Manali refinery is equipped with three Crude distillation units with combined capacity of 10.5 MMTPA. CDU-1 process Lube bearing crudes and other two CDUs are capable of processing opportunity crudes. Major Process units are as follows:
Once Through Hydro Cracker Unit (OHCU) was licensed by M/s Chevron and it was commissioned in August 2004 along with Refinery-III Expansion project. The design capacity of the unit is 1.85 MMTPA and the unit was revamped to a capacity of 2.25 MMTPA in March 2017 along with Resid Upgradation project. The unit produces high quality Sulphur free Diesel and ATF. The unit is designed for 55% conversion of low value Vacuum Gas Oils to lighter, low Sulphur valuable products.
Fluid Catalytic Cracking Unit (FCCU) was licensed by M/s UOP and was commissioned in 1984 along with Ref-II. The design capacity of the unit is 0.6 MMTPA and later revamped in October 2004 to a capacity of 0.78 MMTPA. Post revamp, the feed to FCCU is Unconverted Oil (UCO) from the Once Through Hydrocracker Unit (OHCU). The unit produces high quality products like LPG and MS.
CCR (Continuous Catalytic Reforming) unit was licensed by M/s Axens and was commissioned in December 2004 along with Refinery-III Expansion project. The design capacity of the unit is 0.255 MMTPA in Semi Regeneration mode. The unit was revamped to a capacity of 0.303 MMTPA with Continuous Catalytic Reforming Unit (CCRU) in 2010. Unit produces high octane reformate which is utilized in producing in MS product. Hydrogen produced as a by-product in the unit is used in the Hydrocracker Unit.
ISOM unit (Isomerisation) converts linear molecules in Naphtha stream to higher-octane branched molecules for blending into MS product. The Isomerization unit capacity is based on producing 140,000 TPA of isomerate with unit turndown rate of 40% of design capacity. The unit is licensed by M/s Axens India (P) Limited and commissioned in 2011.
DCU (Delayed Cracker Unit) was licensed by M/s ABB Lummus and commissioned in Nov 2017 along with Resid Upgradation project. The design capacity of the unit is 2.2 MMTPA. The unit is designed to process vacuum residue from the upstream vacuum distillation unit. The process thermally cracks and upgrades heavy fractions into more valuable distillate products and Petroleum grade coke.
DHDS (Diesel Hydro De-Sulphurization Unit) was licensed by M/s Axens India (P) limited and was commissioned in May 2000. The design capacity of the unit is 1.8 MMTPA and later revamped to a capacity of 2.34 MMTPA in March 2018. The unit is designed to process straight run and cracked light and middle distillate streams. The unit is capable of producing BS-VI grade diesel.
DHDT (Diesel Hydro Treating Unit) was licensed by M/s Axens India (P) limited and was commissioned in May 2011. The design capacity of the unit is 1.8 MMTPA and later revamped to a capacity of 2.34 MMTPA in November 2019. The unit is designed to process straight run and cracked light and middle distillate streams. The unit is capable of producing BS-VI grade diesel.
CPCL commissioned it’s operation in 1969 with CDU/VDU unit (with a capacity of 2.5 MMTPA) & subsequently revamped to 2.8 MMTPA with in-house debottlenecking.
In the year 1984, 2nd CDU/VDU unit was commissioned with a capacity of 2.8 MMTPA for processing low sulphur & high sulphur crude oil. Subsequently unit was revamped to 3.7 MMTPA in the year 1992/93. Later the unit was revamped on 2012 for upgrading it’s diesel quality to meet Euro-IV diesel spec.
3rd unit was commissioned in the year 2004 with a capacity of 3.0 MMTPA, subsequently revamped to 4.0 MMTPA to meet Euro-IV spec for MS & HSD. Units are designed for processing Arab mix & Upper zakum crude oil.
CPCL has three hydrogen generating units, having a combined capacity of generating 1.42 lakh to 1.54 nm3/hr hydrogen. Two units are licensed by M/s Technip & one unit is licensed by M/s Haldor Topsoe.
Hydrogen generating unit adopts a state of art techology that generates hydrogen from naphtha. This unit produces hydrogen of 99.9% purity to meet the demand of the secondary processing units. The main Hydrogen Generation Unit (HGU) consists of feed Pre-desulfurisation section, followed by desulfurisation, reforming and process gas cooling with high temperature shift conversion to increase the hydrogen content of the process gas. Purification is done with a Pressure Swing Adsorption unit.