Indian Refineries Overview

1

ContentsContents ContentsContents

• Indian oil scenarioIndian oil scenario• Crude oil sourcingCrude oil sourcing• Refining ProcessesRefining Processes• Refinery overviewRefinery overview

Refineries in IndiaRefineries in India Refineries in IndiaRefineries in India

* MUMBAI 2 Nos.

* KOYALI

* MATHURA

*HALDIA

* VISHAKAHAPATNAM

* CHENNAICOCHIN *

* MRPL

BARAUNI *

* PANIPAT

JAMNAGAR *

* BONGAIGAON* DIGBOI

* NUMALIGARH

* GUWAHATI

Refining capacitiesRefining capacitiesRefining capacitiesRefining capacities

HPCL – Mumbai 5.50 CPCL – Chennai 6.50HPCL – Visakh 7.50 CRL – Narimanam 0.50 HPCL – Total 13.00 CPCL – Total 7.00

IOC – Guwahati 1.00 NRL – Numaligarh 3.00IOC – Barauni 4.20 BPCL – Mumbai 6.90IOC – Koyali 12.50 MRPL – Mangalore 9.69IOC – Haldia 3.75 RPL – Jamnagar 27.00IOC – Mathura 7.50 CRL – Cochin 7.50IOC – Panipat 6.00 BRPL – Bogaingaon 2.35IOC – Digboi 0.65 IOC – Total 35.60

Total Refining capacity 112.04 All Figures are in Million tons per annum

Dependence on Crude Oil importsDependence on Crude Oil importsDependence on Crude Oil importsDependence on Crude Oil imports

• Refining capacity increased from 52 MMPTA to 121 MMTPA over last Refining capacity increased from 52 MMPTA to 121 MMTPA over last decadedecade

• Stagnant indigenous production (33 MMTPA) resulted in crude oil Stagnant indigenous production (33 MMTPA) resulted in crude oil imports from 19 MMTPA to 88 TMT during last decadeimports from 19 MMTPA to 88 TMT during last decade

• Indian crude mix shifted from lighter to heavier Indian crude mix shifted from lighter to heavier • Crude sourced from Middle east, Far east, West Africa and South Crude sourced from Middle east, Far east, West Africa and South

AmericaAmerica

Indigenous crude supply Vs Demand

020406080

100120140

1990-9

1

1995-9

6

97-9

8

98-9

9

99-0

0

00-0

1

'01-0

2

'02-0

3

'03-0

4

Millio

n t

on

s

Supply Demand

Indigenous Vs Imports

0%

20%

40%

60%

80%

100%

1990-9

1

1995-9

6

97-9

8

98-9

9

99-0

0

00-0

1

'01-0

2

'02-0

3

'03-0

4

Indigenous Import

From net imports to net exportsFrom net imports to net exportsFrom net imports to net exportsFrom net imports to net exports

• Petroleum product imports increased from 5.5 MMT during 1990-91 to Petroleum product imports increased from 5.5 MMT during 1990-91 to 25 MMT during 1998-99.25 MMT during 1998-99.

• Start up of new refineries and capacity additions to older ones, since Start up of new refineries and capacity additions to older ones, since 2001 resulted in India becoming net exporter of Petroleum products2001 resulted in India becoming net exporter of Petroleum products

-40000

-20000

0

20000

40000

60000

80000

100000

120000

TMT

1990-91 1995-96 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04

Product deficit to product surplus

Prod. Demand Net exports

7

Crude oil sourcingCrude oil sourcingCrude oil sourcingCrude oil sourcing

Crude OilCrude Oil Crude OilCrude Oil

Crude oils are complex mixtures containing many different hydrocarbon Crude oils are complex mixtures containing many different hydrocarbon

compounds that vary in appearance and composition from one oil field compounds that vary in appearance and composition from one oil field

to another. Crude oils range in consistency from water to tar-like solids, to another. Crude oils range in consistency from water to tar-like solids,

and in color from clear to black. An "average" crude oil contains about and in color from clear to black. An "average" crude oil contains about

84% carbon, 14% hydrogen, 1%-3% sulfur, and less than 1% each of 84% carbon, 14% hydrogen, 1%-3% sulfur, and less than 1% each of

nitrogen, oxygen, metals, and salts. nitrogen, oxygen, metals, and salts.

