0 0 24 Dec 2014 1536306771Annexure-Pre-feasibilityReport

DETAILED FEASIBILITY REPORT
FOR
HPCL MUMBAI REFINERY EXPANSION
HINDUSTAN PETROLEUM CORPORATION LIMITED
REPORT NO: A430‐RP-0241‐0001

VOLUME 1 OF 1
NOV 2014
This report is prepared for M/s HPCL and it is for use by M/s
HPCL or their assigned representatives/organizations only.
The matter contained in the report is confidential.

DETAILED FEASILBLITY REPORT
FOR
HPCL MUMBAI REFINERY EXPANSION
CLIENT
HINDUSTAN PETROLEUM CORPORATION LIMITED
MUMBAI
PREPARED BY
ENGINEERS INDIA LIMITED
NEW DELHI
EIL JOB NO: A430
REPORT NO: A430-RP-0241-0001

VOLUME 1 OF 1
NOV 2014
Table of Contents Document No.
Configuration Study & DFR For A430-RP-02-41-0001
HPCL Mumbai Refinery Expansion Rev A
Page 1 of 1
TABLE OF CONTENTS
SECTION CONTENTS PAGE
1. EXECUTIVE SUMMARY Ch 1 Page 1 to 20

2. INTRODUCTION Ch 2 Page 1 to 3
3. SCOPE Ch 3 Page 1 to 2
4. DESIGN BASIS Ch 4 Page 1 to 96
Attachments
4A Existing Unit details
4B Offsite Facilities
4C Financial parameters
4D Assays
4E Existing Utility Systems
5. MARKET STUDY Ch 5 Page 1 to 2
6. PROJECT LOCATION Ch 6 Page 1 to 2
7. PROJECT DESCRIPTION
7.1 PROJECT CONFIGURATION Ch 7.1 Page 1 to 4
7.2 REFINERY CONFIGURATION STUDY Ch 7.2 Page 1 to 71
7.3 PROCESS DESCRIPTION Ch 7.3 Page 1 to 27
7.4 MATERIAL BALANCE Ch 7.4 Page 1 to 3
7.5 UTILITIES DESCRIPTION Ch 7.5 Page 1 to 14
7.6 OFFSITES DESCRIPTION Ch 7.6 Page 1 to 12
7.7 LOGISTICS Ch 7.7 Page 1 to 7
8. ENVIRONMENTAL CONSIDERATIONS Ch 8 Page 1 to 19
9. PROJECT IMPLEMENTATION AND Ch 9 Page 1 to 6
SCHEDULE
10. PROJECT COST ESTIMATE Ch 10 Page 1 to 7
Attachment
10A Cost Summary
11. FINANCIAL ANALYSIS Ch 11 Page 1 to 5
Attachment
11A Financial Analysis
12. HEALTH,SAFETY AND ENVIRONMENT Ch12 Page 1 to 3
13. RECOMMENDATIONS Ch13 Page 1 to 2
No of Sheets
ANNEXURES
1 OVERALL PLOT PLAN 1

2A EQUIPMENT LIST 16
2B PROCESS FLOW SCHEME 2
3 BLOCK FLOW DIAGRAMS 2
BASE CASE
Refinery Expansion Case
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

EXECUTIVE SUMMARY Document No.
HPCL Mumbai Refinery Expansion Ch 1 Page 1 of 20
SECTION 1
EXECUTIVE SUMMARY

1.0 EXECUTIVE SUMMARY
1.1 INTRODUCTION
HPCL’s Mumbai Refinery was established in 1954. Through progressive

revamps/ capacity expansions, current crude oil processing capacity of HPCL-
MR is 7.5 MMTPA. It currently has two trains of primary distillation units (CDU-
I and II), secondary processing facilities viz. FCCUs, DHDS, MS Block
(NHT/ISOM, NHT/CCR and Prime-G), LOBS production facilities and other
associated treating and utility facilities.
The refinery has recently implemented the DHT project which includes
processing facilities such as a new Diesel Hydrotreating Unit, SRU, ARU, SWS
and necessary utilities and offsites.
With the installed facilities, the refinery shall be able to produce gasoline and
Diesel meeting Euro IV quality specifications, besides other petroleum
products like LPG, Naphtha, Kerosene, ATF, Fuel oil and Sulphur.
HPCL intends to increase the refining capacity of its Mumbai refinery upto 9.5
MMTPA. As a first step to accomplish the target, it is planned to revamp one of
its CDU/VDU units i.e. the FRAPS unit. Process Consulting Services (PCS)
has prepared a process package to revamp the FRAPS unit (CDU) upto 6
MMTPA capacity. For processing the equivalent quantity of RCO generated
from FRAPS, PCS has recommended installing a new VPS unit (VDU)
replacing the existing FRVPS and LRVPS units.
In order to estimate the capital investment within accuracy of ± 20% and to

establish the implementation plan for increase in crude processing capacity
with minimum modifications, HPCL has retained EIL’s services to prepare
detailed feasibility study report for Mumbai refinery.
1.2 SCOPE OF WORK
The scope of work under this project is performed in two parts:
1. Configuration Study
2. Detailed Feasibility Report
Broad Scope of Work
The scope of work shall comprise the following:
 Development of Base Case LP Model (based on current refinery operation

and constraints).
 Expansion case developed in LP and analyze various residue upgradation

technology options.

 Shortlist options after a broad evaluation of a number of options and

subsequent review by HPCL and EIL.
 Carry out a detailed evaluation of the shortlisted options to arrive at the

recommended option.
 Compilation of the Configuration Study Report.
 Detailed evaluation of the recommended option and implementation strategy

for refinery expansion to be accordingly planned.
 Identify augmentation in existing process units, utilities, offsite facilities and

other infrastructure.
 Determination of the Capital investment for expansion facilities and carry out
techno-economic comparison of alternatives based on CAPEX estimation
with +/- 20% accuracy level, OPEX, sales realization, etc.
 Preparation of refinery layout optimizing the usage of existing land with

minimum relocation and satisfying all statutory requirements.
 Compilation of the Detailed Feasibility report (DFR).
1.3 METHODOLOGY
Configuration Study
EIL shall develop the LP model for the refinery using in-house information on
yield, utilities, catalyst, and chemicals for various process units. PIMS software
will be used to develop the LP model.
EIL will study various refinery configurations using above LP model and
analyze and present results as part of screening study to HPCL. The
configurations developed will be discussed with HPCL for mid-term
corrections.
The short listed options shall be further detailed and capital cost /IRR shall be
estimated to come with recommended option
Detailed Feasibility Report (DFR)
EIL will develop requisite details of various facilities including utilities, offsites
and infrastructural facilities and prepare the DFR for the selected configuration
to provide +/-20% cost accuracy.

1.4 BASIC DESIGN PARAMETERS
The Basic Design Parameters are summarized below:
1.4.1 Refinery Capacity
The expansion capacity for study is considered as 9.5 MMTPA.

FR : 6MMTPA
FRE : 3.5 MMTPA
1.4.2 Crude Mix
Design Case (for expansion case)

1. Bombay High (3.5 MMTPA)
2. Kuwait (6 MMTPA)
1.4.3 On-Stream hours
The stream hour considered for the study is 8000hrs/Annum.
1.4.4 Objectives of the study
 Capacity Expansion of the refinery from 7.5 MMTPA to 9.5 MMTPA

 Meeting Euro IV Specs of MS and HSD.
 Maximisation of Distillate Yields.
 Maximisation of LOBS production (450KTPA).
 Improving GRM in post expansion case.
1.4.5 Product Demand
At present the production of LPG, MS and Diesel are not intended to be

limited in their production. The product demand considered for the study is as
below:

Table 1.1: Product Demand

Expansion phase (‘000 TPA)
PRODUCT
Min- Max
Fuel Refinery
Liquefied Petroleum Gas As Produced
Hexane 30-30
Light Aromatic Naphtha (LAN) To be minimized
Heavy Aromatic Naphtha 96-96
SOL-1425 8.5-8.5
Euro IV Gasoline To be maximized
Euro IV Diesel To be maximized
MTO 48-48
SKO 52.2-52.2
ATF 600-600
Light Diesel Oil (LDO) 0-0
Industrial Fuel Oil (IFO) To be minimized
Low Sulphur Heavy Stock
(LSHS)
Sulphur
Lube Refinery
IO-100 15 - 15
Spindle Group - I 15 - 15
Spindle Group – II 32 - 32
150 N Group – I 70 - 70
150 N Group – II 76 - 76
500 N Group – I 100 - 100
500 N Group – II 92 - 92
Bright Stock Group – I 50 - 50
Rubber Processing Oil (RPO) -
Carbon Black Feed Stock -
Asphalt/ Bitumen 1050-1050
1.4.6 Feed and Product Prices
The Crude Prices are the actual average Crude price of last three years(2011-
12,2012-13,2013-14) and single year price of 2013-14 and the Product Prices
are the average Refinery Transfer Price of last three years (i.e. 2011-14) and
single year price of 2013-14.
All three years average refinery prices and single year price which will be
considered for configuration study are tabulated below:

