Refineries
Overview
History
Refinery Performance
New Projects
Energy Conservation
Safety & Environment
Research & Development
Recognition & Awards
Contact us
Overview
Hindustan Petroleum Corporation Limited (HPCL) is a Global Fortune 500 company in the Energy business. HPCL has two refineries located in Mumbai (West Coast) with a capacity 5.5 MMTPA and Visakh (East Coast) with a capacity 7.5 MMTPA, producing wide range of petroleum products, viz. LPG, MS, SKO, ATF, HSD, Bitumen etc. and over 300 grades of lubricants, specialties and greases as per BIS standard. HPCL has been sustaining almost 20% of India’s refining requirements
Mumbai Refinery is a Lube based refinery with the largest lube production capacity in India.. The refinery produces superior quality lube base oils. The offsite product handling facilities of refineries at Mumbai and Visakhapatnam has been automated. Projects have been implemented and facilities upgraded to produce green fuels like unleaded petrol and low sulphur diesel.
The refineries have been benchmarked by an international agency for various performance parameters. Both the refineries are recipients of numerous awards in recognition of their efforts in the field of energy conservation, environment and safety.
Both the Refineries have grown over the years and maintained their capacity utilization above 100% of their installed capacity.
History
Mumbai Refinery
Visakh Refinery
Refinery Performance (Last 5 years)
Crude Thruput in MMTPA
Crude Thruput in MMTPA for the period FY-2002-03 to FY2006-07
New Projects
Identification and implementation of projects for improvement of refinery margins, safety and environment is an ongoing process. The following new projects are being undertaken by both refineries to increase the profitability / margin of refineries
Refineries are implementing various projects for profitability and product quality improvement. The major projects that are under advance stages of implementation in this regard are as follows:
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Facilities for Euro-III & IV grade Gasoline :Refinery is executing Green Fuels & Emission Control Project (GFECP) to install the facilities for producing BS-III/IV gasoline. The project is expected to be completed by 2nd Quarter of 2008-09. Along with meeting quality stipulations, the project will also enable refinery to upgrade Naphtha to Gasoline, i.e. value added product.
- New FCCU project at Mumbai Refinery:In order to enhance production of value added products like LPG, MS and HSD, Refinery is installing a new FCCU of 1.4 MMTPA capacity. The total VGO processing capacity will increase from existing level of 1 MMTPA to 2.4 MMTPA and expected to be completed by 3rd qtr of 2008-09.
- Environmental facilities:Environmental facilities are being upgraded by installing an Integrated Effluent Treatment Plants to comply with Pollution control board limits.
- Clean Fuel Project (CFP):Refinery is executing Clean Fuel Project (CFP) to install the facilities for producing BS-III/IV gasoline. The project is expected to be completed mechanically by second quarter of 2008-09.
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Delayed Coker project:Visakh Refinery is setting up delayed Coker project for bottom upgradation.
- LOBS Project: Mumbai refinery produces various grades of LOBS with sulphur above 300 ppm and saturates below 90%, which fall under API Gr-I category. Customer requirement & market demand is for LOBS quality with sulphur below 300 ppm and saturates above 90%, which falls under API Gr-II category. Hence, to retain/increase market share of LOBS, under this project, it is intended to improve LOBS specifications to API Gr-II category,by 2010, with a capability to produce API Gr-III.
Energy Conservation (ENCON)
Refinery uses energy in various forms viz., fuel, steam, electricity, etc. in different process units for converting crude oil to usable petroleum products. Most of these refinery processes are energy intensive and themselves use part of the finished products produced in the refinery to derive their energy requirement. Thus any reduction in consumption of energy directly results in higher availability of finished products, which in turn results in higher profit. Hence, energy conservation has direct impact on refinery profits.
