MUMBAI REFINERY

IT IS YOUR APTITUDE

AND

ATTITUDE

THAT ONLY WILL DETERMINE ALTITUDE

IN YOUR LIFE

• INTELLEGENCE IS QUICKNESS TO LEARN• ABILITY IS THE SKILL TO APPLY WHAT IS LEARNED• COMPETENCE IS THE ABILITY AND THE DESIRE TO APPLY WHAT IS LEARNED• DESIRE IS THE ATTITUDE THAT MAKES A SKILLFULL PERSON COMPETENT• MANY SKILLFULL PEOPLE ARE INCOMPETENT• ABILITY WITHOUT RIGHT ATTITUDE IS WASTED

LPG

NAPHTHA

PETROL

SOLVENTS

ATF

KEROSENE

DIESEL

LUBRICATING OIL

FUEL OIL

ASPHALT

CARBON BLACK FED STOCK -

HPCL - MUMBAI REFINERY PRODUCTS

DOMESTIC FUEL

PETROCHEMICALS

FERTILISERS

PLASITCS

DYES

PRIVATE TRANSPORT INDUSTRY

PAINTS

EDIBLE OIL REFINING

AVIATION TURBINE FUEL

DOMESTIC FUEL

INDUSTRY

ROAD BUILDING

SHIPPING

AUTOMOBIL / INDUSTRY

HIGH SPEED DIESEL

LIGHT DIESEL OILINDUSTRY

AGRICULTURE

TYRE INDUSTRY

CRUDE OIL

PETROLEUM HISTORY

• Col. Edwin Drake discovered oil in 1859 ,First to drill oil in village Titusville in Pennsylvania, called father of modern oil industry.

• 1865 JOHN D ROCKFELLER formed STANVAC.• 1908 oil struck in IRAN• 1927 in IRAQ• 1934 in KUWAIT• 1938 in S. ARABIA• 1950 in RUSSIA• 1960 OPEC was formed in Baghdad.• In India oil was struck in Makum near Margherita in Assam

1867

DISTRIBUTION OF CRUDE OIL RESERVES

• NORTH AMERICA 6%• SOUTH AMERICA 9 %• EUROPE 2%• FORMER SOVIET UNION 6 %• AFRICA 7 %• ASIA PACIFIC 4 %• MIDDLE EAST 65 % (PERSIAN GULF)

MAJOR OIL RESERVES IN WORLD

S. N. COUNTRY MILL. TONNES WORLD % SHARE

1 S. ARABIA 36000 25%2 IRAQ 15100 11%3 KUWAIT 13300 9%4 UAE 12600 9%5 IRAN 12300 9%6 VENEZUELA 10500 7%7 RUSSIA 6700 5%8 MEXICO 4100 3%9 LIBYA 3900 3%10 USA 3500 3%11 CHINA 3300 2%12 NIGERIA 3100 2%13 NORWAY 1400 1%14 INDIA / MAL. 600 0.5%

INDONESIA

WORLD TOP REFINERSNO. OF REFINERIES.

• U. S. A. 154 165 LAKH B/D

• CHINA 95 45 LAKH B/D

• RUSSIA 51 73 LAKH B/D

• JAPAN 35 50 LAKH B/D

• INDIA 17 23 LAKH B/D

MAJOR OIL CONSUMERS IN WORLD (MMT)

S. N. COUNTRY TOTAL OIL DEMAND OWN PRODN. OIL IMPORT

1 U.S.A. 900 350 5502 CHINA 200 160 403 RUSSIA 180 300 (-)1204 JAPAN 260 -0 2605 GERMANY 130 0 1306 FRANCE 100 0 1007 INDIA 100 36 648 S. KOREA 100 0 1009 ITALY 90 6 8410 BRITAIN 80 140 (-)6011 UKR 1312 BRAZIL 80 60 2013 MEXICO 80 170 (-) 9014 SPAIN 70 0 7015 IRAN 60 175 (-)10516 S. AFRICA 20 0 2017 S. ARABIA 60 400 (-)34018 AUSTRALIA 40 25 15