Table 1.2: Feed and Product Prices considered for Configuration study
3 years’ average price,
2011-14 (without/ with
octroi recovery)
(Rs/MT)
Crude
Bombay High 47478 / 46372
Kuwait 43749/ 42730
Arab Mix 44756/ 43713
Basra Light 43073/ 42069
Arab Extra Light 47722/ 46610
Product Prices
Liquefied Petroleum Gas 49812
Hexane 66326
Light Aromatic Naphtha (LAN) 50374
Heavy Aromatic Naphtha 53051
SOL-1425 66326
Euro III Gasoline 55547
Euro IV Gasoline 56396
MTO 56245
SKO 52533
ATF 52655
Euro III Diesel 52587
Euro IV Diesel 52736
Light Diesel Oil (LDO) 49719
Industrial Fuel Oil (IFO) 37307
Low Sulphur Heavy Stock (LSHS) 37805
Sulphur 4933
IO-100 57310
Spindle Group - I 57310
Spindle Group – II 59547
150 N Group – I 57310
150 N Group – II 59547
500 N Group – I 60878
500 N Group – II 62906
Bright Stock Group – I 70258
Rubber Processing Oil (RPO) 36543
Carbon Black Feed Stock (CBFS) 36370
VG-10 29084
VG-30 32816

Utility Prices
Raw Water (Rs./m3) 43.2
60356/ 58950 (upto
Natural Gas (Rs./MT) purchase of 30KTPA)
82651 (beyond purchase
of 30 KTPA)
Power (Rs/kWH) 8.14
1.4.7 Product Specifications
Product specifications as provided by HPCL in agreed Design basis has been

followed in the Study. Primarily MS and diesel shall confirm to Euro-IV quality.
1.5 REFINERY CONFIGURATION STUDY
The configuration study involves two parts:
1. Study for Suitability / Adequacy of Existing units for 10 MMTPA crude

processing
2. Configuration study considering various options for Residue upgradation

unit
EIL has developed a comprehensive LP model for build-up of configurations

for various options of the integrated expansion refinery.
A total of around 200 numbers of refinery configurations are evaluated

covering various Residue conversion options using LP PIMS model.
The various options for Residue upgradation which were considered to arrive
at the most optimum refinery configuration are listed below:
Sl. No. Case Description
1. No residue upgradation + MS block 20% revamp

2. No residue upgradation + MS block revamp open
3. SDA (52% lift) + MS block 20% revamp
4. SDA (52% lift) + MS block revamp open
5. SDA (52% lift) + MS block 20% revamp, without VGO
Hydrotreating in DHDT
6. SDA (25% lift) + MS block 20% revamp
7. SDA (25% lift) + MS block revamp open
8. SDA (25% lift) + Euro V MS production
9. Visbreaker Unit (with vacuum flasher) + MS block 20% revamp

Sl. No. Case Description

10. Visbreaker Unit (without vacuum flasher) + MS block 20% revamp
11. Visbreaker Unit (with vacuum flasher) + MS block revamp open
12. Visbreaker Unit + MS block revamp open, without VGO
Hydrotreating in DHDT
13. Visbreaker Unit + MS block 20% revamp + Flue gas PSA for H2
recovery
14. Visbreaker Unit + MS block 20% revamp + Kero Hydrotreating
unit
15. SDA (25% lift)+ Visbreaker Unit (with vacuum flasher) + MS block
20% revamp
16. SDA (25% lift)+ Visbreaker Unit (with vacuum flasher) + MS block
revamp open
17. Slurry HCU + MS block 20% revamp
18. Slurry HCU + MS block revamp open
19. VBU + MS block 20% revamp + 100% Euro V Diesel production
20. VBU + MS block 20% revamp + ratio of production of Euro IV
and Euro V Diesel, same as Euro III and IV in base case
21. VBU + MS block 20% revamp + natural gas purchase = 40.8
KTPA
22. VBU + MS block 20% revamp + natural gas purchase open
23. VBU + MS block 20% revamp + natural gas purchase open, also
routed to HGU and CPP
24. VBU + MS block 20% revamp + natural gas purchase open, also
routed to HGU and CPP + No internal fuel oil
25. VBU + MS block 20% revamp + 100% Euro V MS production
26. VBU + MS block 20% revamp + ratio of production of Euro IV and
Euro V MS, same as Euro III and IV in base case
On the basis of detail screening of various refinery configurations, the

following options are shortlisted for detailed analysis:
1. Refinery expansion upto 9.5 MMTPA crude processing capacity with

Visbreaker unit as an option for residue upgradation
2. Refinery expansion upto 9.5 MMTPA crude processing capacity with Slurry
hydrocracker unit as an option for residue upgradation
The final configuration is arrived at, after thorough analysis and discussions
held during various meetings, which are enumerated below:
 The design basis was finalized between HPCL and EIL during a meeting held
on 13th March 2013, at EIL HO.
The following were finalized with respect to Expansion study:

 Refinery capacity shall be 10 MMTPA (FR= 6MMTPA, FRE = 4MMTPA)
 Two cases of design crude mix to be studied:

Design Case 1: Kuwait (100%)

Design Case 2: Bombay High (20%)+Kuwait (40%)+Arab Light (40%)
 The new residue upgradation options to be studied were Visbreaker unit,
Solvent Deasphalting Unit (SDA) – 2 cut and 3 cut, low and high lift
 SOX limit to be considered for the refinery shall be a maximum of 12.6 TPD.
 Refinery configuration for base case (for crude thru ‘put of 7.5 MMTPA) was
developed in LP using the existing design and operating data.
Preliminary runs for expansion case for both design cases were done with
SDA as possible residue upgradation option.
 The base case developed by EIL was analyzed during the meeting held on
15th April 2013 at EIL HO. Minor modifications based on HPCL comments
(such as keeping MS and Diesel production slate for base case in line with
present EuroIII/IV Production ratio, were incorporated and the BASE case LP
model was frozen.
The configuration for expansion study for both design cases were also
discussed during this meeting and following key features were decided to be
incorporated in the expansion model:-
 Hydro treating of SRVGO in DHDT and subsequent routing of

hydrotreated VGO to Old FCCU.
 New Kero hydrotreater Unit of capacity = 100m3/hr
 Revamp of MS block units (NHT/ISOM, NHT/CCR and Prime-G).
 Adequacy of FRE APS column was carried out and it was found that
column is adequate upto 125% on BH crude (over a GFEC design
capacity of 3 MMTPA) without prefractionator and subject to the high
capacity trays adequacy by respective vendors. Based on the same, it was
decided that expansion for Design Case-1 and 2 shall be studied for 9.5
MMTPA and 9.75 MMTPA respectively.
 For both design case-1 and 2, LP runs were taken considering full capacity
utilisation of New FCC and New DHDT with:
 SDA with variations in DAO yields (25% and 50%)
 With / without VGO processing in DHDT
 With / without alkylate Blending for Euro V MS production
The results were presented in the first Apex level review meeting held on 3rd
May 2013 at HPCL Mumbai Refinery. The major points of discussion are as
follows:-
 Prices of crude, products, RLNG and alkylate would be revisited by HPCL.

 Production of 100% Euro V Diesel and MS would be the intent.
 A check case shall be done considering the ratio of Euro IV and Euro V MS
and HSD in expansion case to be maintained same as the.current ratio of
Euro III and Euro IV production in base case.

 Natural gas requirements should be considered in two cases. One as use in

boilers and process heaters and other as use in CPP, HGU, boilers and
process heaters.
 VBU+SDA option to be studied as another option of residue
upgradation.
 A high lift SDA and saturation of FCCU capacity are preferred in expansion
cases.
 A meeting was held on 11th June 2013 at EIL HO, New Delhi in order to
review the status of all the action points discussed during the Apex level
review meeting. Preliminary discussion on FRE APS/VPS heater
adequacy for revamped capacity was also held.
 The LP runs were carried out for the following Residue upgradation options,
limiting revamp of MS Block units upto 20% and subsequently keeping their
revamp open (in order to target zero naphtha sales):
 No residue upgradation case
 Visbreaker
 Slurry Hydrocracker
This was followed by another interim review by HPCL on July 1-2, 2013 at
EIL HO in which results of above cases were discussed.
It was finalized to run VBU with vacuum flasher to give improved yields.
Also, in order to accommodate the entire Prime-G naphtha into EURO IV MS
pool, it was decided that the possibility of reducing its sulphur (upto 50ppmw)
would be explored by licensor interaction.
 Subsequently, for both design case-1 and 2, LP runs were taken incorporating
above changes for the four options:
 No residue upgradation
 Visbreaker Unit (VBU)
 SDA
 (VBU+SDA)
These above cases were analysed for keeping MS block revamp upto 20% as
well as fully open. Also sensitivity analyses were performed for the
configuration to produce various ratios of Euro IV & Euro v products.
A detailed presentation was given by EIL on the findings of the configuration
study carried out so far during the second Apex Level Review meeting on
19th July 2013 at HPCL Mumbai refinery.
The three resid upgradation options that emerged out for further study were
Visbreaker Unit (VBU), SDA and (VBU+SDA) option.
The following were the key points of discussion:

