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Chennai Petroleum Corporation Limited’s (CPCL), is presently
having a total refining capacity of 10.5 MMTPA. The refining
capacity at the Manali complex is 9.5 MMTPA, including the 3MMTPA
Expansion-cum-Modernisation Project, and the refinery at Panangudi
in Cauvery Basin has a capacity of 1.0 MMTPA.
CPCL’s 3MMTPA Expansion-cum-Modernisation
Project at Manali was accorded investment approval by GoI in
July, 2000 at an estimated cost of Rs.2360.38 crore, with a
completion schedule of 36 months. The major process units of
this expansion project are Crude and Vacuum Distillation, Once-through
Hydrocracker, Hydrogen, Naphtha Hydrotreater & Catalytic
Reformer, Visbreaker, Sulphur Recovery and LPG/Kero Merox. In
addition, utility and offsite facilities are also included as
part of the expansion project.
Further, the expansion project
has been integrated with the existing refinery to improve the
overall distillates yield, product quality and to reduce environmental
emissions from the existing refinery complex. The major process
units of the expansion unit were commissioned in March’04
and the Hydrocracker unit was commissioned in August’04.
The project has been completed well within the approved cost.
Benefits
In addition to bridging the demand-supply gap of petroleum products
in the region, the expansion project enabled CPCL to improve
the overall distillates yield from 67-68 wt% to 71 wt% for the
total refining capacity of 9.5 MMTPA at Manali.
The existing FCC unit has
been revamped and commissioned in October’04 at a cost
of Rs.92 crore. With this revamp, the LPG production has been
more than doubled from 180 TMT per annum to about 400 TMT per
annum. The expansion and integration with CCU has improved Gasoline
(Petrol) production also from 390 TMT to 700 TMT. With the above
process integration, the quality of products from FCCU has also
improved significantly with very low sulphur content in Gasoline
(‘S’ < 10 ppm and RON 91) and HSD (‘S’
< 100 ppm).
It may be noted that CPCL
is the first refinery in India to process 100% Hydrocracker
bottom in FCCU for achieving enhanced LPG and MS yields. The
implementation of the 3MMTPA Expansion and FCCU Revamp projects
have enabled CPCL to achieve the overall improvement in Auto
Fuel quality (MS and HSD) to meet Bharat Stage-II and Euro-III
equivalent specs well ahead of the scheduled implementation
schedule of April’05.
The new units have stabilized
and the Manali refinery is operated for more than 100% capacity
utilization of the expanded capacity of 9.5 MMTPA from December’04.
| CDU/VDU |
EIL |
3.0 MMTPA |
| Visbreaker |
Lummus, Netherlands |
1.15 MMTPA |
| Hydrocracker |
Chevron Lummus Global, USA |
1.65 MMTPA |
| CRU |
Axens, France (formerly IFP) |
225,000 TPA |
| Hydrogen |
Technip Benelux, Netherlands |
56,000 TPA |
| LPG & |
|
42,000 TPA |
| Kero Merox |
UOP, USA |
600,000 TPA |
| Sulphur plant |
EIL / Delta Hudson, Canada |
125 TPD |
| Amine Regeneration |
EIL |
330 MT/hr |
| Amine Treating: |
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| a) Fuel Gas treating |
EIL |
35,000 TPA |
| b) LPG treating |
EIL |
60,000 TPA |
| Sour Water Stripper |
EIL |
60 TPH |
MMTPA - Million Metric Tonnes Per Annum
TPA - Tonnes Per Annum
TPD - Tonnes Per Day
MT/hr - Metric Tonnes Per Day
TPH - Tonnes Per Hour
Total No. of Piles - 17,500
Total volume of RCC (M - 1,30,000
Total Weight of Steel (MT) - 23,000
Total running Metres of Piping - 5,00,000
Length of Electrical Cable - 1100 KMs
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