Classification of Crude OilClassification of Crude Oil Classification of Crude OilClassification of Crude Oil

• Crude oils are generally classified as paraffinic, naphthenic, or Crude oils are generally classified as paraffinic, naphthenic, or

aromatic, based on the predominant proportion of similar hydrocarbon aromatic, based on the predominant proportion of similar hydrocarbon

molecules. Mixed-base crudes have varying amounts of each type of molecules. Mixed-base crudes have varying amounts of each type of

hydrocarbon. Refinery crude base stocks usually consist of mixtures of hydrocarbon. Refinery crude base stocks usually consist of mixtures of

two or more different crude oils. two or more different crude oils.

• Relatively simple crude oil assays are used to classify crude oils as Relatively simple crude oil assays are used to classify crude oils as

paraffinic, naphthenic, aromatic, or mixed. One assay method (United paraffinic, naphthenic, aromatic, or mixed. One assay method (United

States Bureau of Mines) is based on distillation, and another method States Bureau of Mines) is based on distillation, and another method

(UOP "K" factor) is based on gravity and boiling points. More (UOP "K" factor) is based on gravity and boiling points. More

comprehensive crude assays determine the value of the crude (i.e., its comprehensive crude assays determine the value of the crude (i.e., its

yield and quality of useful products) and processing parameters. yield and quality of useful products) and processing parameters.

• Crude oils are usually grouped according to yield structure.Crude oils are usually grouped according to yield structure.

Classification of Crude OilClassification of Crude Oil Classification of Crude OilClassification of Crude Oil

• Crude oils are also defined in terms of API (American Petroleum Crude oils are also defined in terms of API (American Petroleum

Institute) gravity. Institute) gravity.

• The higher the API gravity, the lighter is the crude. For example, light The higher the API gravity, the lighter is the crude. For example, light

crude oils have high API gravities and low specific gravities. Crude oils crude oils have high API gravities and low specific gravities. Crude oils

with low carbon, high hydrogen, and high API gravity are usually rich in with low carbon, high hydrogen, and high API gravity are usually rich in

paraffins and tend to yield greater proportions of gasoline and light paraffins and tend to yield greater proportions of gasoline and light

petroleum products; those with high carbon, low hydrogen, and low API petroleum products; those with high carbon, low hydrogen, and low API

gravities are usually rich in aromatics. gravities are usually rich in aromatics.

• Crude oils that contain appreciable quantities of hydrogen sulfide or Crude oils that contain appreciable quantities of hydrogen sulfide or

other reactive sulfur compounds are called "sour." Those with lower other reactive sulfur compounds are called "sour." Those with lower

sulfur are called "sweet." sulfur are called "sweet."

Common crudes processed in IndiaCommon crudes processed in India Common crudes processed in IndiaCommon crudes processed in India

High SulfurHigh Sulfur Low SulfurLow Sulfur

Arab Light (Saudi Arabia)Arab Light (Saudi Arabia) Bonny Light (Nigeria)Bonny Light (Nigeria)

Arab Mix (Saudi Arabia)Arab Mix (Saudi Arabia) Cieba (Equ. Guinea)Cieba (Equ. Guinea)

Basrah (Iraq)Basrah (Iraq) Escravos (Nigeria)Escravos (Nigeria)

DubaiDubai Farcados (Nigeria)Farcados (Nigeria)

KuwaitKuwait Essider (Libya)Essider (Libya)

Iran MixIran Mix Labuan (Malaysia)Labuan (Malaysia)

Murban (UAE)Murban (UAE) Masila (Yemen)Masila (Yemen)

OmanOman Miri Light (Malaysia)Miri Light (Malaysia)

