The major projects presently being undertaken
1. BS VI up-gradation
As per Auto Fuel Policy and directives from the Ministry of Petroleum and Natural Gas, the entire country has to move towards BS-VI quality specifications for MS and HSD. The project involves the setting up of new units and additional facilities. M/s. Engineers India Ltd is the Engineering, Procurement and Construction Management Consultant for the job. The project was affected by the first wave of Covid in March 2020 and the second wave and lockdown in Karnataka from the last week of April 2021. However, Mechanical Completion of the main unit – FGTU is achieved on 31.12.2020. The unit is in the advanced stage of commissioning, and product out is envisaged in the month of July 2021. On commissioning and stabilization of the FGTU process unit, the complex will produce an additional 25 TMT/month BS-VI MS. Mechanical completion of auxiliary units is scheduled in the third quarter of FY 2021-22.
2. Desalination Plant
To meet the water requirement of the Refinery, freshwater is sourced from the Nethravathi River. Mangalore city also draws water from the Nethravathi river for drinking water. During severe drought conditions, when the Nethravathi river is running dry, District Administration stops river water pumping to industries for catering to the drinking water requirement of Mangalore city. In 2012, the entire Refinery was shut down, and in 2016 and 2019, we were forced to take partial shutdown due to the non-availability of water. Hence as the Nethravathi river, as a single source, is risky, the Sea Water Desalination project was conceived as an alternate option for meeting the water requirements of the Refinery. This plant of the current capacity of 30 MLD (expandable to 70 MLD) will cater to the future water requirement of the company. M/s. Fichtner India is the Project Management Consultant, and M/s VA Tech Wabag Ltd. is the LSTK contractor. The plant was scheduled to be completed by the third quarter of FY 2020-21. However, the first wave of Covid-19 in March 2020 and the second wave and lockdown in Karnataka from the last week of April 2021 had a major impact on Mechanical Completion, which is now scheduled in the second quarter of FY 2021-22.
3. Marketing Terminal at Devongonthi, Bangalore
We are constructing a Marketing Terminal at Devangonthi, Bengaluru, to cater to business primarily in the state of Karnataka. The Terminal would receive finished petroleum products (MS, HSD & ATF) through the existing PMHB pipeline from MRPL. The supplies of petroleum products to the retail outlets/customer / aviation stations would be met through road tankers. M/s. Nauvata Engineering Private Limited is a Project Management Consultant. Tendering for the execution of the project is in progress. The Terminal is scheduled to be completed by May 2023.
4. 2G Ethanol
MRPL has been informed by MOP&NG to set up a 2G ethanol plant in the state of Karnataka. We are exploring various technologies for producing 2G Ethanol. Land for the same is allotted by KIADB at Harihara, Davangere.
5. Modification of Gas Turbines for Natural Gas firing
MRPL has two Gas Turbines. Presently, GT-1 is fired using Light Cycle Oil and GT-2 by Refinery Fuel Gas. However, with the availability of Natural Gas, it is economical to fire the Gas Turbines using Natural Gas which is a clean fuel. M/s. L&T-SL is the Project Management Consultant and M/s. BGGTS is the Licensor for the project. The project is on track to be commissioned by the fourth quarter of FY 2021-22.
6. CCR-1 Revamp
CCR-1 converts heavy naphtha feedstock into high octane reformate for gasoline blending and produces hydrogen for hydrotreating/hydrocracking. Revamp of Regenerator section of CCR-1 is being carried out to increase Regenerator Coke burn capacity, thereby resulting in overall capacity increase to 80 m3/hr (from current 75 m3/hr). M/s. Triune Energy Services Pvt. Ltd. is the Engineering, Procurement and Construction Management Consultant for the job. Mechanical Completion of the project is scheduled for the third quarter of FY 2021-22.
7. PFCC Stack Wet Gas Scrubber System
Petrochemical Fluidized Catalytic Cracking (PFCC) unit processes unconverted oil from hydrocracker units, straight run low sulphur vacuum gas oil and hydrotreated heavy coker gas oil and converts into value-added products such as propylene, LPG and gasoline. During this process, carbon is deposited on the catalyst, which reduces the ability of the catalyst to aid the cracking process. The carbon is then burnt off, and the catalyst is regenerated. The regeneration process produces flue gas which passes through a system of cyclones and separators to remove catalyst fines. The project is conceived to reduce the SPM limit in the flue gas of PFCC as a pollution control measure and to meet emission norms. M/s. Thyssenkrupp Industrial Solutions (India) Private Ltd. is the Project Management Consultant for the project. Mechanical Completion of the project is scheduled in the first quarter of FY 2023-24.
8. PFCC LPG + Propylene Amine Scrubber
While processing feed with high Sulphur content in Petrochemical Fluidized Catalytic Cracking (PFCC), higher Hydrogen Sulfide (H2S) is expected in LPG and Propylene stream. The current system to meet H2S in LPG and Propylene products is a caustic wash. Amine Scrubber System reduces dependency on caustic wash to a large extent. The system removes H2S in the LPG and Propylene streams and minimizes the spent caustic generation in the existing Caustic Treatment System. M/s. Triune Energy Services Pvt. Ltd. is the Engineering, Procurement and Construction Management Consultant for the job. Mechanical Completion of the project is scheduled for the first quarter of FY 2023-24.