 HPCL requested EIL to study a new case : processing SDA pitch as
feed to VBU

 HPCL informed EIL that production of Euro IV HSD and MS is envisaged for
post expansion case. Hence all cases should now be run with the objective
of producing Euro IV MS and HSD.
 HPCL informed EIL that the efficiency of some of the existing heaters was
being improved. Accordingly, the fuel consumption can be reduced and the
same had to be captured in the LP Model also
 It was followed by an interim meeting with HPCL on 19th August, 2013 at EIL
HO. During this meeting, HPCL informed EIL that the existing DHDT could be
operated as a Mild Hydrocracker, as per feedback from UOP. However the
option of co processing diesel, in MHCU mode of operation, would not be
possible. Since the quantity of middle distillates produced in the expansion
scenario required operation of DHDT also after saturating the DHDS, thus the
possibility of converting the DHDT into a mild hydrocracker was ruled out.
 The PCS FR process package was shared by HPCL.EIL estimated the

capital investment for the revamp of FR APS and New FR VPS based on
inputs. The cost sheets were submitted to HPCL for review on 5th September
2013.
 Based on the feedback obtained in the previous Apex level meeting, SDA
pitch was routed to Visbreaker. However, the same was limited to 15% of the
total VBU feed. Also, revised crude and product pricing (as furnished by
HPCL on 26th August, 2013) was fed in the LP Model. The revised findings
were analyzed for all the residue upgradation options of both the design
cases.
The results for the following cases were presented in the third Apex level
review meeting held on 31st October,2013 at HPCL Mumbai refinery:
 Visbreaker Unit (VBU),

 Low lift SDA unit
 VBU+Low Lift SDA
VBU and Slurry HCU options were finalized for the configuration study.
Based on the selected residue upgradation option, the Draft Configuration

Study report was submitted by EIL on 2nd December, 2013.
Additional units considered for Configuration study of the Refinery

Expansion case:
 HPCL intended to install a swing unit for producing isobutylene and

propylene from cracked LPG of both the FCCUs. EIL, thus, worked out
their potential in the refinery. The recovery that can be achieved for
isobutylene produced from the swing unit is around 45%.Due to low recovery,
production of isobutylene was ruled out by HPCL and EIL.
EIL also reported the improvement in refinery margin based on the price of
propylene furnished by HPCL.The same shall be elaborated in section 7.1 of
DFR.

As per original scope of the job, the option of manufacturing Mixed Xylenes
was to be studied .However it was later ruled out as Aromatics and RON
cannot be maintained in Reformate to be blended in MS Euro IV Pool after
producing Mixed Xylene.
Post submission of the Configuration Study report, there were meetings held
in EIL HO on 28th March and 24th April, 2014 with HPCL. It was decided that
the refinery expansion shall include the revamp of FRAPS upto 6 MMTPA and
implementation of a new VDU (as per the PCS process package) and a new
Visbreaker Unit (for residue up gradation).
As indicated by M/S PCS, FRAPS shall be revamped upto 6 MMTPA and a

new single VPS column will be set up instead of two existing VDUs-FRVPS
and LRVPS.
Based on the above, the Draft DFR was submitted to HPCL on 11th July,
2014.
1.6 DETAILED FEASIBILITY REPORT
1.6.1 Description of selected case
On basis of detail economic screening of the shortlisted refinery configuration

options, the following option is selected for detailed analysis.
Refinery expansion capacity : 9.5 MMTPA

Crude mix considered for Expansion case:
 Bombay High (3.5 MMTPA);
 Kuwait (6 MMTPA)
Additional Key Considerations:

The following updations in LP Model were done on the basis of the existing
refinery operating feedback:
 The CCR yields and reformate properties (RON, aromatics vol%) were
revised. The RON of reformate from CCR was reduced to 100 from 103. The
yield of hydrogen from CCR was decreased.
 The refinery CPP has a power generation capacity of 49 MW. The existing
power production in the refinery was limited to 13 MW max and balance
power was imported from the grid.
 The fuel oil firing rate per ton of steam production in the Utility boilers and the
naphtha firing rate per MW of power production in the gas turbines were
updated.

 The hydrogen consumption in MSDW/RHDT was increased to 12 TPD.
 A mechanical loss of 1.44 TPD in DHDT H2 consumption, for design capacity,

was also incorporated.
In addition to the above, the Base Case was revised for the same crude mix
(4 MMTPA Kuwait, 3.5 MMTPA BH) as considered for the Expansion case.
The final refinery expansion configuration is:
Case Description
 Revamp of FRAPS to 6 MMTPA crude processing capacity

as per BEDP prepared by PCS.
 A new VPS unit for the revamped FRAPS
 Revamp of MS block units (NHT/ISOM, NHT/CCR and
Expansion
Prime-G) by 20%
case
 A new Hydrogen generation unit of capacity 36 KTPA
(9.5 MMTPA)
 Modifications in DHDT to hydrotreat VGO
 A new Visbreaker unit of capacity 565 KTPA for residue
upgradation.
This case has the following features:
1. Feed Stock price per MMTPA for Base case is Rs 4568 Cr/Annum where as
the same for Expansion case is Rs 4527Cr/Annum due to increase in low
cost Kuwait Crude proceesing from 4MMTPA to 6 MMTPA.This results into
decrease in feed stock price which ultimately leads to Higher GRM.
2. LPG produced in the Expansion case is high owing to increase in crude

processing capacity and higher FCC thru'put (in expansion case).
3. LAN in expansion case is lower than that in Base Case due to revamp in MS
block units (NHT/ISOM and NHT/CCR) by 20%.
4. Prorating the crude processing capacity, the MS produced in expansion case

should increase by (9.5/7.5)*100= 127%. However, MS produced in this case
is even more than that due to higher FCC thru'put.
5. The production of diesel improves in Expansion Case owing to increase in

refinery crude thru’put, higher FCCU capacity and operation of a new VBU.
6. Prorating the crude processing capacity, fuel oil in expansion case should
increase by (9.5/7.5)*100= 127%. FO produced in this case is even more
than that due to higher yield of Vacuum residue (VR) in expansion Case..VR

in expansion case =1944 KTPA (20.5 wt%) wheras the same in Base Case
is 1289 KTPA (17.1wt%).
1.6.2 Material balance
LP runs for the selected case has been done for design crude mix meeting all
product specifications as mentioned in design basis.
The material balance and unit capacities considered for IRR estimation are
presented below in the Tables-1.3 and 1.4 respectively.
Table 1.3: Overall Material Balance of Refinery
Base Expansion %
Stream
Case Case Increase
FEED (000’TPA)
Bombay High 3500 3500 0
Kuwait 4000 6000 +50
Natural gas 24 24 0
PRODUCT (000’TPA)
LPG 332 471 +42
LAN 272 238 -13
SCN 96 96 0
Treated Hexane 30 30 0
Solvent 1425 8.5 8.5 0
MS Euro III 1075 0
MS Euro IV 0 1590
Total MS 1075 1590 +48
MTO 48 48 0
ATF 600 600 0
SKO 52 52 0
Euro III Diesel 1810 0
Euro IV Diesel 776 3466
Total diesel 2586 3466 +34
LDO 88 0 -100
RPO 70 0 -100
FO 180 cst 567 816 +44
Sulphur 37 67
150 N Gr-I 81 70
500 N Gr-I 206 100
Spindle Oil –Gr-I 15 15
Spindle Oil –Gr-II 19 32
150 N Gr-II 38 76
500 N Gr-II 7 92
Bright Stock 61 50

Base Expansion %
Stream
Case Case Increase
IO-100 9 15
Total LOBS 436 450 +3
VG-10 Bitumen 229 505
Total bitumen 707 1050 +49
1.7 PROJECT DESCRIPTION
The capacity of HPCL Mumbai refinery is increased from 7.5 MMTPA to 9.5
MMTPA. The desired capacity increase is proposed to be achieved by
implementation of the expansion project as below:
 Revamp of FRAPS upto 6 MMTPA crude thru’put

 Post expansion, the existing FRVPS and LRVPS units shall be dismantled. A
new VPS unit (VDU) shall be installed for processing the RCO generated
from FRAPS (based on the PCS process package).
 A revamp of 20% shall be done in the MS block units (NHT/ISOM, NHT/CCR
and Prime-G) in order to accommodate the increased light distillates.
 Modifications in DHDT for Hydrotreating VGO
 A new HGU unit, in order to meet the peak requirement of hydrogen during
VGO Hydrotreating in DHDT.
 A new Visbreaker unit, as an option of residue upgradation
1.7.1 Process Units
The extent of augmentation in the process units is tabulated below:
Table 1.4: Unit capacities in Expansion