Suez Mix (Egypt)Suez Mix (Egypt) Tapis (Malaysia)Tapis (Malaysia)

Umm Shaif (UAE)Umm Shaif (UAE) RavvaRavva (KGB India) (KGB India)

Upper Zakum (UAE)Upper Zakum (UAE) Mumbai HighMumbai High

Yield Patterns from different CrudesYield Patterns from different Crudes Yield Patterns from different CrudesYield Patterns from different Crudes

High SulfurHigh Sulfur Low Sulfur Low Sulfur

BasrahBasrah AXLAXL Mum HighMum High Qua IboeQua Iboe

APIAPI 33.233.2 37.937.9 40.540.5 37.237.2

LPGLPG 1.61.6 1.81.8 4.24.2 4.24.2

MSMS 1.81.8 2.32.3 12.912.9 14.014.0

NaphthaNaphtha 9.69.6 10.410.4 15.615.6 12.112.1

ATF/SKOATF/SKO 15.215.2 9.39.3 11.511.5 11.511.5

HSDHSD 15.715.7 38.438.4 41.541.5 30.630.6

LDOLDO 8.68.6 6.56.5 -- --

LubesLubes 8.08.0 8.08.0 -- --

IFO/LSHSIFO/LSHS 24.224.2 8.08.0 8.38.3 21.621.6

BitumenBitumen 7.57.5 7.57.5 -- --

F&LF&L 7.57.5 7.57.5 6.06.0 6.06.0

GRM $/bblGRM $/bbl 4.914.91 3.143.14 6.046.04 (2.52)(2.52)

13

Crude oil RefiningCrude oil RefiningCrude oil RefiningCrude oil Refining

Crude OilCrude Oil RefiningCrude OilCrude Oil Refining

• Refining is a collection of processes necessary to convert low valued Refining is a collection of processes necessary to convert low valued

crude oil to wide range of high valued productscrude oil to wide range of high valued products

• Refining processes are broadly divided into four typesRefining processes are broadly divided into four types

– FractionationFractionation

– ConversionConversion

– Treating Treating

– BlendingBlending

FractionationFractionationFractionationFractionation

• First & most important step in crude refining First & most important step in crude refining

• Hydrocarbon molecules do not change in structureHydrocarbon molecules do not change in structure

• No new compounds are formedNo new compounds are formed

Atmospheric DistillationAtmospheric Distillation

– Separation of crudes into fractions using the principal of boiling point Separation of crudes into fractions using the principal of boiling point difference i.e. Light ends at the top & Heavy at the bottom difference i.e. Light ends at the top & Heavy at the bottom

– main products are LPG, Naphtha, Kerosene, ATF, HSD, Reduced Crude main products are LPG, Naphtha, Kerosene, ATF, HSD, Reduced Crude Oil.Oil.

Vacuum DistillationVacuum Distillation– Re-distillation of Reduced Crude Oil for further separation.Re-distillation of Reduced Crude Oil for further separation.

– Separation under vacuum to avoid decomposition of reduced crudeSeparation under vacuum to avoid decomposition of reduced crude

– Main products are vacuum gas oil, distillates for lubes, FCC feed stock, Main products are vacuum gas oil, distillates for lubes, FCC feed stock, Bitumen & LSHSBitumen & LSHS

FractionationFractionationFractionationFractionation

Conversion ProcessesConversion ProcessesConversion ProcessesConversion Processes

Change in size and structure of the hydrocarbon molecule in order to Change in size and structure of the hydrocarbon molecule in order to convert surplus by products from fractionation to high valued convert surplus by products from fractionation to high valued marketable productsmarketable products

1.1. Decomposition (dividing) Decomposition (dividing) • Fluidized catalytic crackingFluidized catalytic cracking• Hydro crackingHydro cracking• VisbreakingVisbreaking• Delayed CokingDelayed Coking

2.2. Unification (combining) Unification (combining) • Alkylation Alkylation • PolymerizationPolymerization

3.3. Alteration (rearranging) Alteration (rearranging) • Isomerization Isomerization • Catalytic reformingCatalytic reforming..

