Environment Management System at MRPL

MRPL is committed to prevent pollution through effective control on waste management, spillages, leakages, and emissions from regular refinery and petrochemicals operations. Complying with all applicable legal, statutory and other requirements related to the environment, with a major focus on continual improvement in the performance of the Environment Management system. MRPL has a dedicated Environmental Management Cell and a NABL-accredited laboratory for monitoring the environment.

Water Management at MRPL

MRPL complex requires water for industrial cooling, domestic purposes, demineralized water, industrial service water, steam generation, firefighting purposes, and washing/quenching purposes, etc.

Sources of Water for MRPL:

A. Treated city sewage water
B. Desalination: Permeate water
C. Recycled internally treated effluent
D. River water (Netravathi River)

Water Conservation at MRPL:

MRPL has implemented many water-saving measures by investing in water treatment and recycling technologies to reduce the freshwater footprint.

Treated city sewage water: MRPL receives treated Mangalore city municipal sewage from Mangalore Special Economic Zone (MSEZ), processed in a dedicated Reverse Osmosis (RO) system at MRPL for DM water make-up and cooling tower make-up.
Desalination Plant: To address summer water shortages and enhance process reliability, MRPL has set up a desalination plant at the Tannirbhavi site, enabling fresh river water use for domestic and other purposes in Dakshina Kannada District/Mangaluru City.
Dedicated Waste-Water Treatment Plants (WWTP): Separate plants treat refinery and aromatics effluents, meeting statutory standards with advanced treatment technologies including Sequential Batch Reactor (SBR), Membrane Bio-Reactor (MBR), and RO systems.
Stripped sour water: This major wastewater source in the refinery is reused for crude desalting.
Condensate Recovery Units: Operational to reduce freshwater consumption.
Wet Air Oxidation (WAO) unit: Continuously treats spent caustic effluent to improve WWTP performance.
Cooling water reduction: Maximum utilization of fin fan coolers and trim coolers reduces cooling water requirements.
Hydrogen peroxide: Used in WWTPs to achieve high-quality treated wastewater through in-house developed methods.

Air Quality Management

MRPL implemented BS VI specifications to produce MS and HSD products, reducing vehicle emissions.
Sulphur Recovery Units (SRUs) operate with over 99% efficiency to meet environmental standards.
Flare Gas Recovery System installed to indirectly reduce air emissions.
RLNG maximization by replacing fuel oil/naphtha.
Low Sulphur Fuel Oil is used in major heaters to minimize Sulphur Dioxide emissions.
Low NOx burners are installed in major heaters to reduce NOx emissions.
Adequate stack heights for all process units have been installed.
Safety vents of all process equipment are routed to flare systems.

Dust Control Measures

Sulphur pastillization units are in place to reduce dust at sulphur production.
A covered shed over the sulphur storage yard mitigates sulphur dust.
Closed conveyor and silo storage systems transport coke products.
Railway sliding systems are used for coke transportation.
Fog generation systems, dry fog systems, water sprinklers, wind breaking walls, and floor sweeping machines prevent dust generation during petcoke handling.
Advanced cyclones and Fourth Stage Separator (FSS) reduce dust from Petro-Fluidized Catalytic Cracking Unit (PFCC); a new wet gas scrubber is being installed for further dust reduction.

Noise Control Measures

Thermal insulation is provided in vacuum ejectors.
Acoustic hoods, silencers, and mufflers are used in noise-generating equipment to drastically reduce noise levels.
Vibration analysis is periodically conducted on all critical rotary and heavy equipment, with continuous monitoring via DCS.
Acoustic insulation is provided in SRU incinerator blowers to reduce noise.
Necessary safety equipment is provided for workers.

Odor / Fugitive Emissions Control Measures

In-house developed and patented photo-catalytic technology is used to mitigate smell issues, with a commercial-scale plant successfully installed in the refinery.
Floating roof tanks for crude and light products, along with primary and secondary seals, reduce fugitive emissions.
Vapor Recovery Systems (VRU) for dome roof tanks minimize fugitive emissions.
Variable Speed Drive (VSD) mechanisms are installed to conserve energy and reduce air emissions.
Volatile Organic Components (VOC) from oily effluent handling units are collected and treated to comply with CPCB norms.

Hazardous Waste Management

MRPL generates solid waste, including hazardous waste such as spent catalysts, oily sludge, spent clay, and insulation waste, which must be disposed of in an environmentally friendly manner. MRPL's robust waste management system includes recycling, reusing, and responsible disposal of hazardous waste.

An online waste management system has been implemented for effective waste management.
Dedicated hazardous waste storage sheds have been constructed for better management at the refinery and aromatic complexes.
Hazardous waste is co-processed in cement industries, serving as an alternate energy source.
Spent catalysts are recycled through SPCB-authorized recyclers to recover precious metals.
Oily sludge from WWTP is reused in the Delayed Coker Unit (DCU) to reduce waste.
MRPL is a pioneer in plastic waste management and has successfully completed its extended producer responsibility (EPR) obligations.
E-waste is disposed of through SPCB-authorized recyclers.

Environment Monitoring at MRPL

Continuous online analyzers (SO₂, NO_x, CO & PM) are installed in all fired heater stacks, with data linked to the CPCB portal. Manual monitoring of all stacks is conducted regularly.
Two Continuous Ambient Air Quality Monitoring Stations (CAAQMS) are installed at the MRPL Refinery complex, and one at the Aromatic complex, to monitor online ambient air quality. A total of 15 Ambient Air Quality (AAQ) stations are installed in and around MRPL, with monitoring done by KSPCB-approved external agencies.
Continuous online analyzers (pH, BOD, COD, TSS & Flow) are installed at the final treated effluent lines at WWTP plants, with parameters linked to the Central Pollution Control Board (CPCB) portal. Final treated effluent quality is analyzed daily in the lab.
Groundwater, surface water, treated effluent, and seawater samples are analyzed regularly by KSPCB in and around MRPL.
Independent studies on treated effluent at the marine outfall are conducted every fortnight.
Routine boundary management of the storm channel is monitored.
A Leak Detection and Repair (LDAR) program is carried out to reduce VOC emissions.
Full-fledged meteorological stations are installed inside MRPL.
A digital display board has been installed at the MRPL Cargo Gate and Aromatic Complex entry gate to display environmental data in accordance with Supreme Court Monitoring Committee (SCMC) directives.
Environmental awareness programs are regularly conducted in neighboring villages and schools.
Noise levels are monitored inside process units and along the MRPL boundary wall.