Design
Post Revamp % Increase in
Units Capacity
Capacity (KTPA) Capacity
(KTPA)
4260(Bas/Kuw)
FRAPS 6000 141
4400 (AL/AM)
New VPS - 3400
FREAPS 3570 (BH)
3500 -
/VPS 3710 (AXL)
NAPHTHA
1222 939 -
SPLITTER UNIT
NHT/ ISOM 250 300 120
NHT/CCR 545 654 120
PRIME G+ 475 570 120
NEW FCCU 1456 1019 -

Design
Post Revamp % Increase in
Units Capacity
Capacity (KTPA) Capacity
(KTPA)
OLD FCCU 950 813 -
DHDS 2270 2034 -
DHDT 2200 1100 -
VGO FEED POOL
- 147 -
(DHDT)
DIESEL FEED POOL
2200 741 -
(DHDT)
PDA 755 755 -
HGU 14.5 14.5 -
New HGU - 36 -
VBU - 565 -
Note: New units are indicated in bold.
1.7.2 New Utility Systems
The revised utility consumption, required post revamp of the above facilities,
has been worked out based on estimation of utility consumption of the process
units.
Following New utility Systems shall come up in Post expansion case.
Table 1.5 New Utility Systems

Utility system Description
Bearing Cooling water system
Bearing Cooling Water Cells 1(W) Cells each of 150 m3/hr Capacity.
Bearing Cooling Water Pumps 1W+1S pumps each of 150m3/hr.
Balance all utility systems are adequate in order to cater the additional
requirement post expansion. The details are given in Section 7.5 of DFR.
1.7.3 New Offsite Facilities
The existing storage and transfer facilities of the refinery (for the various feed
and product streams) commensurate with the additional quantities to be
handled for the Expansion Project. Thus, in this project no new additional
crude and product tanks shall be considered.
Intermediate tanks viz Raw Diesel Storage Tanks, HGU Feed Tanks, VBU
Feed Tanks, VGO Feed Tanks, Hydrotreated VGO tanks, Diesel back

blending stream tank, Slop/off spec tanks are coming up in Expansion Case.
The details are given in Section 7.6 of the DFR.
Following New Tanks shall come up in Post expansion case.
Table 1.6 List of New Tanks

No of
S.No Service Type HxD(mxm)
Tanks
Raw Diesel
1 2 Floating Roof 20x30
Storage Tanks
2 HGU Feed Tanks 2 Floating Roof 20x9
3 VBU Feed Tanks 2 Fixed Roof 20x16
Cone Roof with N2
4 VGO Feed Tanks 2 20x25
blanketing
Hydro treated Cone Roof with N2
5 2 20x23
VGO blanketing
Diesel back
6 blending stream 2 Floating Roof 20x13
tank
Slop/Offspec
7 1/2 Floating Roof 20x20/20x13
tanks
The new offsite tanks shall also be associated with new offsite pumps
respectively.
1.8 ECONOMIC EVALUATION FOR SELECTED EXPANSION CASE
The financial results for the expansion case (based on 3 Years average prices,
with octroi recovery) is worked out & tabulated below:
Table 1.7 Financial evaluations

Total Cost
S.NO Description
(Rs. Crs)
1 Capex 3223.43
2 Opex 8695.95
3 Sales 9547.13
IRR on Total Capital
Pre-tax, % 24.03%
Post-tax, % 20.60%
IRR on Equity
Pre-tax, % 50.85%
Post-tax, % 43.46%
Sensitivity Analysis
Sensitivity analysis has been carried out to check the impact on Internal Rate
of Return considering change in Capex, Opex & Sales. The IRR for all these
cases has been tabulated below based on following two scenarios:

1. Equity concurrent to Debt
Table 1.8: Sensitivity analysis for “Equity concurrent to Debt” scenario

Total Capital Equity
S.No Description
Pre-Tax Post-Tax Pre-Tax Post-Tax
Base Case 24.03% 20.60% 50.85% 43.46%
1 Capex: +10% 21.99% 18.92% 44.83% 38.17%

Capex: -10% 26.48% 22.62% 58.24% 49.93%
2 Opex: +10% -ve -ve -ve -ve

Opex: +5% 12.15% 10.69% 17.27% 13.61%
3 Sales: -10% -ve -ve -ve -ve

Sales: -5% 10.67% 9.39% 13.00% 9.67%
2. Debt after Equity
Table 1.9: Sensitivity analysis for “Debt after Equity” scenario

Total Capital Equity
S.No Description
Pre-Tax Post-Tax Pre-Tax Post-Tax
Base Case 24.04% 20.54% 39.89% 34.47%
1 Capex: +10% 22.00% 18.86% 36.00% 30.97%

Capex: -10% 26.49% 22.55% 44.44% 38.56%

Opex: +5% 12.16% 10.65% 15.89% 12.73%

Sales: -5% 10.68% 9.35% 12.46% 9.48%
Above table indicates that Project IRR is more senstive to variation in Opex &
Product prices as compared to variation in Capex.

1.9 IMPLEMENTATION STRATEGY
To achieve the expansion refinery thru’put of 9.5 MMTPA, the implementation

of the expansion project shall include the following:
 Revamp of FRAPS upto a crude thru’put of 6 MMTPA as per the BEDP

prepared by M/S PCS.
 Installing a new VPS unit (VDU) for processing equivalent quantity of RCO
generated from FRAPS.
 Dismantling the existing FRVPS and LRVPS units.
 The increase in distillate yields due to increase in crude thru’put upto 9.5
MMTPA shall be accommodated in the existing refinery configuration.
However, a revamp of 20% is considered in NHT/ISOM, NHT/CCR and
Prime-G respectively for necessary enhancement of gasoline make.
 Modifications in DHDT unit to ensure hydrotreating of Vacuum gas oil (VGO).

The hydrotreated VGO shall be routed to Old FCCU as feed.
 Installing a new Hydrogen generation unit of capacity 36 KTPA in order to

meet the peak requirement of hydrogen during operation of DHDT in VGO
mode.
 A new Visbreaker unit, as an option of residue upgradation: This would

improve high sulfur and heavier crude processing capability and also improve
distillate yield for value addition by reduction of cutter in fuel oil pool.
 Necessary Utilities and Offsite tankages
1.10 ENVIRONMENTAL EMISSIONS
The stipulated SOX emission limit is 12.6 TPD for HPCL Mumbai Refinery. For
the enhanced capacity of 9.5 MMTPA, SOX emissions are estimated to remain
within the maximum limits. This is possible as a result of various measures
taken-up during the configuration study of the project, such as improved
furnace efficiency, use of only low sulphur fuel oil in furnaces and also due to
two Sulphur recovery units (DHDS and DHDT) which are modeled to track
H2S produced from various process units with a sulphur recovery of 99.9 % in
DHDS SRU and 99.8% in DHDT SRU.

1.11 RECOMMENDATION
 The HPCL Mumbai Refinery capacity can be increased from 7.5 MMTPA to
9.5 MMTPA considering modifications as enumerated in the report. The
desired capacity increase is proposed to be achieved by the revamp of one
of its CDUs (FRAPS), installing a new VPS unit, minor revamp in MS Block
units, and modifications in utilities and offsites.
 The option of VBU in the expansion case gives a fairly high yield of middle
distillates. It is a proven technology and requires no auxiliary units (such as
HGU, etc). The space requirement is low and it needs relatively low Capital
investment.
 The total estimated capital cost for the Expansion case is Rs. 3223.43
crores.
 The cost estimates has an accuracy of ± 20% and the validity of the above
cost is as of 4th Qtr. of 2014.
 Post tax IRR on total capital for the expansion is 20.60% (based on 3 year
average price, with octroi recovery).
 It is concluded that investments made can be suitably justified by increase

of product pool (MS and Diesel) and commensurate shrinkage of naphtha
as well as reduction of cutter to Fuel oil pool.