HPCL Refineries accord highest priority to energy conservation and both Refineries have a dedicated Energy Conservation (ENCON) cell, consisting of Managers & Engineers, to monitor ENCON measures on a day - to - day basis. It has been a constant endeavor of our Refineries to make optimal use of energy and this philosophy has been zealously pursued over the years. Since the last decade, HPCL Refineries are currently implementing new projects, coupled with increased awareness levels amongst the employees, have resulted in continuous lowering of fuel consumption and loss over the years.
Various ENCON measures at HPC Refineries
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Energy Conservation Measures implemented in the past include:
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Adoption of co-generation principle for generation of steam / power, etc. which includes installation of FCCU CO - Boiler at Mumbai Refinery
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Modernization of Fired Heaters
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Maximization of crude preheat by optimization of Heat Exchanger Train using Pinch Technology
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Effective use of Waste Heat
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Modernization of Instrumentation and Advanced Control Strategies
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HPCL was one of the first oil companies in the country to initiate and implement full-fledged automation of its offsite facilities at both the Refineries. The facilities comprise of the following:
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Automation of tank gauging & inventory management system
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Advanced on - line blend control
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Continuous on - line monitoring of quality of critical products / streams
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Accurate measurement and monitoring of custody transfer operations
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Continuous monitoring of critical off - site transfer pumps
The Off site Automation facilities have been designed to reduce loss, reduce quality giveaway, optimize allocation of various Refinery streams to give final blended product, improve overall distillate yield and improve product accounting.
As a part of this project, a customized software package has been implemented which models the Refinery operation. The model will help to decide optimal crude mix based on prevailing prices & demand of various products and optimize plant throughputs and product slate to get maximum netbacks.
- A detailed Hydrocarbon loss study has been carried out by M/s British Petroleum for Mumbai Refinery and the various recommendations implemented.
- A brief on some recently completed equipment related energy conservation related activities at both Refineries is as follows:
- Sonic Soot Blowers installed at boiler house which uses kinetic energy of sound waves to avoid soot deposition. This results in direct steam savings as compared to conventional steam soot blower
- On - line oxygen analyzers on furnaces / boilers have been provided to control excess air. These measures the oxygen content of flue gas on continuous basis. Control of oxygen content in flue gas helps in improving the furnace efficiencies
- Ultrasonic Flare meters have been provided to measure the flow rates as well as molecular weights of different hydrocarbons going to the flare. This helps to identify the source, type, and quantity of hydrocarbon going to flare.
- Mass flow meters have been installed in various furnaces / heaters for monitoring individual furnace fuel consumption
- CCTV for round-the-clock viewing / controlling of flare stack has been installed
- Electronic themoprobes have been installed for taking accurate measurement of tank temperatures. The measurement of accurate temperature reduce the inaccuracy in accounting due to inaccurate temperature readings, which were earlier reflected in hydrocarbon loss
- A CO - Boiler is being installed as part of FCCU - I revamp under the second Expansion Project of VR. The CO - Boiler will result in recovery of heat from FCCU flue gas and generation of steam
As a result of the various afore mentioned ENCON projects / measures the Fuel & Loss for Visakh Refinery has reduced from 7.46 wt% in 1985-86 to a level of 5.4 wt% for 1999-2000 and specific energy consumption reducing from 242.4 MBTU/BBL/NRGF to 121.5 MBTU/BBL/NRGF.
There has been similar significant improvement in Mumbai Refinery as well and currently the Fuel & Loss for Mumbai Refinery is restricted to 5.5 wt% (average for last few years) and specific energy consumption is 125.5 MBTU/BBL/NRGF. These figures compare favorably with national/ international Fuel & Loss and Specific Energy Consumption levels.
Environment & Safety:
Our Commitment to Environment
As a corporate citizen, HPCL is committed to environment protection and constantly endeavors to ensure that increasing scale of operation does not lead to environment degradation. HPCL conferred with International Safety Rating System (ISRS) level 8 which is comparable safety level with International Refineries. The efforts of the both refineries were well recognized in the Industry and have been awarded from various Government as well as Non Government Organizations for the effort towards safety.
