Hexane NMP treating in Hexane 15.415.4 19971997• NMP solvent in SEUs NMP solvent in SEUs 26.0 26.0 19951995
Green Fuels & Emission Control Project Green Fuels & Emission Control Project Green Fuels & Emission Control Project Green Fuels & Emission Control Project
• ObjectivesObjectives
• To meet EURO-III specifications for MS To meet EURO-III specifications for MS
• Augmentation of crude processing capacity to 7.9 MMTPA Augmentation of crude processing capacity to 7.9 MMTPA
• Project Cost:Project Cost: Rs 1152 Crores (256 Mill. USD)Rs 1152 Crores (256 Mill. USD)
• New Units New Units
• Naphtha SplitterNaphtha Splitter
• Naphtha HydrotreaterNaphtha Hydrotreater
• Catalytic Reforming UnitCatalytic Reforming Unit
• Isomerization unit Isomerization unit
• FCC Gasoline Hydrotreater (Prime G+)FCC Gasoline Hydrotreater (Prime G+)
• Flue Gas Desulfurization UnitFlue Gas Desulfurization Unit
• De NOx FacilitiesDe NOx Facilities
Green Fuels & Emission Control ProjectGreen Fuels & Emission Control ProjectGreen Fuels & Emission Control ProjectGreen Fuels & Emission Control Project
Naphtha
SPLITTER
ISOM
Naphtha HydrotreaterNaphtha Hydrotreater& Isomerization& Isomerization
GASOLINE
POOL
HydrotreaterHydrotreater
IsomerateIsomerate
ReformateReformate
SHU
Selective HydrogenationSelective Hydrogenation& Splitter& Splitter
PRIME G+
Light FCC GasolineLight FCC Gasoline
Heavy FCC GasolineHeavy FCC Gasoline
FCCU CrackedNaphtha
H2
H2
H2
CCR
ReformerReformer
NHT Make up HMake up H22
Light NaphthaLight Naphtha
Heavy NaphthaHeavy Naphtha
LPGLPG
Major MilestonesMajor MilestonesMajor MilestonesMajor Milestones
19541954 Refinery commissionedRefinery commissioned
19691969 Lube refinery commissionedLube refinery commissioned
19771977 II Vacuum Distillation Unit AddedII Vacuum Distillation Unit Added
19831983 Lube Refinery ExpandedLube Refinery Expanded
19851985 Fuels Refinery ExpandedFuels Refinery Expanded
19891989 Captive Power Plant CommissionedCaptive Power Plant Commissioned
1993-941993-94 Achieved 6.0 MMTPA for 1Achieved 6.0 MMTPA for 1stst time time
1994-951994-95 LRE-II Commissioned & Solvent Extraction units converted LRE-II Commissioned & Solvent Extraction units converted
to eco friendly NMPto eco friendly NMP
CONTD.CONTD.
1995-961995-96 Commissioned DCS in all process units of refinery Commissioned DCS in all process units of refinery
1996-971996-97 Highest ever crude t’put of 6.5 MMTPAHighest ever crude t’put of 6.5 MMTPA
1998-991998-99 Commissioned new 14000 BSD (0.65 MMTPA) FCCUCommissioned new 14000 BSD (0.65 MMTPA) FCCU
1999-20001999-2000 DHDS project commissionedDHDS project commissioned
2000-012000-01 implemented CMMSimplemented CMMS
2002-032002-03 Supply of Euro-II Petrol & DieselSupply of Euro-II Petrol & Diesel
2004-052004-05 DHDS-II Project commissioned. Production of Euro-III DHDS-II Project commissioned. Production of Euro-III
DieselDiesel
Major MilestonesMajor MilestonesMajor MilestonesMajor Milestones