INTRODUCTION Document No.
Configuration
0 Study & DFR For A430-RP-02-41-0001
SECTION 2
INTRODUCTION

Configuration
0 Study & DFR For A430-RP-02-41-0001
2.0 INTRODUCTION
HPCL’s Mumbai Refinery was established in 1954. Through progressive
revamps/ capacity expansions, current crude oil processing capacity of HPCL-
MR is 7.5 MMTPA. It currently has two trains of primary distillation units (CDU-I
and II), secondary processing facilities viz. FCCUs, DHDS, MS Block
(NHT/ISOM, NHT/CCR and Prime-G), LOBS production facilities and other
associated treating and utility facilities.
The refinery is has recently implemented the DHT project which includes
processing facilities such as a new Diesel Hydrotreating Unit, HGU, SRU, ARU,
SWS and necessary utilities and offsites.
With the installed facilities, the refinery shall be able to produce Gasoline and
Diesel meeting Euro IV quality specifications, besides other petroleum products
like LPG, Naphtha, Kerosene, ATF, Fuel oil & Sulphur.
The schematic sketch of existing refinery is depicted below:
Figure 2.1: Schematic sketch of Existing Refinery
HPCL intends to increase the refining capacity of its Mumbai refinery upto 9.5
MMTPA. As a first step to accomplish the target, it is planned to revamp one of
its CDU/VDU units i.e. the FRAPS, Stabilizer, FRVPS and LRVPS units.
Process Consulting Services (PCS) has prepared a process package to
revamp the FRAPS unit (CDU) upto 6 MMTPA capacity. PCS has
recommended installing a new VPS unit (VDU) for processing the equivalent
quantity of RCO generated from FRAPS. Hence, this would require dismantling
of the existing FRVPS and LRVPS units.

Configuration
0 Study & DFR For A430-RP-02-41-0001
In view of the above, the following case have been shortlisted for detailed
analysis:
Expansion Case Description

Implementation of complete revamp of FRAPS, new VPS (as per PCS
BEDP) +MS block 20% revamp +New HGU+VBU +Revamp of DHDT for
VGO Mode+ Utilities and Offsites
Refinery expansion Case
An case considering complete revamp of FRAPS, new VPS (i.e. as per PCS
BEDP) and the following has been evaluated:
a) MS Block (NHT/CCR, NHT/ISOM and Prime-G) revamp of 20%

b) Dismantling cost of FRVPS and LRVPS units
c) New HGU
d) new VBU
e) Revamp of DHDT for VGO mode.
f) Utilities and Offsites
In order to estimate the capital investment within accuracy of ± 20% and to

establish the implementation plan for increase in crude processing capacity with
minimum modifications, HPCL has retained EIL’s services to prepare detailed
feasibility study report for Mumbai refinery.

SCOPE Document No.
SECTION 3
SCOPE

SCOPE Document No.
3.0 SCOPE OF WORK
The scope of Detailed Feasibility Report is to estimate capital cost of project with
accuracy of ± 20%, financial analysis and tentative schedule for overall project
implementation to achieve the processing objective of sustained refinery operation
at 9.5 MMTPA crude throughput through refinery expansion.
In addition, environmental considerations, overall refinery plot plan and

implementation philosophy for this project are studied and included in report.
3.1 DETAILED FEASIBILIT REPORT
The report consists of the following:
1. Design basis
2. Project description
3. Project configuration
4. Process description for the new process units.
5. Block flow diagram for the entire refinery for shortlisted cases
6. Generic Process Schematic diagrams for the new process units.
7. Overall Refinery material balance summary
8. Refinery product slate and quality
9. Utilities and offsite facilities
10. Environmental Considerations
11. Project Capital Cost
 Preparation of cost estimates with ± 20% accuracy for shortlisted options
 Estimated basic design and engineering fees, License / know-how fees,
list & estimated cost of proprietary items (if any), commissioning and
training fees based on quote from Licensors / Consultants’ in-house data
for similar projects in recent past.
 Estimated consultancy fees for carrying out detailed engineering,
procurement, inspection and expediting of equipment/materials,
construction supervision, etc.
 Estimates for civil, electrical materials, piping, structural, instrumentation
materials.
 Capital cost breakup as foreign exchange component and indigenous
component.
12. Operating cost for shortlisted options
13. Financial analysis
14. Project implementation strategy and project schedule along with bar chart.
15. Conclusion & Recommendations.
16. Overall Plot plan.

DESIGN BASIS Document No.
SECTION 4
DESIGN BASIS

4.0 DESIGN BASIS
Design basis considered for Configuration Study & DFR of HPCL Mumbai Refinery
Expansion Project is detailed in section 3.1
4.1 BASIC DESIGN PARAMETERS
Study to be Done by EIL DFR  FR Other

Execution Methodology For Project LSTK CONV  HYBRID
Project Duration Required in Months
4.1.1 OTHER STUDIES
By
By Others Remarks
EIL
Market demand and supply shall
Market survey/study report (Demand and
1 be considered as provided by
supply analysis)
HPCL
EIA and EMP study and data
2 Rapid Environmental impact study collection are excluded from
present scope
3 Site evaluation/selection Existing refinery area
Not in present scope. Will be
4 Evaluation/Selection of licensors
done at subsequent stage.
RRA study and data collection
5 Rapid Risk analysis
excluded from EIL scope.
6 Soil investigation Not Applicable
Hydrological survey Not applicable
Contour survey Not applicable
Route survey (for transport of ODC
7
materials from various ports / industrial As per existing plant.
areas of the country.)
Marine Survey-effluent dispersion study As per existing plant
Health assessment /inspection reports (For
8 Not applicable
Revamp)
Not applicable
9 Downtime assessment report (For Revamp) Approx Shutdown days for
revamp if any to be indicated.
4.1.2 PLANT LOCATION
Village City State Nearest Railway Station

Mumbai Maharashtra Mumbai
4.1.3 LAND AVAILABILITY DETAILS (Refer existing plot plan)

Plot Area Rerouting Requirement

1. Soil investigation, site Rerouting of any existing facilities like
details like Extent/cost of road, power lines, drains etc. required/ As per
land filling/ piling data, if not required (if required, details of the existing plant
available may be furnished. same may be furnished).
2. Land availability Grid power availability Nearest Dist Grid power
Level may be
considered
for expansion
4.1.4 RAW MATERIAL
Name FOR CONFIGURATION STUDY: Natural Gas

/Composition A. Design case1: 10 MMTPA Kuwait case
B. Design case 2: 2 MMTPA BH+4MMTPA
Arab Light+4MMTPA Kuwait
C.No check case to be considered.
FOR DFR:
A. 6 MMTPA Kuwait + 3.5 MMTPA BH
Source Pipeline Pipeline
Refer Section 4A.1 in Attachment 4A for
CDU/VDU Cut Points and Attachment 4D
for crude assays
4.1.5 PRODUCTS
Name Product names, its maximum and minimum demands

Annual Capacity and their specifications are detailed in sec 4.2
Market Place (preferred)
4.1.6 PLANT UNITS (As per Customer or as per EIL study approved by customer )
Process Capacity Utilities to be Capacity Catalyst / chemicals

Units generated Name Quantity Unit Rate
Existing unit details are given in Attachment 4A at the end of this chapter.
The following processes are to be reviewed based on economics:

A) Solvent Deasphalting Unit
B) Propylene Unit
C) Mixed Xylenes Unit
D) ATF hydro treating
E) Hydrogen Recovery unit
F) VGO desulphurization Unit

4.1.7 OFFSITE, RAW MATERIAL/ PRODUCT AND OTHER STORAGES
Optimal storage for new facilities may be considered based on existing best
practices in refinery project.
Details of existing tankage data is detailed in Attachment 4B at the end of this
chapter.
Materials
Raw Material Intermediate Products Finished Products
Name State No of Name State No of Name State No of
Liquid/ days of Liquid/ days of Liquid/ days of
solid storage solid storage solid storage
4.1.8 PRODUCT EVACUATION BY RAILWAY/TRUCK/ PIPELINE (Refer Sec 7.7)
Product % of product % of product to % of product to be % of product to be

Name to be moved be moved by evacuated evacuated through
by rail road through Pipeline Coastal
movement sea
tankers.
Length of rail to be laid/ distance between plant and railway

siding NA
Details of any major crossing (river/road/rail) coming on the way

NA
to Railway station to be considered as part of Project cost.
4.1.9 UTILITIES
Refer Attachment 4E for details of existing utility systems
4.1.9.1 Raw Water For Plant Operation
Source As per existing plant

Distance from river/sea As per existing refinery
Raw water Analysis (if available) As per existing plant
4.1.9.2 Electric Power For Plant Operation
Source Thermal power station

Volts At design Stage
Frequency At design Stage
Rate Rs./kWH NA
Distance _________ km from
Captive Power to be generated As required
Level of Generation At Design stage
Contract Demand Charges NA
Energy charges NA

Minimum energy charges (as % of NA

Contract Demand)
Incase this is not available, whether a No surplus power generation capacity is
system is to be designed/included in available in existing refinery. Presently,
execution extra requirement of power is met by
importing power from grid. For any
further requirement of power, new facilities/
power import from the grid shall be
considered.
For expansion, estimated steam power
balance is worked out by EIL.
4.1.9.3 Construction Power
Available Not Available.

Volts
KM away
Rate (Rs./KWH)
Contract Demand Charges
Energy charges
Minimum energy charges (as % of
Contract Demand)
4.1.9.4 Construction Water
Available Not Available.