Decomposition ProcessesDecomposition ProcessesDecomposition ProcessesDecomposition Processes

Fluidized catalytic crackingFluidized catalytic cracking

• Fluidized Catalytic cracking breaks complex hydrocarbons into simpler Fluidized Catalytic cracking breaks complex hydrocarbons into simpler molecules in order to increase the quality and quantity of lighter, more molecules in order to increase the quality and quantity of lighter, more desirable products and decrease the amount of residuals. This process desirable products and decrease the amount of residuals. This process rearranges the molecular structure of hydrocarbon compounds to rearranges the molecular structure of hydrocarbon compounds to convert heavy hydrocarbon feedstock into lighter fractions such as convert heavy hydrocarbon feedstock into lighter fractions such as kerosene, gasoline, LPG, heating oil, and petrochemical feedstockkerosene, gasoline, LPG, heating oil, and petrochemical feedstock

• Produces better quality (High Octane) Gasoline by cracking Vacuum Produces better quality (High Octane) Gasoline by cracking Vacuum Gas oils in presence of a catalystGas oils in presence of a catalyst

• Simultaneously produces large amount of LPGSimultaneously produces large amount of LPG

Fluidized catalytic CrackingFluidized catalytic CrackingFluidized catalytic CrackingFluidized catalytic Cracking

Decomposition ProcessesDecomposition ProcessesDecomposition ProcessesDecomposition Processes

Hydro crackingHydro cracking

• A two-stage process combining catalytic cracking and hydrogenation,A two-stage process combining catalytic cracking and hydrogenation,

• Heavier feedstock cracked in the presence of hydrogen to produce more Heavier feedstock cracked in the presence of hydrogen to produce more desirable products like Kerosene, Gasoline & Diesel. desirable products like Kerosene, Gasoline & Diesel.

• Process employs high pressure, high temperature, a catalyst, and Process employs high pressure, high temperature, a catalyst, and hydrogen. hydrogen.

• Used for feed stocks that are difficult to process by either catalytic Used for feed stocks that are difficult to process by either catalytic cracking or reforming due to high polycyclic aromatic content and/or cracking or reforming due to high polycyclic aromatic content and/or high concentrations of catalyst poisons like sulfur and nitrogen high concentrations of catalyst poisons like sulfur and nitrogen compounds.compounds.– Atmospheric column residueAtmospheric column residue

– Vacuum column residueVacuum column residue

– Heavy Gas oils from Coker Heavy Gas oils from Coker

Hydro CrackingHydro CrackingHydro CrackingHydro Cracking

Decomposition ProcessesDecomposition ProcessesDecomposition ProcessesDecomposition Processes

VisbreakingVisbreaking

• Reduces viscosity of Vacuum residue by thermal processReduces viscosity of Vacuum residue by thermal process

• IFO generation reduces by 30 – 35% due to lower diesel requirement for IFO generation reduces by 30 – 35% due to lower diesel requirement for cutting viscositycutting viscosity

• LPG & Naphtha are produced as by-productsLPG & Naphtha are produced as by-products

Delayed CokingDelayed Coking

• A severe method of thermal cracking used to upgrade heavy residuals A severe method of thermal cracking used to upgrade heavy residuals into lighter products or distillates. into lighter products or distillates.

• Produces straight-run gasoline (coker naphtha) and various middle-Produces straight-run gasoline (coker naphtha) and various middle-distillate fractions used as FCCU feedstock. distillate fractions used as FCCU feedstock.

• The process completely eliminate hydrogen so that the residue is a form The process completely eliminate hydrogen so that the residue is a form of carbon called "coke." of carbon called "coke."

Delayed cokingDelayed cokingDelayed cokingDelayed coking

Unification ProcessesUnification ProcessesUnification ProcessesUnification Processes

PolymerizationPolymerization

• Makes high octane gasoline from olefins and refinery gases using Makes high octane gasoline from olefins and refinery gases using

catalystcatalyst

AlkylationAlkylation

• Same as polymerization but the end product has better performance in I. Same as polymerization but the end product has better performance in I.