The "Environment Policy" adopted by the Corporation commits it to conduct all its operations in such a way as to be compatible with the environment. Both the refineries of HPCL have systems and procedures, which ensure compliance with MINAS standards and other statutory stipulations of CPCB and State PCBs. Extensive green coverage has been provided in our Refineries and continuous efforts are being made on this front in areas surrounding the Refineries.
Effluent Treatment Plants take care of process waste water, floor wash water and tank farm drains. API separators and skim pond handle cooling water discharge. SO2 emission is controlled by sulphur recovery units. FCC Unit has a CO Boiler to burn CO generated so that no CO is emitted to the atmosphere.
The major environmental projects like DHDS have been completed and commissioned producing HSD with less than 0.25 % sulphur. The Refineries have Continuous Ambient Air Monitoring Stations inside the Refineries which measures ambient air quality in and around the Refineries' premises in coordination with State Pollution Control Board meeting the regulations of Ministry of Environment and Forests.
Environment Protection Measures
Mumbai & Visakh refineries have been meeting the statutory regulations and standards set by Pollution Boards and Ministry of Environment & Forest, Govt. of India. Both refineries have been certified as ISO 14001.
Mumbai Refinery
The following environmental protection activities have been carried out.
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Three new RSPM Analyzers were installed and commissioned at all three Ambient Air Monitoring Stations in the refinery
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Thirteen Stack Analyzers were installed and commissioned on major fire equipment in the refinery
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Mechanical Oil recovery from oily sludge has been started.
Visakh Refinery
Several innovative environmental protection steps were taken during the year. The efforts were recognized in the form of an Award for “Best innovative measures in Environment” from Honorable Mayor of Visakhapatnam.
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Processing of Oily sludge is being done to recover oil.
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Bio-remediation farm construction for the treatment of Oily sludge has been started.
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Aerobic Vermi Bacterial (AVB) system for treating 200kgs per day of canteen waste has been commissioned.
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Three new RSPM Analyzers were installed and commissioned at all three Ambient Air Monitoring Stations in the refinery
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Thirteen Stack Analyzers were installed and commissioned on major fire equipment in the refinery
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Mechanical Oil recovery from oily sludge has been started
Research & Development:
HPCL is having collaborative research projects with various academic / research institutions. The details of the projects and the project costs are given below:
- The Energy and Resource Institute (TERI), New Delhi:The Project is “Screening and selection of efficient microbial strains for bio hydrogen production” with TERI at an approximate time frame of 24 months.
- Gandhi Institute of Technology and Management (GITAM), Visakhapatnam: The projects with GITAM are as follows:
- Effect of Nano-particle inclusion in the lubricating properties of lubricants with a time frame of 2 years.
- Bioremediation: Bio desulphurization of petroleum oil by non pathogenic microorganisms at a time frame of 1 year.
- Bioremediation of petroleum oil by non pathogenic microorganisms with a time frame of 1 year.
- Indian Institute of Science (IISc), Bangalore: “Society for Innovation and Development” (SID) is an innovation centre of IISc and will collaborate on behalf of IISc with HPCL. The scope of MoU covers assistance for setting up of R&D centre and taking up various collaborative projects. Currently a project on nanoparticles is undertaken.
- Central Institute for Mining and Fuel Research (CIMFR, erstwhile CFRI), Dhanbad: This project involves characterization of 3 bottom streams i.e. VTB, FCC resid and PDA bottoms utilizing the pilot plant available at CIMFR. It is then proposed to install a 100 kg/hr scaled up plant at Corporate R&D centre for which the designing, commissioning supervision, interpretation of data generated development of protocols for operating and testing of the plant will be in the scope of CIMFR.
- Research Triangle Institute (RTI), USA: The project involves collaborative R&D activities between RTI and HPCL, which would cover one or more of the following areas:
- Advisory support for the establishment of a catalyst laboratory and its associated development for synthesis and evaluation.
- Diesel desulphurization including demonstration scale-up, protocols, knowledge transfer and IP access to assist in achieving tight timelines for 2010 quality standards, and
- Resid gasification including characterization.