LOCATION REFINERY CPACITY PRODUCTION MMT 2004-05 MMT

NORTH IOC MATHURA 8.0 6.383IOC PANIPET 6.0 6.387

SOUTH HPCL-VIZAK 7.5 7.826CPCL 6.5 8.181KRL 7.5 7.924CPCL-NARIMANAM 0.5 0.742

EAST IOC-GUWAHATI 1 1.002IOC-BARAUNI 4.2 5.078IOC-HALDIA 4.6 5.419IOC-DIGBOI 0.65 0.651BRPL-BONGAIGAON 2.35 2.312NRL NUMALIGARH 3.00 2.042

WEST IOC KOYALI 13.7 11.701 BPCL-MUMBAI 12.0 9.138 HPCL-MUMBAI 5.5 6.119 MRPL-MANGLORE 9.7 11.809 RPL JAMNAGAR 27 34.308 TOTAL 119 127.114

OIL REFINEIES IN INDIA

HPCL PERFORMANCE CRUDE PROCESSING MMT/YR

YR CRUDE PROCESSED

MR VR

1999 - 00 10.5 6.0 4.56

2000 - 01 11.98 5.58 6.4

2001 - 02 12.33 5.63 6.7

2002 - 03 12.93 6.079 6.85

2003 - 04 13.7 6.10 7.60

2004 - 05 13.94 6.11 7.84

CRUDE OIL COMPOSITION

Elemental composition

Typically over 95% hydrogen + carbon (hydrocarbons)

Hetroatoms as undersirable contaminants ( sulphur, nitrogen,

oxygen, nickel, vanadium, iron)

Possibly thousands of compounds.

Boiling range -256 to 1000oF.

Principal organic compounds

Paraffins

Naphthenes

Aromatics Asphaltenes

PARAFINIC SERIES.

• CH4 METHANE C2H6 ETHANE C3H8 PROPANE C4H10 BUTANE C5H12 PENTANE C6H14 HEXANE C7H16 HEPTANE C8H18 OCTANE C9H20 NENONE CnH2n+2 xxx.

TYPES OF CRUDES PROCESSED AT OUR REFINERIES

REFINERY LOAD PORT COUNTRY GRADES

MUMBAI RASTANURA

RASTANURA

ZIRKU. ISLAND

BY PIPELINE

S. ARABIA

S. ARABIA

ABU DHABI

INDIA

ARAB LIGHT

ARAB MIX.

UPPER ZAKUM

BOMBAY HIGH

VISAKH VISAKH

FATEH

MINA AL AHMADI

AL BAKER

AL SHIHR

NIGERIA

INDIA

DUBAI

KUWAIT

IRAQ

YEMEN

NIGERIA

RAWA

DUBAI

KUWAIT

BASARA LIGHT

MASILA

QUAIBE

BONNY LIGHT

ESCRAVOS

FORCADOS

CABINDA

CRUDE SELECTION IS A VERY IMPORTANT PROCESS.

Once selected, refinery yields are largely predetermined.

Crude units are designed on a particular crude or crude mix and therefore running of other crudes may result in sub-optimal operation.

Constrains may be overcome by blending crudes appropriately.

The same crude in different types of refineries will give different yields.

Different crudes in the same refinery will give different yields.

Crudes And Characteristics

• SAUDI ARABIAN CRUDES.• CRUDE API SUL. WT%

Arabian Extra Lt 36.4 1.19

Arabian Heavy 27.5 2.92

Arabian Light 32.7 1.8

Arabian Medium 31.8 2.45

Arabian Super Lt 50.6 0.04

IMP. PROPERTIES OF CRUDES.

• 80/20 ARAB MIX B. H. CR.

•

• SPECIFIC GRAVITY 0.8640 0.8280

• API 32.30 39.40

• BARRELS/TONNE 7.3 7.65

• SULPHUR WT% 2.030 0.170

• POUR POINT DEC C -35.0 30.0

PETROLEUM REFINING

PETROLEUM REFINING IS A GROUP OF PROCESSES TO

CONVERT THE CRUDE OIL TO WIDE RANGE OF HIGH

VALUE AND HIGH DEMAND PRODUCTS. IT IS DIVIDED

INTO FOUR TYPES :

•SEPERATION

•CONVERSION

•TREATING

• BLENDING

SEPERATION

SEPERATION IS THE 1ST PROCESS / STEP INVOLVING A BASIC

PRINCIPLE OF DERIVING PRODUCTS BASED ON PHYSICAL

PROPERTIES LIKE MOL, WT, SIZE AND B.P. IT IS THE MOST

VERSATILE METHOD AND MOST ECONOMIC BY WAY OF

DISTILLATION. THE MOLECULAR STRUCTURE OF THE

HYDROCARBON MOLECULE REMAINS MORE OR LESS

UNCHANGED AND NO NEW COMPOUNDS ARE FORMED. THE

VARIOUS COMPONENTS ARE SEPARATED OUT FROM

DISTILLATION TOWER OVER A RANGE OF BOILING POINTS.

