MUMBAI REFINERY

1
MUMBAI REFINERY
2

• IT IS YOUR APTITUDE
• AND
• ATTITUDE
• THAT ONLY WILL DETERMINE ALTITUDE
• IN YOUR LIFE

3

• 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

4
LPG
DOMESTIC FUEL
PLASITCS
PETROCHEMICALS
NAPHTHA
DYES
FERTILISERS
PETROL
PRIVATE TRANSPORT INDUSTRY
PAINTS
SOLVENTS
EDIBLE OIL REFINING
ATF
AVIATION TURBINE FUEL
KEROSENE
DOMESTIC FUEL
CRUDE OIL
HIGH SPEED DIESEL
DIESEL
INDUSTRY
LIGHT DIESEL OIL
AGRICULTURE
LUBRICATING OIL
AUTOMOBIL / INDUSTRY
INDUSTRY
FUEL OIL
SHIPPING
ASPHALT
ROAD BUILDING
CARBON BLACK FED STOCK -
TYRE INDUSTRY
HPCL - MUMBAI REFINERY PRODUCTS
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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

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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)

7
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
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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

9
MAJOR OIL CONSUMERS IN WORLD (MMT) S.
N. COUNTRY TOTAL OIL DEMAND OWN PRODN. OIL
IMPORT 1 U.S.A. 900
350 550 2 CHINA
200
160 40 3 RUSSIA
180 300 (-)120 4 JAPAN
260
-0 260 5 GERMANY
130 0
130 6 FRANCE 100
0 100 7 INDIA
100
36 64 8 S. KOREA 100
0
100 9 ITALY 90
6
84 10 BRITAIN 80
140 (-)60 11 UKR
13 12 BRAZIL
80 60
20 13 MEXICO 80
170 (-) 90 14 SPAIN
70
0 70 15 IRAN
60 175 (-)105 16 S.
AFRICA 20
0 20 17 S. ARABIA 60
400 (-)340 18 AUSTRALIA
40 25
15
10
OIL REFINEIES IN INDIA
LOCATION REFINERY CPACITY
PRODUCTION MMT 2004-05
MMT NORTH IOC MATHURA 8.0
6.383 IOC PANIPET 6.0
6.387 SOUTH HPCL-VIZAK 7.5
7.826 CPCL 6.5
8.181 KRL 7.5
7.924 CPCL-NARIMANAM 0.5
0.742 EAST IOC-GUWAHATI
1
1.002 IOC-BARAUNI 4.2
5.078 IOC-HALDIA
4.6
5.419 IOC-DIGBOI 0.65
0.651 BRPL-BONGAIGAON
2.35 2.312 NRL
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
11
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
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• 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

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PARAFINIC SERIES.

• CH4 METHANE
• C2H6 ETHANE
• C3H8 PROPANE
• C4H10 BUTANE
• C5H12 PENTANE
• C6H14 HEXANE
• C7H16 HEPTANE
• C8H18 OCTANE
• C9H20 NENONE
• CnH2n2 xxx.

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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
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• 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.

16
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

17
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

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• 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

21

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.
22
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.
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SIMPLE DISTILLATION
WATER
Thermometer
Cooler / condenser
WATER
Mixture
Distillate
Heat
24
CRUDE DISTILLATION UNIT
UNSATBILISED NAPHTHA TO STABILISER COMPRESSOR
FBS D/O
ATF / KERO D/O
LVGO D/O
FURNACE
DESALTER
EXCHANGER
EXCHANGER
JBO D/O
CRUDE TANK
HVGO D/O
PUMP
PRODUCT
EFF. WATER
F.O.
F.G.
WATER
RCO TO VPS
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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.

27
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.

28
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.

