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Mangalore Refinery & Petrochemicals Limited

Gaurav Bajpai
B.Tech 3rd Year
Department of Chemical Engg
NIT Jalandhar

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Profile:
MRPL located in a beautiful hilly terrain north of Mangalore city
subsidiary of ONGC
MRPL has a design capacity to process 9.69 million metric tonnes per annum
MRPL is the only Refinery in India to have 2 Hydrocrackers producing Premium Diesel (High Cetane).
MRPL is the only Refinery in India to have 2 CCRs producing Unleaded Petrol of High Octane.
Out of the total refining capacity of India, the contribution of Mangalore Refinery and Petrochemicals Limited is 8%
MRPL has high standards in refining and environment protection matched by its commitments to society.
MRPL is planning to expand its refinery to 15 MMTPA from the existing nameplate capacity of 9.69 MMTPA.

History:

Before acquisition by ONGC in March 2003, MRPL, was a joint venture Oil Refinery promoted by M/s Hindustan Petroleum Corporation Limited (HPCL), a public sector company and M/s IRIL & associates (AV Birla Group).
MRPL was set up in 1988 with the initial processing capacity of 3.0 Million Metric tonnes per annum .
It was later expanded to the present capacity of 9.69 Million Metric tonnes per annum.

Other Accolades earned by MRPL

Accredited Five Star rating by British safety council, UK in the year 2003 for its best Health and Safety Management Systems.
Oil Conservation Award from Ministry of Petroleum and Natural Gas on January 31, 2003.
MRPL has bagged the second prize in Jawaharlal Nehru Centenary Awards for Energy Performance of Refineries for 2007-08.
Winner of First Prize of Jawaharlal Nehru Centenary Award, selected by Centre For High Technology, functioning under the aegis of MoP&NG, for the Best Performance in Energy consumption, for the year 2004-05 .
National Safety Award for the year 2004 from Ministry of Labour, GOI.

Manufacturing facilities:
Crude and Vacuum Distillation Units:
The Atmospheric, Vacuum Distillation Units and Naphtha Splitter Unit designed by M/s Engineers India Ltd., are heat integrated, using Pinch Technology to achieve high-energy efficiency, thereby reducing Fuel Oil consumption and in turn reducing air emissions.



Hydrocracker Units:
The Hydrocracker Units produce high quality Sulphur free Diesel and ATF. The Plant is designed for 100 percent conversion of low value Vacuum Gas Oils to lighter, low Sulphur valuable products.

Merox (technology UOP , USA)
LPG Merox Unit reduces the Sulphur content in LPG. The kerosene Merox Unit converts mercaptans to disulphide.


Hydrogen Plant(Technology KTI , Holland)
The Hydrogen Plant designed by M/s KTI, Holland, produces Hydrogen by Steam Reforming of Naphtha. Hydrogen purity of 99.9 percent is achieved through the UOP Pressure Swing Adsorption (PSA) Unit.

Platforming Unit
The Hydrogen Plant designed by M/s KTI, Holland, produces Hydrogen by Steam Reforming of Naphtha. Hydrogen purity of 99.9 percent is achieved through the UOP Pressure Swing Adsorption (PSA) Unit.
s (technology UOP , USA)


Other supported facilities:
Oil Jetty to receive Crude Oil and dispatch Petroleum products by ocean tankers.
Raw Water line, 43 kms long from river Netravathi.
Well equipped laboratory
Blast proof centralized Control Room
DCS based Control Room for all Process Units and offsites.
75 Storage Tanks including 4 Horton Spheres.

Refining

THE REFINING PROCESS:
Crude Oil comprises of Carbon and Hydrogen molecules in complex chains. In addition, impurities like Sulphur, Nitrogen and Metals are also present in the Crude. They are classified as Paraffinic, Naphthenic or Aromatic Crudes depending on their composition.
The Refinery processes are classified into:
Primary Processing Units
Secondary Processing Units
Treating Units

Primary Processing Unit:
The Crude Unit is the Primary Processing Unit in an Oil Refinery wherein Crude Oil is separated into various products depending on the relative volatility of the Hydrocarbon components.
Secondary Processing Unit:
Secondary Processing Units receive feedstock from the Crude Unit and upgrade it to value added products. The main Secondary Processing Units in MRPL are:
Hydrocracker Unit
Continuous Catalytic Regeneration Platforming Unit
Visbreaker Unit
Bitumen Unit