KM away
4.1.9.5 Cooling water
Existing Cooling Water system configuration & capacity has been provided by
HPCL.Post expansion, additional cooling water requirement shall be met by new
facilities
4.1.9.6 Nitrogen system
Existing Nitrogen system configuration & capacity has been provided by HPCL.Post
expansion, additional nitrogen requirement shall be met by existing facilities.
4.1.9.7 Air system
Existing Air system configuration & capacity to be provided by HPCL. Post

expansion, additional compressed air requirement shall be met by existing facilities.
4.1.9.8 Steam system
Post expansion, additional steam requirement shall be met by existing facilities.
4.1.9.9 DM Water

Existing DM Water system configuration &capacity to be provided by HPCL. Post

expansion, additional DM water requirement shall be met by existing facilities.
4.1.9.10 Condensate system
Existing Condensate system configuration & capacity to be provided by HPCL. Post

expansion, new facilities shall be considered for condensate treating if required.
NOTE: HPCL to confirm if augmentation of utility systems is envisaged as facilities

required for generation of additional utilities for meeting internal demand have to be
considered in complex.
4.1.9.11 Flare
No revamp of flare is envisaged. For the purpose of configuration study, flare load
adequacy shall be preliminary in nature and shall be based on estimated load of new
units & load provided by HPCL for existing units.
4.1.9.12 ETP
ETP adequacy is to be checked.
4.1.10 ENVIRONMENTAL REQUIREMENT
4.1.10.1 Effluent Specifications
Liquid Effluent As per MINAS standard

Gaseous Effluent
Solid Waste
Stack height (Limitation to be By HPCL, for the new stack
specified)
Location of effluent discharge & its As per existing refinery
distance from B/L of plant standard
Note: Details to be furnished below in case State Pollution Board
specifications exist
4.1.10.2 Green Belt Requirement*
As advised by State Government

during site selection visit.
* In absence of this data 100 M all
around shall be included.
4.1.10.3 REIA (In case of DFR) / Rapid Risk Analysis (In case of FR)
REIA (In case of DFR) / Rapid Rapid risk analysis is excluded

Risk Analysis (In case of FR) from EIL’s scope of work
4.1.11 BUILDING REQUIRED (PLANT & NON PLANT)

Name Type Area in M2

Administrative Building NR
Warehouse(Chemical, Spares, NR
Product, Cement)
Workshop NR
Canteen NR
Lab As required
Control room with rooms for As required
operating supervisors and
conference rooms
Training Center NR
Substations As required
Fire station As required
Operator Cabins As required
Service Buildings As required
Security Cabins As required
Any other building as required NR
4.1.12 CONSTRUCTION AIDS
Not required (None of the construction equipment can be provided by

HPCL)
Heavy crane to be purchased by owner Yes/No

(If yes, please specify capacity of range Capacity range -------------
proposed and hiring charges) Hiring charges -------------
Whether Hydra, and medium size crane Yes/No
(up to 35 Tons can be brought by Erection XX
Contractor)
4.1.13 OWNER EXPENSES DURING PROJECT IMPLEMENTATION
Expenditure Heads To be Included in report

Expenses Towards Public Issue Yes/No
Salaries Yes/No
Perks And Facilities To Be Provided By Yes/No
Owner To People Employed On This Job
Communication Yes/No
Travel Yes/No
Training Yes/No
Legal Expenses Yes/No
PMC Fees Yes/No
Contigency Yes/No
Any Other
Total Amount For All The Above Heads Rs-------------------------
4.1.14 ADDITIONAL INFORMATION, FOR MARGIN MONEY CALCULATION

Item Days
Salaries and wages and operating
manhours/manpower envisaged
Repairs and maintenance spare inventory
Goods in process
Finished goods
Bills Receivable (Outstanding)
Cash in hand
Trade Credits
Inventory level for Catalysts
Inventory level for Chemicals
4.1.15 INFORMATION FOR FINANCIAL ANALYSIS (Refer Attachment 4C)
Project Funding % Grant

Equity Debt-Equity
Ratio-2:1
Debt
Expenditure Equity before debt or concurrent Concurrent
Pattern (Grant
Terms Required)
Equity Contribution Promoter
% Financial Institution
Public
Equity Foreign Equity
Composition % Contributors Equity
Dividend on Equity
Equity Expenditure Promoter fund followed by F1 and then
Pattern Public
Promoter and F1 equal share and then
Public
Foreign Equity flow pattern
Debt Composition Foreign Currency Financial Instituions
% Suppliers Credit
Financial Instituions
Rupee Portion Debentures to Financial
Institutions
Debentures to Public
Terms and From FII’s and Front end processing
Conditions of Suppliers’ Credits fees
Debts / Debentures (Foreign Currency Exposure fees
and Rupee) Commitment fees
Guarantee fees
Interest Rates and
Calculation
Methodology
Loan Repayment Moratorium (from
Terms Commercial Operations
commencement)
Number of installments

Frequency of
Installments
For Debentures to Coupon rate
Fis and Public Redemption Terms
Interest rate on Short Term Loan
Capacity Buildup 1st year
2nd year
3rd year
4th year
5th year
Factory Gate Prices for the following to be furnished
Raw Materials, Chemicals and Catalysts etc. (inclusive of transportation and all taxes and
duties). Excise duty rates and countervailing duty rates (for imported items) may be
separately indicated for Modvat benefit calculations wherever applicable.
Bought out Utilities (inclusive of all burdens)
Product and By-product prices (excluding duties and taxes etc.). However, the excise
duty rates may be indicated for use in Modvat calculations wherever applicable.
Applicable Tax Benefits Yes/No
Furnish Crude & Individual Product Price (FOB), freight & Insurance cost to be
considered for analysis (also provide basis of pricing).
4.1.16 KEY CONSIDERATIONS
A. No new secondary processing unit shall be considered. However VGO HDS option
shall be worked out.
B. Due to space constraints, SDA shall be considered for resid up gradation. SDA
data provided by HPCL to be considered.
C. FRE capacity shall be considered as 3.5 MMTPA and no modification shall be
considered.
D. For expansion study the data of FR APS, Stabilizer and New VPS such as cut
points, equipment details, and revamp modifications shall be considered as per
inputs provided by HPCL (PCS Study Report).
E. HPCL to confirm if manufacture of specialty products such as Propylene, Mixed
Xylenes etc is envisaged and if so, quantity to be produced and grade of propylene
to be produced – chemical or polymer to be provided by HPCL
F. Disposal of Asphalt
G. One option will be considered with existing DHDS as VGO HDT
H. One option will be considered with IOH as Kero hydrotreater
I. In case of non-availability of natural gas, IFO shall be considered as internal fuel in
the refinery.
J. Crude Blending facilities shall be considered in DFR stage
K. H2 recovery from H2 rich gases from DHDS, DHDT etc shall be considered

4.2 PRODUCT DEMAND
Product Demand considered for the study is tabulated in Table 4.1 below:
Table 4.1-Product Demand Portfolio
Name Annual capacity

Minimum Maximum
(000TPA) (000 TPA)
DFR CASE 1 & 2
Kuwait 6 MMTPA
Bombay High 3.5 MMTPA
Fuel Refinery
LPG OPEN
Hexane 30 30
TO BE
Light Aromatic Naphtha (LAN)
MINIMIZED
Heavy Aromatic Naphtha (HAN) 96 96
SOL-1425 8.5 8.5
Euro IV Gasoline (Export/Domestic) 100% EURO IV
Euro V Gasoline(Export/Domestic)
MTO 48 48
SKO 52.2 52.2
ATF 600 600
Euro IV Diesel(Export/Domestic) 100% EURO IV
Euro V Diesel(Export/Domestic)
Industrial Fuel Oil (IFO) TO BE
(180 CST/BUNKER) MINIMIZED
Low Sulphur Heavy Stock (LSHS)
Sulphur
Lube Refinery
IO – 100 15 15
Spindle Group-I 15 15
Spindle Group-II 32 32
150 N Group-I 70 70
150 N Group-II 76 76
500 N Group-I 100 100
500 N Group-II 92 92
Bright Stock Group-I 50 50
Carbon Black Feed Stock (CBFS)
Asphalt/Bitumen 1050 1050

4.3 FEED & PRODUCT PRICES
The Crude Prices are the actual average Crude price of last three years (2011-
12,2012-13,2013-14), and the Product Prices are the average Refinery Transfer
Price of last three years (2011-12,2012-13,2013-14).
All three years average refinery prices which will be considered for configuration
study are tabulated below in table 4.2:
Table 4.2-Feed & Product Prices
Price (Rs/MT)
(without/ with octroi
Crude
recovery)
(2011-12,12-13,13-14)
Bombay High 47478 / 46372
Kuwait 43749/ 42730
Arab Mix 44756/ 43713
Basra Light 43073/ 42069
Arab Extra Light 47722/ 46610
Fuel Refinery
LPG 49812
Hexane 66326
Light Aromatic Naphtha (LAN) 50374
Heavy Aromatic Naphtha (HAN) 53051
SOL-1425 66326
Euro III
55547
Gasoline(Export/Domestic)
Euro IV
56396
Gasoline (Export/Domestic)
MTO 56245
SKO 52533
ATF 52655
HSD (0.05%SUL) 52735
Euro III Diesel(Export/Domestic) 52587
Euro IV Diesel(Export/Domestic) 52736
Industrial Fuel Oil (IFO) 37307
Low Sulphur Heavy Stock (LSHS) 37805
Sulphur 4933
Lube Refinery
IO – 100 57310
150 N Group I 57310
150 N Group II 59547
500 N Group I 60878
500 N Group II 62906
Spindle Group-I 57310
Spindle Group-II 59547
Bright Stock Group-I 70258
Carbon Black Feed Stock (CBFS) 36370
VG-10 29084

VG-30 32816
Utility Prices
Raw Water 43.2 Rs/MT
60356/58950(Upto 30
Natural Gas KTPA)
82651(Beyond 30 KTPA)
Power (Rs/kWH) Rs 8.14/KWh
NOTES:
1. Tabulated prices of crude/products were as provided by HPCL.