THESE SIDE STREAMS / CUTS DRAWN OUT FROM THE

DISTILLATION UNIT TOWER ARE THEN SUBJECTED TO

FURTHER PROCESSES TO OBTAIN THE FINAL PRODUCTS FOR

SALE.

Distillation is defined as a process in which a liquid or vapour mixture of two or more substances is seperated into its components fractions of desired purity by application and removal of heat

This process of seperating components of liquid mixture is based on their difference in boiling points.

WATER

WATER

Thermometer

Cooler / condenser

Mixture

DistillateHeat

SIMPLE DISTILLATION

WATER

EFF. WATER

CRUDE TANK

F.O. F.G.

PUMP PRODUCT

DESALTEREXCHANGER EXCHANGER

FURNACE

FBS D/O

ATF / KERO D/O

LVGO D/O

JBO D/O

HVGO D/O

RCO TO VPS

UNSATBILISED NAPHTHA TO STABILISER + COMPRESSOR

CRUDE DISTILLATION UNIT

BUBBLE CAP TRAYS

• BUBBLE CAP TRAY IS FLAT PERFORATED PLATE WITH RISER AROUND THE HOLES AND THE CAPS IN THE FORM OF INVERTED CUPS OVER THE RISER.

SIEVE TRAYS

• THE SIEVE TRAY IS A PERFORATED PLAT.VAPOUR RAISES THROUGH THE HOLES TO GIVE MULTIORIFICE EFFECT.THE VAPOUR VELOCITY KEEPS LIQUID FROM FLOWING DOMMWN THROUGH THE HOLES.

VALVE TRAYS

• THE VALVE TRAY HAS A VALVE DISKS WHICH RISE AS VAPOUR RATE IS INCREASED. THE VALVE OPENING IS ADUSTED ACCORDING TO THE THE VAPOUR FLOW. VALVE OPENING REDUCES WHEN VAPOUR FLOW IS LESS. THIS STOPS LIQUID WEEPING.

CHIMNEY TRAYS

• TRAYS USED FOR LIQUID DRAW OFFS

• NO MASS TRANSFER ACROSS THE TRAY

D/O

TYPICAL 1 - 2 SIEVE TRAY CONFIGURATIONFOR DISTILLATION COLUMN

VL

L

L L V V

V V

D/O

VALVE TRAYS

VL

V

MIDDLE DISTILLATES :- 40 to 45 %.

** Further Distilled at normal pressure to get final product or blending streams.

CRUDE SEPARATION

LIGHT ENDS :- 12 to 15 %.

** Further Distilled at high pressure ( > 120 psig. ) to separate - C3 , C4 , C5 , C6 .

HEAVY ENDS :- 35 to 40 %.

** Further Vacuum Distilled to get Lube product or blending streams.

HOT

CRUDE

WATER

EFF. WATER

CRUDE TANK

F.O.

F.G.

PUMP PRODUCT

DESALTEREXCHANGER EXCHANGER

FURNACE

FBS D/OATF / KERO D/O

LVGO D/O

JBO D/OHVGO D/O

5

12

19

32

42 / 48

RCO TO VPS

UNSATBILISED NAPHTHA TO STABILISER + COMPRESSOR

30 0C

120 0C 270 0C 365 0C

348 0C

165 0C

200 0C

260 0C

330 0C

350 0C

108 0C1.7 Kg/cm2

CRUDE DISTILLATION UNIT

PRODUCT

RCO TO VPS

CRUDE DISTILLATION TOWER

DISTILLATION COLUMN.

FBS 160 0C

ATF/ KERO201 0C

LVGO

268 0C

JBO336 0C

HVGO

351 0C

BPA

TPA

Cooler

Cooler

CRUDE from Furnace O/L.