29
CHIMNEY TRAYS

• TRAYS USED FOR LIQUID DRAW OFFS
• NO MASS TRANSFER ACROSS THE TRAY

D/O
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MIDDLE DISTILLATES - 40 to 45 . Further
Distilled at normal pressure to get final product
or blending streams.
32
CRUDE DISTILLATION UNIT
UNSATBILISED NAPHTHA TO STABILISER COMPRESSOR
108 0C
1.7 Kg/cm2
165 0C
42 / 48
FBS D/O
200 0C
32
ATF / KERO D/O
260 0C
19
LVGO D/O
FURNACE
330 0C
EXCHANGER
12
DESALTER
EXCHANGER
JBO D/O
30 0C
350 0C
CRUDE TANK
HVGO D/O
5
120 0C
365 0C
270 0C
PUMP
PRODUCT
EFF. WATER
F.O.
F.G.
WATER
348 0C
RCO TO VPS
33
CRUDE DISTILLATION TOWER
DISTILLATION COLUMN.
UNSATBILISED NAPHTHA LVN
PRODUCT
FBS
160 0C
ATF/ KERO
TPA
201 0C
LVN to LEU
Cooler
BPA
LVGO
268 0C
Cooler
JBO
336 0C
HVGO
CRUDE from Furnace O/L.
351 0C
RCO TO VPS
34
O/ H Condenser
REFLUX
55
51
DISTILLATE DRUM
D-1001
49
STRIPPER
48
4
43
ATF
WATER
1
42
STEAM
NAPHTHA
33
ATF
32
4
30
LVGO
PUMP
28
1
STEAM
22
TPA
LVGO
TOWER DETAILS
21
20
STRIPPER
4
Bottom Section - 8 ft. dia. x 8 ft. Ht.
19
FBS
17
Middle Section - 16 ft. dia. x 48.75 ft. Ht.
1
STEAM
BPA
13
Top Section - 14 ft. dia. x 80 ft. Ht.
12
FBS
4
6
JBO
5
1
Trays 1 -- 55 - Sieve Trays - Double pass
STEAM
Tray Spacing - 2 - 2.75 Ft.
4
HEATED CRUDE
4
Tray Hole Diameter - 1/2 inch.
HVGO
STEAM
APS T-301
1
STEAM
TRAY 1
HVGO
FLOW PLANE FOR FR - APS DISTILLATION
SECTION
RCO
35
REFLUX
58
DISTILLATE DRUM
49
D-1001
STRIPPER
4
FBS
WATER
1
STEAM
35
NAPHTHA
TPA
FBS
34
4
SKO
PUMP
31
1
STEAM
21
SKO
TOWER DETAILS
20
BPA
STRIPPER
Bottom Section - 8 ft. dia. x 8.8 ft. Ht.
17
4
Middle Section - 16 ft. dia. x 77. 5 ft. Ht.
LVGO
10
1
Top Section - 12 ft. dia. x 50 ft. Ht.
STEAM
5
LVGO
Trays 1 -- 58 - Sieve Trays - Double pass
4
HEATED CRUDE
4
Tray Spacing - 2 - 3 Ft.
JBO
1
STEAM
Tray Hole Diameter
APS T-1001
JBO
STEAM
TRAY 1
FLOW PLANE FOR FRE - APS DISTILLATION
SECTION
RCO
36
80/20 AM CRUDE
BH CRUDE
VR.LPG
L.E.
L.E.
LVN
LVN
SOLVENT
FBS
FBS
ATF
KERO
MIDDLE DISTILLATES
MIDDLE DISTILLATES
BH CRUDE
T-1001
P.G. CRUDE
T-301
LVGO
LVGO
JBO
JBO
HVGO
RCO
RCO
H.E.
H.E.
DISTILLATES
37
VACUUM DISTILLATION UNIT
VGO TO DIESEL
-0.88Kg/cm2.
112 0C
165 0C
EXCESS VGO D/O TO DIESEL
265 0C
14
I SS D/O TO LUBE
FURNACE
335 0C
II SS D/O TO LUBE
9
375 0C
5
III SS D/O TO LUBE
348 0C
406 0C
RCO
-.63Kg/cm2.
399 0C
F.O.
F.G.
4
330 0C
VTB TO ASPHALT / DE-ASPHALTING
VACUUM DISTILLATION FOR HEAVY ENDS
38
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.
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LUBE PLANT OVERVIEW.

• CONTROL FUNCTION
• VISCOSITY, COLOR, FLASH POINT.
• VISCOSITY, COLOR, CCR
• VI
• COLOR-STABILITY, DENITRIFICATION,
  DE-SULPHURIZATION
• CLOUD POINT , POUR POINT

• PROCESS
• VDU
• (DISTILLATES / SS)
• PROPANE DEASPHALTING UNIT(PDA)
• SOLVENT EXTRACTION
• HYDROFINER
• (HYDROFINED
• RAFFINATE)
• PROPANE DEWAXING UNIT(PDU)
• (DEWAXED OIL)

40
MUMBAI REFINERY
41
O/ H Condenser
DRUM
WATER
LPG FOR TREATING
PREHEATER
PUMP
LAN
REBOILER
PUMP
STEAM
HEXANE FEED
MEROX UNIT
HIGH PRESSURE DISTILLATION FOR LIGHT- ENDS
FRACTIONATOR
42