2. For the configuration study, the prices of crude & products provided in Aug’13
were considered.

4.4 PRODUCT SPECIFICATIONS
The product specifications adopted for this Project are given as under
1. LPG (BIS:4576-1999)
Manufacturing Standard Shipping

Product Unit
Spec Spec Spec
Vapor pressure at 40 °C, max kPa 1050 1050
Odor, min 2 -
C2 minus content, max wt% 0.2 -
C5 plus, max wt% 2 2.5 Vol%
Total volatile sulfur, max wppm 150 150
Copper strip corrosion, max No. 1 No. 1
Hydrogen sulfide wppm Nil Pass
Mercaptans wppm Nil 20 Min.

Free water Nil None
Evaporation temperature for
°C 2
95 vol%, max 2
2. Solvent 1425

Product Unit
Spec Spec Spec
Clear, Free
Bright &
Appearance from visible
Clear
impuriries
Aromatics Content, Max %wt 1.0 2.0
Benzene content, Max %wt 0.1 -
Colour, Min Saybolt +30 +25
Distillation:
50 Min – 70
IBP, Min Deg C 75
Max
100 Min – 120
DR, Max Deg C 135
Max
Mg/100
Non volatile matter, Max 5 5
ml
Sulphur Content, Max wppm 1 0.1 Wt%

3. Light Aromatic Naphtha (LAN)

Product Unit
Spec Spec Spec
Total Sulphur, Max % wt 0.15 -
mg/100 -
Residue on Evaporation, Max ml 5
Paraffins, Min %v 65 -
Aromatics, Max %v 11 -
Olefins, Max %v 1 -
Distillation:
IBP, Min Deg C 34 -
FBP, Max Deg C 180 -
RVP @38 Deg C, Max psi 10 -
Lead as Pb, Max ppb wt 50 -
Colour (Saybolt), Min +20 -
Chlorides as Cl, Max wppm 10 -
Napthenes+Aromatics %vol 34 -
4. Heavy Aromatic Naphtha (HAN)

Product Unit
Spec Spec Spec
Density @15oC g/ml 0.682 - 0.75 -
Total Sulphur, Max % wt 0.1 -

Clear and -
Appearance Bright
Colour Colourless -
mg/100 -
Residue on Evaporation, Max ml 5
Aromatics, Max %v 20 -
Olefins, Max %v 1 -
Gross Calorific Value, Min Kcal/kg 11300 -
Distillation:
50% recovered @ Deg C, Max Deg C 130 -
FBP, Max Deg C 180 -
RVP @38 Deg C, Max psi 10 -
Lead as Pb, Max ppm 0.2 -
K.V@15 Deg C, Min cst 0.5 -
5. Export grade Naphtha


Product Unit
Spec Spec Spec
Specific gravity
min 0.69 -
max 0.735 0.74 0.74
RVP (100 Deg F), max psia 13 10 12.0
C/H ratio, max 6 -
Sulphur, max wppm 450 500 500
Chloride, max wppm 1 2
Gross Calorific Value, min kcal/kg 11000 11000 -
IBP, min °C 25 30
FBP, (ASTM D86) max °C 170 180 204
Total Paraffins, min vol% 60 62 65
Colour (Saybolt), min +20 +20 +20
Olefins, max vol% 0.2 1 -
Lead, max wt ppb 100 15
Residue on evaporation mg/100ml 5 max 5 Max
Ramsbottom carbon content wt% 0.2 max -
Sodium ppm 1 max 1.0 Max
Potassium ppm 1 max 1.0 Max
Vanadium ppm 0.2 max 0.2 Max
Zinc ppm 0.2 max 0.3Max
Nickel ppm 0.2 max 0.2 Max
Calcium ppm 0.75 max 0.75 Max
Aromatics vol% 12 max 16 Max
6. MTO

Product Unit
Spec Spec Spec
Colour (Saybolt), Min +20 +21
Flash point (Abel), Min Deg C 35 30
Distillation Range:
IBP, Min Deg C 145 125
Dry point, Max Deg C 205 240
Aromatic Content, Max %v/v 40 40
Copper Strip Corrosion for 3 Not worse Not worse than
hrs at 50 Deg C than No. 1 No. 1
mg/100 5 5
Residue on evaporation, Max ml
7. SKO


Product Unit
Spec Spec Spec
Specific gravity
min 0.775 -
max 0.84 -
Olefins, max vol% 5 -
Sulfur total, max wt% 0.25 0.16 0.10
10 % recovery ,(ASTM D86) -
deg C 205
max
FBP, (ASTM D86) max deg C 280 280
Flash point (Abel),min deg C 35 42 38
Smoke point mm 19 18 18
8. Aviation Turbine Fuel

Product Unit
Spec Spec Spec
Specific gravity
min 0.775 0.775
max 0.84 0.840
Aromatics, max vol% 26 22 20.0
Sulfur total, max wt% 0.31 0.25 0.25
10% recovery, (ASTM D86) 205
°C
max 205
FBP, (ASTM D86) max °C 300 300
Flash point (Abel), min °C 38 38 38
Freeze point, max °C (-) 45 (-) 47 (-) 47
Smoke point mm 26 19 Min
9. EURO IV Gasoline (Premium/Regular)

Product Unit
Spec Spec Spec
Density @ 15°C 720-769 720 - 775
RON Min. -/92 95/91 92
MON Min. -/81 85 /81 81
Sulphur Max wppm 20 50 40
Benzene Max Vol% 1.0 1.0 1.0
Olefins Max Vol% /21 18 /21 21
Aromatics Max Vol % 42 35 35
Distillation Vol%
Recovery @ 70 C Min. 10 10 10
Recovery @ 70 C Max. 45 45 45
Recovery @ 100 C Min. 40 46 40


Product Unit
Spec Spec Spec
Recovery @ 100 C Max. 70 70 70
Recovery @ 150 C Min. 75 75
Recovery @ 180 C Min. 75 -
FBP 190, Max 190 Max
RVP kPa 60 60 60 Max
Lead content g/l 0.005 max 0.005 Max
Vapor Lock index
Summer May – July 750
Winter 750 750 Max
950 950 Other Months
950 Max
Existent gum g/m3 40 max 40 max 40 Max
Oxidation stability Min 360 min 360 min 360 Min
Oxygen content % by
2.7 max 2.7 max 2.7 Max
mass
10. Gasoline (EURO V)

Product Unit
Spec Spec Spec
Specific gravity -
min 0.72 -
max 0.775 -
Sulfur, max wppm 10 -
RON, min 95 -
MON, min 85 -
Reid vapour pressure, max kPa 60 -
Recovery at 70 °C (ASTM -
D86)
min vol% 10 -
max vol% 45 -
Recovery at 100 °C (ASTM -
D86)
min vol% 46 -
max vol% 70 -
Recovery at 150 °C, (ASTM -
75
D86) min vol%
FBP, (ASTM D86) max °C 210 -
Aromatics, max vol% 35 -
Benzene, max vol% 1 -
Oxygen content, max wt% 2.7 -
Oxygenates content, max -
Methanol vol% 3 -
Ethanol vol% 10 -
Iso-propyl alcohol vol% 12 -


Product Unit
Spec Spec Spec
Iso-butyl alcohol vol% 15 -
Tertiary-butyl alcohol vol% 15 -
Ethers with 5 or more carbon -
22
atoms vol%
Other oxygenates vol% 15 -
Existent Gum Content (solvent -

5
Washed) max mg/100ml
Oxidation Stability, min minutes 360 -
Lead Content (as Pb) -
0.005
max g/l
Vapor Lock Index -
a) Summer -
750
max
b) Other months -
950
max
rating Class 1 -
11. Light Diesel Oil (LDO)