LVN to LEU

UNSATBILISED NAPHTHA LVN

4

1

FBS

1

4

ATFSTEAM

STEAM

FBS

STEAM

STEAM

LVGO

49

55

TRAY # 1

DISTILLATE DRUMD-1001

APS T-301

4

5

BPA

RCO

STEAM

FLOW PLANE FOR FR - APS DISTILLATION SECTION

HEATED CRUDE

4

1

1

4

HVGO

LVGO

JBO

STRIPPER

STRIPPER

REFLUX

NAPHTHA

WATER

6

1

4HVGO

STEAM

12

17

21

22

20

19

TPA

28

30

3233

4243

48

51

13

ATF

O/ H Condenser

TOWER DETAILS

Bottom Section :- 8 ft. dia. x 8 ft. Ht.

Middle Section :- 16 ft. dia. x 48.75 ft. Ht.

Top Section :- 14 ft. dia. x 80 ft. Ht.

Trays 1 -- 55 :- Sieve Trays - Double pass

Tray Spacing :- 2 - 2.75 Ft.

Tray Hole Diameter - 1/2 inch.

PUMP

4

1FBS

1

4

SKO

STEAM

STEAM

FBS

SKO

4

1

1

4

STEAM

STEAM

LVGO

JBO

LVGO

JBO4

5

10

17

20

21

31

34

35

49

58

TRAY # 1

DISTILLATE DRUMD-1001

APS T-1001

TPA

BPA

RCO

STEAM

TOWER DETAILS

Bottom Section :- 8 ft. dia. x 8.8 ft. Ht.

Middle Section :- 16 ft. dia. x 77. 5 ft. Ht.

Top Section :- 12 ft. dia. x 50 ft. Ht.

Trays 1 -- 58 :- Sieve Trays - Double pass

Tray Spacing :- 2 - 3 Ft.

Tray Hole Diameter

FLOW PLANE FOR FRE - APS DISTILLATION SECTION

HEATED CRUDE

STRIPPER

STRIPPER

REFLUX

NAPHTHA

WATER

PUMP

LVN

FBS

ATF

LVGO

JBO

HVGO

RCO

VR.LPG

HEXANE

NAPHTHA

HSD

ATF

HSD/IFO

HSD/LDO

LDO/RFO

LUBE feed

LVN

FBS

KERO

LVGO

JBO

RCO

VR.LPG

SOLVENT

HSD

HSD/IFO

HSD/IFO

LSHS

L.E. L.E.

DISTILLATES

T-301

T-1001

P.G.

CRUDE

BH

CRUDE

80/20 AM CRUDE BH CRUDE

H.E.

MID

DL

E

DIS

TIL

LA

TE

S

MID

DL

E

DIS

TIL

LA

TE

S

H.E.

F.O.

F.G.

FURNACE

EXCESS VGO D/O TO DIESEL

I –SS D/O TO LUBE

II – SS D/O TO LUBE

III – SS D/O TO LUBE

4

5

9

14

VTB TO ASPHALT / DE-ASPHALTING

VGO TO DIESEL

406 0C

330 0C

165 0C

265 0C

335 0C

375 0C

112 0C-0.88Kg/cm2.

VACUUM DISTILLATION UNIT

348 0C

RCO

399 0C -.63Kg/cm2.

VACUUM DISTILLATION FOR HEAVY ENDS

VDU S.S. conversion

Sr.No

SIDE STREAM 1st Step 2nd Step 3rd Step Product

1 XVGO

(TOBS)

NMP

extracted

Hydrogenated Dewaxed Spindle oil

2 1 s. s.

( M.O.)

NMP extracted Hydrofined Dewaxed 150 N

150 turbine oil

3 2 nd S. S.

( M. O.)

NMP extracted Hydrofined Dewaxed 500 N

500 Turbine

4 3rd S. S.

(M. O. operation).

3rd S. S.(I. O.)

NMP extracted Hydrofined Dewaxed

Dewaxed

1300N

Railex

250/350

5 VTB Propane

Deasphalted

NMP extracted Hydrofined

Dewaxed Bright Stock.

LUBE PLANT OVERVIEW.PROCESS

• VDU

• (DISTILLATES / SS)

• PROPANE DEASPHALTING UNIT(PDA)

• SOLVENT EXTRACTION

• HYDROFINER

• (HYDROFINED

• RAFFINATE)

• PROPANE DEWAXING UNIT(PDU)

• (DEWAXED OIL)

CONTROL FUNCTION

• VISCOSITY, COLOR, FLASH POINT.