C. Engines.C. Engines.

• Combines isobutane with light olefins to produce very high quality Combines isobutane with light olefins to produce very high quality

gasoline (RON >105)gasoline (RON >105)

Alteration ProcessesAlteration ProcessesAlteration ProcessesAlteration Processes

Catalytic reformingCatalytic reforming

• Convert low-octane naphthas into high-octane gasoline blending Convert low-octane naphthas into high-octane gasoline blending

components called reformates. components called reformates.

• Reforming is a mixture of cracking, polymerization, dehydrogenation, Reforming is a mixture of cracking, polymerization, dehydrogenation,

and isomerization taking place simultaneously. and isomerization taking place simultaneously.

• Depending on the properties of the naphtha feedstock and catalysts Depending on the properties of the naphtha feedstock and catalysts

used, reformates can be produced with very high concentrations of used, reformates can be produced with very high concentrations of

toluene, benzene, xylene, and other aromatics useful in gasoline toluene, benzene, xylene, and other aromatics useful in gasoline

blending and petrochemical processing. blending and petrochemical processing.

• Hydrogen is produced a significant by-productHydrogen is produced a significant by-product

Alteration ProcessesAlteration ProcessesAlteration ProcessesAlteration Processes

IsomerizationIsomerization

• Isomerization converts n-butane, n-pentane and n-hexane into their Isomerization converts n-butane, n-pentane and n-hexane into their

respective isoparaffins of substantially higher octane number. respective isoparaffins of substantially higher octane number.

• The straight-chain paraffins are converted to their branched-chain The straight-chain paraffins are converted to their branched-chain

counterparts whose component atoms are the same but are arranged in counterparts whose component atoms are the same but are arranged in

a different geometric structure. a different geometric structure.

• n-butane is converted into isobutane to provide additional feedstock for n-butane is converted into isobutane to provide additional feedstock for

alkylation units, alkylation units,

• N-pentanes and n-hexanes are converted into higher branched isomers N-pentanes and n-hexanes are converted into higher branched isomers

for gasoline blending. for gasoline blending.

Isomerization & Reforming processIsomerization & Reforming processIsomerization & Reforming processIsomerization & Reforming process

Naphtha

SPLITTER

ISOM

Naphtha HydrotreaterNaphtha Hydrotreater& Isomerization& Isomerization

GASOLINE

POOL

HydrotreaterHydrotreater

IsomerateIsomerate

ReformateReformate

H2

H2

H2

CCR

ReformerReformer

NHT Make up HMake up H22

Light NaphthaLight Naphtha

Heavy NaphthaHeavy Naphtha

LPGLPG

Treating ProcessesTreating ProcessesTreating ProcessesTreating Processes

• Intended to prepare hydrocarbon streams for additional processing and Intended to prepare hydrocarbon streams for additional processing and

to prepare finished products. to prepare finished products.

• Includes the removal or separation of aromatics and naphthenes as well Includes the removal or separation of aromatics and naphthenes as well

as impurities and undesirable contaminants. as impurities and undesirable contaminants.

• Involves chemical or physical separation such as Dissolving, Involves chemical or physical separation such as Dissolving,

Absorption, or precipitation using a variety and combination of Absorption, or precipitation using a variety and combination of

processes including desalting, drying, hydrodesulfurizing, solvent processes including desalting, drying, hydrodesulfurizing, solvent

refining, sweetening, solvent extraction, and solvent dewaxing. refining, sweetening, solvent extraction, and solvent dewaxing.