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.
43
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.
44
FLUIDISED CATALYTIC CRACKING UNIT (FCCU)
CRACKING BREAKING DOWN OF LONG CHAIN ,
MOLECULE IN TO SMALL MOLECULES.
-C- -C- -C- -C- -C -C-
-C -C- -C- -C-

Heat
Heavy waxy oils
Light Hydrocarbons
Catalyst
FUEL GAS LPG PETROL DIESEL RESIDUE
F C C U
WAXY DISTILLATES
45
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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 SSs ARE MIXED WITH
EACH OTHER AND IN APPROPRIATE RATIO AND A PROPER
BELND OF COMBINATION IS FORMULATED TO THE
REQUISITE PROPERTIES FOR SPECIFIC APPILCATIONS.
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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.

52
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_at_100F
  95_at_ 370C
• 6
  WINTER
  MAX.
• LDO 1.8 21 SUMMER
  66 MIN. 80 _at_100F
• 12
  WINTER
  MAX.
• IFO 4.0 MAX. 27 MAX.
  66 MIN. 820 _at_ 50C
• LSHS 1.2 60 MAX
  66 MIN. 14MIN TO 59MAX
• 
  
  _at_100 C

53
MUMBAI REFINERY PROCESS UNITS
LPG
L E Unit
NAPHTHA
FR APS
PG CRD
ATF/SKO
ATF Treating
HSD
EL HSD
LDO
D H D S
LOBS
LUBE BLOCK
FR/LR VPS
PG RCO
LPG
S
NAP
H S D
FRE APS
ASP./ IFO
BH CRD
SKO/MTO
F C C U
LPG
FRE VPS
MS

HSD
BH RCO
LSHS
54
DISTRIBUTED CONTROL SYSTEM

• DCS. CONTROL ROOM
• - FLOW
• - PRESSURE
• - TEMPERATURE
• - LEVEL
• O M S AUTOMATION AND AUTO- PRODUCT
  BLENDING.
• APC.

55
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
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62
REFINERY PROCESS UNITS

• CRUDE DISTILLATION - 2
• VACUUM DISTILLATION - 3
• F C C U
• D H D S
• NAPHTHA STABILISER - 2
• NAPHTHA CAUSTIC MEROX TREATING

63
REFINERY PROCESS UNITS

• HEXANE MAXIMISATION UNIT
• LPG TREATING FACILITIES
• PROPANE UNIT
• ATF TREATING
• BITUMEN BLOWING UNIT

64
REFINERY PROCESS UNITS

• LUBE EXTRACTION UNITS-3
• LUBE HYDROFINER - 2
• PRPANE DEWAXING UNIT.
• PROPANE DEASHALTING UNIT.
• BOILER HOUSE.

65
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

66
PRODUCT STATE
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
67
TOTAL PRODUCTS 30FUELS13 LUBES10
SPECIALITIES7

• 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
• AVIATION TURBO FUEL
• HIGH SEED DISEL 13 LSHS.

68
TOTAL PRODUCTS 30FUELS13 LUBES10
SPECIALITIES7

• LUBE PRODUCTS10
• NEUTRAL OILS3
• TURBINE OILS 2
• INDUSTRIAL OILS2
• SPINDLE OIL
• TRANSFORMER OIL BASE STOC
• BRIGHT STOCK

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

69
TATA
BPT PIRPAU
JAWAHAR
MANIFOLD
DWEEP
LPG BOTTLING PLANT
LSHS
NAPHTHA,HSD,
HP REFINERY
MAHUL
KERO/ATF
SP. OILS
TERMINAL
VASHI
LONI,WADALA
O N G C
WADI BUNDER
TROMBAY
SEWREE,MAZGAON
HP
HP
SANTACRUZ
BH-GAS / NGL
LPG
BPCL REFINERY
PRODUCT MOVEMENT FACILITIES
70
MPT - PIPE LINE NEWTWORK
SEWREE WADALA
NEW PIRPAV
BPCL REF.
C-2
C-1
W-2
LPG
W-1
BOL
W-3
LSHS
C-1 - CRUDE LINE
PIRPAV M / F
C-2 - CRUDE LINE
W-1 - NAPHTHA LINE
W-2 - HSD LINE
W-3 - KERO LINE
W-1
W-1
C-1
BOL- BLACK OIL LINE
W-3
W-3
W-2
W-2
C-2
BOL
C-1
BOL
WATER
J 4
HPCL REF.
J 1
J 2
J 3
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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.

72
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, OG,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.

73
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

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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.

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