• VISCOSITY, COLOR, CCR

• VI

• COLOR-STABILITY, DENITRIFICATION, DE-SULPHURIZATION

• CLOUD POINT , POUR POINT

MUMBAI REFINERY

DRUM

LPG FOR TREATING

WATER

O/ H Condenser

PUMP

PUMP

PREHEATER

LANREBOILER

STEAM

MEROX UNIT

HEXANE FEED

HIGH PRESSURE DISTILLATION FOR LIGHT- ENDS FRACTIONATOR

CONVERSION

PROCESS CAUSES A CHANGE IN THE SIZE AND STRUCTURE OF

HYDROCARBON MOLECULE. IT INVOLVES A CHEM. CHANGE

OF THE PETROLEUM FRACTIONS OR STREAMS WHICH ARE

EXCESS IN ORDER TO MAKE THEM MARKETABLE AND HIGH

VALUE PRODUCTS. IF CRUDE OIL IS SUBJECTED TO

SEPERATION PROCESS ONLY THEN PRODUCT AVAILABILITY

OF REINERY WILL BE TOTALLY OUT OF BALANCE V/S MARKET

DEMANDS. HENCE ADDITIONAL PROCESSES HAVE TO BE

EVOLVED LIKE.

CONVERSION PROCESSES

SOME OF THE CONVERSION PROCESS MAINLY USED TO MAXIMISE / IMPROVE GASOLINE

A] CATALYSTIC REFORMING.

B] ALKYLATION.

C] ISOMERISATION.

D] HYDROTREATING.

E] CATALYTIC CRACKING.

F] HYDROCARCKING.

CRACKING : BREAKING DOWN OF LONG CHAIN , MOLECULE IN TO SMALL MOLECULES.

| | | | | | | | | |-C- -C- -C- -C- -C -C- -C -C- -C- -C- | | | | | | | | | |

FCCU

WAXYDISTILLATES

FUEL GAS

LPG

PETROL

DIESEL

RESIDUE

Heavy waxy oils Catalyst

Heat Light Hydrocarbons

CAB

MAB

CATFEED

REACTOR PRODUCTTo FRACTIONATOR

WASTE HEATBOILER

DILUTE PHASESPRAY

EMERGENCYSTACK SPRAY

REGENERATED CATALYST

SPENT CATALYST

RISER

CYCLONES

Fluid Catalytic Cracking Unit. ( FCCU )

FRESH CATADDITIONLINE

ROV

ROV

INJ STEAM

Gas plant

Gasoline

Gas

LPG

FRACTIONATOR REACTOR

REGENERATOR

Light Gas Oil

Heavy Gas Oil

Resid

Yields % W

5

18

40

30

12

4

To CO-Boiler

15

CAB

MAB

CATFEED

REACTORPRODUCTTO FRACTIONATOR

WASTE HEATBOILER

DILUTE PHASESPRAY

EMERGENCYSTACK SPRAY

PDRC

TT

PT

PT

STACK

TO COB

RISER

CYCLONES

STRIPPINGSTEAM

FCC REACTOR & REGEN SECTION

TT

TT

680C

TT

FRESH CATADDITIONLINE

ROV

ROV

675C

24PSIG

28PSIG

500C

508C

508C

INJ STEAM

: BLENDING

* FINAL PROCESS FOR OBTAINING THE BEST POSSIBLE PRODUCT RANGE OUT OF ANY CRUDE OIL BY JUDICIOUS MIXING OF VARIOUS SIDE STREAMS AND BY PRODUCTS.

* SOME SIDE STREAMS FROM DISTILLATION TOWERS AS WELL AS STREAMS OBTAINED FROM THE SECONDARY PROCESSING UNITS LIKE FCCU CAN NOT BE MARKETED IN ISOLATION DUE TO REASONS LIKE LACK OF DEMAND OF UNSUITABILITY OF THEIR PROPERTIES.

* THESE SS’s ARE MIXED WITH EACH OTHER AND IN APPROPRIATE RATIO AND A PROPER BELND OF “COMBINATION” IS FORMULATED TO THE REQUISITE PROPERTIES FOR SPECIFIC APPILCATIONS.

PRODUCT PROPERTIES.

• FLASH POINT : LOWEST TEMP. AT WHICH VAPOURS FROM THE OIL IGNITE INSTANTANEOUSLY.