• Major Treating processMajor Treating process

– Solvent ExtractionSolvent Extraction

– Solvent DewaxingSolvent Dewaxing

– Solvent De-AsphaltingSolvent De-Asphalting

– Hydro-desulfurizationHydro-desulfurization

Solvent ExtractionSolvent ExtractionSolvent ExtractionSolvent Extraction

• The purpose of solvent extraction is to prevent corrosion, protect The purpose of solvent extraction is to prevent corrosion, protect

catalyst in subsequent processes, and improve finished products by catalyst in subsequent processes, and improve finished products by

removing unsaturated, aromatic hydrocarbons from lubricant and removing unsaturated, aromatic hydrocarbons from lubricant and

grease stocks. grease stocks.

• The solvent extraction process separates aromatics, naphthenes, and The solvent extraction process separates aromatics, naphthenes, and

impurities from the product stream by dissolving or precipitation. The impurities from the product stream by dissolving or precipitation. The

feedstock is first dried and then treated using a continuous feedstock is first dried and then treated using a continuous

countercurrent solvent treatment operation. The feedstock is washed countercurrent solvent treatment operation. The feedstock is washed

with a liquid in which the substances to be removed are more soluble with a liquid in which the substances to be removed are more soluble

than in the desired resultant product than in the desired resultant product

• The most widely used extraction solvents are phenol, furfural, NMP and The most widely used extraction solvents are phenol, furfural, NMP and

cresylic acid cresylic acid

Solvent ExtractionSolvent Extraction

FEED

DRY DRUMWET

DRUM

T206 EXTRACT

STEAM

EXT FURNACE

RAFF FURNACE

F-202

F-201

T-201TREATER

EXT. SOLN

RAFF SOLN

H2

RAF RECOVERY

EXT STRIPPER

STEAM

HP SEPERATOR

VAC DRIER

LP

S/G COMP

ST

RIPP

PE

R

T 203

T 202

HYDROFINER

NMP

SG

SG

Solvent DewaxingSolvent DewaxingSolvent DewaxingSolvent Dewaxing

• Solvent dewaxing is used to remove wax from either distillate or Lube oil Solvent dewaxing is used to remove wax from either distillate or Lube oil

base stock. base stock.

• Steps involve in solvent dewaxing are Steps involve in solvent dewaxing are

– Mixing the feedstock with a solventMixing the feedstock with a solvent

– precipitating the wax from the mixture by chillingprecipitating the wax from the mixture by chilling

– recovering the solvent from the wax and dewaxed oil for recycling by recovering the solvent from the wax and dewaxed oil for recycling by

distillation and steam stripping. distillation and steam stripping.

• The most widely used extraction solvents are Methyl Ethyl Ketone The most widely used extraction solvents are Methyl Ethyl Ketone

(MEK), Propane & Toluene (MEK), Propane & Toluene

Solvent DewaxingSolvent DewaxingSolvent DewaxingSolvent Dewaxing

Solvent De AsphaltingSolvent De AsphaltingSolvent De AsphaltingSolvent De Asphalting

• In this solvent extraction process, propane is used as a solvent In this solvent extraction process, propane is used as a solvent

• Heavy oil fractions are separated to produce heavy lubricating oil (Bright Heavy oil fractions are separated to produce heavy lubricating oil (Bright

Stock), catalytic cracking feedstock, and asphalt. Stock), catalytic cracking feedstock, and asphalt.

• Feedstock and liquid propane are pumped to an extraction tower at Feedstock and liquid propane are pumped to an extraction tower at

precisely controlled mixtures. Separation occurs based on differences in precisely controlled mixtures. Separation occurs based on differences in

solubility. solubility.

• The products are then evaporated and steam stripped to recover the The products are then evaporated and steam stripped to recover the

propane, which is recycled. propane, which is recycled.

Hydro de sulfurizationHydro de sulfurizationHydro de sulfurizationHydro de sulfurization

• Hydrotreating for sulfur removal is called hydrodesulfurization Hydrotreating for sulfur removal is called hydrodesulfurization

• The feedstock is deaerated and mixed with hydrogen, preheated in a The feedstock is deaerated and mixed with hydrogen, preheated in a

fired heater and then charged under pressure through a fixed-bed fired heater and then charged under pressure through a fixed-bed

catalytic reactor. catalytic reactor.