- Advanced Research Technologies (ART), Chevron & IIT Kanpur:
HPCL has entered into a Memorandum of Understanding with
- Advance Refining Technologies LLC (ART),
- Chevron USA Inc. and
- Indian Institute of Technology (IIT) Kanpur
for collaborative research activities to be undertaken at IIT Kanpur under the title “Industry sponsored joint research and exchange program agreement”. As per the MoU, all the three sponsors will equally share the costs of research projects to be undertaken at IIT Kanpur. Accordingly, four projects were identified progressively between April 2005 and June 2007. They are:
- Monolithic reactors for multiphase reactions
- Slurry bubble column hydrodynamics
- Supported Ionic Liquid Catalysis and Hydrodynamics in Packed Bed
- Modeling of mass transfer effects in resid FCC
Recognition and Awards
The efforts of the both refineries were well recognized in the Industry and awards have been received from various Government as well as Non Government Organizations. Some of the recent awards received are:
Mumbai Refinery
- Received prestigious Golden Peacock award from IOD for the second consecutive year for Environment Management in 2007-08
- Received prestigious Green Tech GOLD Award for 2007 for fifth consecutive year for Environment Excellence in 2007-08
- Received Golden Peacock Award 2006 under Environmental Management system from IOD New Delhi in 2006-07
- Received Suraksha Puraskar safety award from National Safety council in 2006-07
- Received Greentech Gold safety award from Green tech Foundation in 2006-07
- Received National Safety Award 2004 for lowest accident frequency rate in 2005-06
- Received Greentech Gold safety award from Green tech Foundation in 2005-06
- Received Green Tech Gold award 2004 for environment excellence in 2005-06
- Received accreditation from CEMILAC, Bangalore for supplying ATF to Defense
- ISO 9001:2000 certification for manufacturing, storage and handling of ATF.
- ISO 9001 certification for Oil Movement and Storage Operations
Visakh Refinery
- Awarded first prize for Energy Conservation in Petroleum sector for the year 2007 by Bureau of energy efficiency, ministry of Power, GOI in 2007-08. Golden Jubilee celebrations on completion of 50 years of successful operations during the year 2007-08
- Received Jawaharlal Nehru Centenary Award for improvement in Specific Energy Consumption from MOP&NG over the previous best in 2007-08
- Awarded for 2nd best improvement in Specific Energy Consumption among Indian PSU refineries by CHT for the year 2006-07
- Awarded Silver Medal by Green Tech Foundation, New Delhi for Environmental Excellence for the year 2006-07
- Visakh refinery won the first prize of National Energy Conservation award in Refineries Sector for best Energy performance for the year 2006-07 from Bureau of Energy Efficiency, Ministry of Power. The award was received from Hon’ble President of India. Visakh Refinery is the only refinery awarded first prize in this category so far.
- Visakh Refinery also won the 2nd prize of Jawaharlal Nehru Centenary award for improvement in Energy Performance of refineries from Ministry of Petroleum and Natural Gas. The award was given by Minister of Petroleum & Natural gas.
- The safety efforts of Mumbai refinery were well recognized in the Industry and the Refinery various prestigious awards. In the recent past, Mumbai Refinery has bagged the ‘Suraksha Puraskar' from National Safety Council in 2006 for developing and implementing effective safety management system. Refinery has also won “Greentech Safety Gold Award 2006” for excellent safety record in Refinery sector.
- As recognition for its efforts on environment management, Mumbai Refinery has won GreenTech Gold Awards for past five consecutive years (2002 to 2007) under the 'Environmental Excellence' category by Greentech Foundation, New Delhi
- Mumbai Refinery has been conferred with “GOLDEN PEACOCK AWARD” for the year 2006 for excellence in Environmental Management Systems.
Contact Us
M. Kesava Rao
Chief Manager - RCD
Petroleum House - 5th Floor
17, Jamshedji Tata Road
Churchgate
Mumbai 400 020
e mail : kesavarao@hpcl.co.in
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