• POUR POINT : LOWEST TEMP. AT WHICH THE OIL NO LONGER FLOW.

• FREEZING POINT: CONSTANT TEMP. AT WHICH OIL SOLIDIFIES.• VISCOSITY : A MEASURE OF RESISTANCE TO FLOW OF OIL.• RECOVERY%: PERCENT OF OIL DISTILLED AT 370 DEC. C.• SULPHUR% : SULPHUR CONTAIN IN OIL AS WT %• OCTANE NO.: DETERMINES THE ANTI-KNOCK PROPERTY OF

GASOLINE. HIGHER THE OCTANE BETTER THE ANTI-KNOCK PROPERTY OF GASO.

• VISCOSITY INDEX: dv/dt. DETERMINES LUBRICATING PROPERTY OF LUBE OIL.

IMP. SPECS OF BLENDED PRODUCTS.

• SULPHUR POUR POINT FLASH POINT. VISCOSITY RECOVERY.

• WT.% DEC.C DEC. C SSU %

• HSD 0.25/0.05 18 SUMMER 32 MIN. 50@100F 95%@ 370C

• 6 WINTER MAX.

• LDO 1.8 21 SUMMER 66 MIN. 80 @100F

• 12 WINTER MAX.

• IFO 4.0 MAX. 27 MAX. 66 MIN. 820 @ 50C

• LSHS 1.2 60 MAX 66 MIN. 14MIN TO 59MAX

• @100 C

MUMBAI REFINERY PROCESS UNITSMUMBAI REFINERY PROCESS UNITS

LPG

PG CRD

BH RCO

LPG

NAPHTHAATF/SKO

LDO

LSHS

MS

ASP./ IFO

LUBE BLOCK

LOBS

PG RCO

FR

APS

FR/LRVPS

FRE

APS

BH CRD F

CCU

L E Unit

ATF Treating

LPG

NAP

SKO/MTO

DHDS

HSD

HSD

H S D

EL HSD

“S”

FREVPS

DISTRIBUTED CONTROL SYSTEM

• DCS. CONTROL ROOM

- FLOW

- PRESSURE

- TEMPERATURE

- LEVEL

* O M & S AUTOMATION AND AUTO- PRODUCT BLENDING.

• APC.

TREATING :REFINERY OPERATION FOR REMOVAL OF UNDESIRABLE COMPONENTS OR IMPURITIES LIKE - CRUDE DESALTING FOR REMOVAL OF SALTS, SEVERAL OPTION FOR REMOVAL OF H2S OR MERCAPTANS AND AROMATICS BY VARIOUS TREATMENTS.

--H2S AND R-SH REMOVAL FROM LPG BY MEA AND

CAUSTIC TREATMENT

-- H2S AND R-SH REMOVAL FROM NAPHTHA BY MEROX

AND CAUSTIC TREATMENT

-- HYDRODESULPHURISATION OF HSD TO REMOVE

SULPHUR

- REMOVAL OF H2S AND R-SH FROM ATF BY MEROX

AND CAUSTIC TREATMENT

REFINERY PROCESS UNITS REFINERY PROCESS UNITS REFINERY PROCESS UNITS REFINERY PROCESS UNITS

• CRUDE DISTILLATION - 2

• VACUUM DISTILLATION - 3

• F C C U

• D H D S

• NAPHTHA STABILISER - 2

• NAPHTHA CAUSTIC & MEROX TREATING

• HEXANE MAXIMISATION UNIT

• LPG TREATING FACILITIES

• PROPANE UNIT

• ATF TREATING

• BITUMEN BLOWING UNIT

REFINERY PROCESS UNITS REFINERY PROCESS UNITS REFINERY PROCESS UNITS REFINERY PROCESS UNITS

REFINERY PROCESS UNITS

• LUBE EXTRACTION UNITS-3

• LUBE HYDROFINER - 2

• PRPANE DEWAXING UNIT.

• PROPANE DEASHALTING UNIT.

• BOILER HOUSE.