• In the reactor, the sulfur and nitrogen compounds in the feedstock are In the reactor, the sulfur and nitrogen compounds in the feedstock are

converted into H2S and NH3. converted into H2S and NH3.

• The liquid stream is sent to a stripping column for removal of H2S and The liquid stream is sent to a stripping column for removal of H2S and

other undesirable components.other undesirable components.

• H2S is further treated in Amine treating & Sulfur recovery unit to H2S is further treated in Amine treating & Sulfur recovery unit to

produce sulfur produce sulfur

Hydro desulfurizationHydro desulfurizationHydro desulfurizationHydro desulfurization

BlendingBlendingBlendingBlending

Blending is the physical mixture of a number of Blending is the physical mixture of a number of

different liquid hydrocarbons streams to produce a different liquid hydrocarbons streams to produce a

finished product with certain desired specificationsfinished product with certain desired specifications

Why Blending is required ?Why Blending is required ?Why Blending is required ?Why Blending is required ?

• Non compliance of individual streams from primary or secondary Non compliance of individual streams from primary or secondary

processing units to any product specification of its ownprocessing units to any product specification of its own

• Non availability of matching secondary processing facilities leading to Non availability of matching secondary processing facilities leading to

excess streams available for disposal as valuable products excess streams available for disposal as valuable products

• Disposal problem for by-products from treating units like extract from Disposal problem for by-products from treating units like extract from

solvent extraction unit or wax from dewaxing unit solvent extraction unit or wax from dewaxing unit

• Upgradation of valuable surplus streams due to lack of upliftment of Upgradation of valuable surplus streams due to lack of upliftment of

specific product and thus avoiding downgradation to heavy endsspecific product and thus avoiding downgradation to heavy ends

Blending maximizes the Refinery profitability by optimizing the overall Blending maximizes the Refinery profitability by optimizing the overall

production slate to extract maximum value from each barrel of crude production slate to extract maximum value from each barrel of crude

processedprocessed

Blended streams / ProductsBlended streams / ProductsBlended streams / ProductsBlended streams / Products

1.1. HSDHSD 3. IFO3. IFO– Heavy NaphthaHeavy Naphtha - VTB - VTB– KeroseneKerosene - JBO - JBO– LVGOLVGO - LVGO - LVGO– JBOJBO - Extract - Extract – VGOVGO - FCC Residue - FCC Residue– X’VGOX’VGO – LCGOLCGO 4. LSHS4. LSHS

2.2. LDOLDO - - VBOVBO• HVGOHVGO - LVGO - LVGO• LVGOLVGO - FCC Residue - FCC Residue• X’VGOX’VGO• I SSI SS 5. Gasoline5. Gasoline

- FCC Cracked - FCC Cracked NaphthaNaphtha

- St. run Naphtha - St. run Naphtha

Examples of blend optimizationExamples of blend optimizationExamples of blend optimizationExamples of blend optimization

• Possible routing of High ‘S’ I SS is 150N, LDO & IFOPossible routing of High ‘S’ I SS is 150N, LDO & IFOValue of I ss realized in 150 NValue of I ss realized in 150 N Rs 16850 / TRs 16850 / TValue realized in LDOValue realized in LDO Rs 15525 / TRs 15525 / TValue realized in IFOValue realized in IFO Rs 10060 / TRs 10060 / T

• Possible routing of VTBPossible routing of VTBValue realized in BitumenValue realized in Bitumen Rs 8400 / TRs 8400 / TValue realized in IFOValue realized in IFO Rs 4420 / TRs 4420 / T

ContentsContents ContentsContents

• Refinery growthRefinery growth• Refinery location & layoutRefinery location & layout• Crude processed Crude processed • ProductsProducts• 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

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%

SK O

6%

HSD

27%

LDO

4%

Lubes

4%

Bitumen

6%

IFO/LSHS

20%

Others

3%

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

• 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

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 1852 Crores (411 Mill. USD)Rs 1852 Crores (411 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