CAPTIVE POWER PLANT

• GTG 1, 2, 3, 4, CAP 7.18 MW EACH

STEAM 33.3 T/HR EACH

• GTG 5 CAP 20 MW

STEAM 60 T/HR

A.Mix. BH CRUDE

(Weight %)

LPG 1.1 2.4

MS 00 5.8

NAPTHA 12.6 13.4

ATF/KERO 16.5 12.0

HSD 20.2 48.8

LDO 7.3 00

LUBES 6.3 00

IFO 26.3 00

ASPHALT 8.6 00

LSHS 00 11.6

F& L 7.0 7.0

PRODUCT STATE

TOTAL PRODUCTS = 30FUELS=13 LUBES=10 SPECIALITIES=7

• FUELS PRODUCTS = 13

1 PROPANE 9 LIGHT DIESEL OIL

2 LPG 10 KERO

3 GASOLINE 11 SPL. CUT KERO

4 LOW AROMATIC NAPHTHA

5 HIGH AROMATIC NAPHTHA

6 SPECIAL CUT NAPHTHA 12 FUEL OIL NORMAL

7 AVIATION TURBO FUEL

8 HIGH SEED DISEL 13 LSHS.

TOTAL PRODUCTS = 30FUELS=13 LUBES=10 SPECIALITIES=7

• LUBE PRODUCTS=10

• NEUTRAL OILS=3

• TURBINE OILS =2

• INDUSTRIAL OILS=2

• SPINDLE OIL

• TRANSFORMER OIL BASE STOC

• BRIGHT STOCK

• SPECIALITIES = 7• HEXANE • SOLVENTS = 2• CBFS / RPO = 2• ASPHALTS =1• SULPHUR

PRODUCT MOVEMENT FACILITIES

BPT PIRPAUMANIFOLD

TROMBAYO N G C

HPHPHP

JAWAHARDWEEP

NAPHTHA,HSD,KERO/ATF

SP. OILS

TATA

LSHS

LONI,WADALA

SEWREE,MAZGAON

WADI BUNDER

BH-GAS / NGLLPG

SANTACRUZ

TERMINAL

LPG BOTTLING PLANT

BPCLREFINERY

MAHUL

VASHI

HP REFINERY

PIRPAV

M / F

BPCL REF.

HPCL REF.

NEW PIRPAV

J 1 J 2 J 3

J 4

SEWREE WADALA

C-1 C-2

W-1W-2

W-3

BOL

C-1 - CRUDE LINE

W-1 - NAPHTHA LINE

W-3 - KERO LINE

BOL- BLACK OIL LINE

C-2 - CRUDE LINE

W-2 - HSD LINE

C-1 W-1W

-1

W-2 W-3

BOL

W-2

W-3

C-1C-2

WATER

BOL

LPG

LSHS

MPT - PIPE LINE NEWTWORK

FACTORS DETERMINIG GRM

• TYPE AND QUALITY OF CRUDE.

• REFINERY TYPE HARDWARE AND COMPLEXITY.

• EFFICIENCY OF UTILIZATION OF GIVEN HARDWARE

• ENERGY EFFICIENCY OF REFINERY OPERATION.

• PREVAILING CRUDE AND PRODUCT PRICES.

• CRUDE FREIGHT COST.

ENVIRONMENT PROTECTION.

• Every component of our ecosystem is it AIR, WATER or LAND is affected due to changes in their inherent characteristics due to industrial activities

• Management of solid waste mass which is generated like sp. Catalyst, spent/used charcoal, oil sludge from storage tanks.

• Management of liquid waste like effluents going out. ETP-1, ETP-2 (pH, O&G,SS,Sulphides,COD,BOD Phenol,Temp.)

• Management of air pollutants.Air quality monitoring, furnace stack emissions control.(SPM,SO2,NOX,CO)

• ISO 14001 and environmental policy.

GFEC PROPOSED PROJECT• GREEN FUELS AND EMISSION CONTROL

PROJECT.• Bring down gasoline sulphur content from existing 1000

wppm to 150 wppm and 50 wppm for EURO3 and EURO 4 respectively.

• Octane to be incresed from existing 89 to 95 for premium gasoline and 91 for regular gasoline.

• Benzene content to be reduced to 1% vol. From 3% vol. Max

• Olefines to be reduced from existing 55vol.% to 18vol% for premium and21vol.% for normal

• Aromatics content to 42vol.% and 35vol% for euro 3 &4

EXCELLENCE

• EXCELLENCE IS A JOURNEY, NOT A DESTINATION.

• EXCELLENCE can be attained

• If You care more than others think is wise.

• Risk more than others think is safe.

• Dream more than others think is practical.

• And expect more than others think is possible.

THANK YOUTHANK YOU