Product Unit
Spec Spec Spec
% by
1.8 1.5
Total Sulphur, max mass
Acidity (inorganic) Nil Nil
% by 0.02
0.02
Ash, Max mass
1.5 (on 0.25 Min
% by
Carbon Residue whole 1.5 Max
mass
(Ramsbottom), Max sample)
Pour point, Max
a) Winter Deg C 12 +12
b) Summer Deg C 21 +21
Not worse than
Not worse
Copper Strip Corrosion for 3 No. 2
than No. 1
hrs at 100 Deg C
Flash point, Pensky Martens,
66 66
OB, Min
Kinematic Viscosity at 40 Deg Min 2.5 – Max
cst 2.5 – 15.7
C 15.0
% by
0.10 0.10
Sediment, Max mass
% by
0.25 0.25
Water Content, Max volume
12. High Speed Diesel

Product Unit
Spec Spec Spec


Product Unit
Spec Spec Spec
Density@15 Deg C 820 - 850 -
Sulphur, Max %wt 0.05 -
Need to -
Flash point (Abel) Max Deg C enhance
Pour Point in summer, Max Deg C 15 -
Pour point in winter, Max Deg C 3 -
Water Content, Max v/%v 0.025 -
Copper Strip Corrosion @ 100 -
Deg C 1
Carbon Residue, Max wt% 0.3 -
Total Acid No., Max mgKOH/g 0.08 -
Sediment by extraction %vol 1.6 -
Ash content, Max wt% 0.01 -
Distillation 90 v/v% Recovery, -
Max Deg C 365
Total aromatics, Max %m/m 25 -
Poly-aromatics, Max %v/v 3 -
13. EURO IV Diesel

Product Unit
Spec Spec Spec
Density Min Kg/m3 821 820
Density Max Kg/m3 845 845 845
Cetane index 50 47 Min.
Cetane No. Min. 52 51 51
Sulphur Max wppm 40 50 40
Poly Aromatics Max vol % 11 11 11
Flash Point Min. deg C 36 35 37
Distillation vol%
T-95, Max 360 360 360
Cu strip corrosion @ 100°C Not worse than
1 max
for 3 hours No. 1
Summer +15.0
°C Summer 15
Pour point Max
°C Winter 3.0
Winter+3.0 Max
Water content mg/kg 200, max 200 Max
Min. 2.0
Kinematic viscosity @ 40°C cst 2.2-4.5
Max 4.5
Ash mass % 0.01 max 0.01 max
Carbon residue on 10%
mass % 0.3 max 0.3 max
residue
Cold filter plugging point Summer 18 Summer +18.0
Winter 6 Max
°C Winter +6.0
°C Max


Product Unit
Spec Spec Spec
Total contamination mg/kg 24 max 24 max
Oxidation stability % by mass 25 max 25 max
Lubricity, corrected wear 460 460
scar@ 60°C microns
Oxygen content % by mass 0.6 -
14. Diesel (EURO V)

Product Unit
Spec Spec Spec
Specific gravity
min 0.82 -
max 0.845 -
Sulfur, max wppm 10 -

Kinematic Viscosity at 40 °C
min cSt 2 -
max cSt 4.5 -
95% recovery, (ASTM D86) -
°C
max 360
Flash point (Abel), min °C 38 -
Cetane number, min 51 -
Cetane index, min (ASTM -
D4737) 50
Poly Aromatic hydrocarbon, -
wt%
max 8
Cold filter plugging point, max
Summer °C 18 -
Winter °C 6 -
Ash, max % wt 0.01 -
Carbon residue(Ramsbottom) -
% wt
on 10% residue, max 0.3
Water Content -
mg/kg
max 200
Total Contaminations -
mg/kg
max 24
Oxidation Stability -
g/m3
max 25
Lubricity, corrected wear scar -
diameter (wsd 1,4) @ 60oC m
max 460
Copper Strip corrosion for 3 -
rating
hrs@50 oC, max Class 1
15. FO 180


Product Unit
Spec Spec Spec
Density @ 15°C g/cc 0.98 -
Flash point °C 80 min 66 Min.
Pour point °C 24 max +27 Max
cst 175 max 180 Max
Kinematic viscosity @ 50°C
cst 125 min 125 Min
Ash content wt% 0.1 max 0.1
Water content vol% 1.0 max 1.0 Max
Sulphur wt% 4 max 4.0 Max
16. FO 380

Product Unit
Spec Spec Spec
Density @ 15°C g/cc 0.98 0.991Max
Flash point °C 80 min 60 Min
Pour point °C 24 max +27 Max
372 max 380 Max
Kinematic viscosity @ 50°C cst 325 -
min
Ash content wt% 0.1 max 0.1 Max
Water content vol% 1.0 max 0.5 Max
Sulphur wt% 4 max 4.5 Max
17. FO-380 Bunker

Product Unit
Spec Spec Spec
Density @ 15°C g/cc 0.998 max 0.991 Max
Sulphur, max % wt 3.5 3.5
Flash Point(PMCC), min °C 80 66
372 max 380 Max
Kinematic Viscosity @50 Deg
cSt 325
C
min
Pour point max °C 24 +30 Max
18. Low Sulphur Heavy Stock (LSHS)

Product Unit
Spec Spec Spec
Pour Point, Max Deg C 66 +60 Max
Flash Point, (PMCC), Min Deg C 76 66


Product Unit
Spec Spec Spec
Kinematic Viscosity @ 100 50 Max
Deg C, Max cst 50
Acidity, Inorganic Nil -
% by -
Ash, Max mass 0.1
% by -
Sediment, Max mass 0.25
% by 0.6
Total Sulphur, Max mass 1.0
Water Content, Max %v/v 1.0 -
19. Rubber Processing Oil

Product Unit
Spec Spec Spec
Grade: HP Elasto 165 / HP Elasto 245 / HP Elasto
Kinematic Viscosity @ 40 Deg 85-107/31- -
C Cst 35/14-18
Aniline Point, Min Deg C 107/98/- -
Flash point, coc, min Deg C 225/190/230 -

Copper Corrosion @ 100 Deg -
C, 3 hrs, Max -/1/1
Clay Gel Analysis 0.6 -
Asphaltenes %wt -/Nil/- -
Polar compounds %wt -/0.6/- -
Aromatics %wt -/20.3/- -
Saturates %wt -/79.1/- -
Grade: HP Elasto 541 / HP Elasto 590

18-23/100- -
Kinematic Viscosity @ 40 Deg 182@54.5
o
C Cst C
Aniline Point, Min Deg C 78/74-96 -
Flash point, coc, min Deg C 160/221 -

Copper Corrosion @ 100 Deg -
C, 3 hrs, Max 1/-
Clay Gel Analysis 0.6 -
Asphaltenes %wt Nil/0.3 -
Polar compounds %wt 2.3/6 -
Aromatics %wt 46.7/- -
Saturates %wt 51/35-65 -
Grade: HP Elasto 710,715/ HP Elasto 31-35


Product Unit
Spec Spec Spec
21.25- -
Viscosity @ 100 Deg C cst 25/26-47
Flash point, coc, min Deg C 218/220 -
40-50/32.2- -
Aniline Point, Min Deg C 51.6
Pour Point, Max Deg C 32/26 -
1.54- -
1.58/1.562-
1.574@ 20
Refractive Index @ 60 Deg C Deg C
Clay Gel Analysis ASTM D -
2007
Less than -
Asphaltenes %wt 0.1/-
Polar compounds %wt 9.2/- -
Aromatics %wt 66.5/- -
Saturates %wt 24.3/- -
20. Carbon Black Feed Stock (CBFS)

Product Unit
Spec Spec Spec
BMCI, Min 78-118 78
Density @ 15 Deg C g/ml 0.995 - 1.08 -
Pour point, Max Deg C 24-42 -
Flash Point, Min Deg C 95 -
Total Sulphur, Max % wt 2.5 – 5.5 -
Water Content, Max % vol 1.0 -

Carbon Residue -
(Ramsbottom) % wt 0.25 - 8.0
Kinematic Viscosity at 98.9 -
Deg C cst 18.0 – 86.0

21. Bitumen

Product Unit
Spec Spec Spec
Grade : VG 10 / VG 20/ VG 30/ VG 40
Absolute Viscosity at 600C, 800/1600/24 800/1600/2400
Min Poise 00/3200 /3200
Kinematic Viscosity at 135 C, 250/300/350 250/300/350/4
Min cSt /400 00
Flash Point (Cleveland Open 220/220/220 220/220/220/2
Cup), Min Deg C /220 20
Solubility in Trichloroethylene, 99/99/99/99
Min % 99/99/99/99
80-100/60- 80-100/60-
Penetration at 250C, 100g, 80/50- 80/50-70/40-60
5s,0.1mm 70/40-60
Softening Point (R&B), Min Deg C 40/45/47/50 40/45/47/50
Viscosity ratio at 600C Max 4/4/4/4 4/4/4/4

Ductility at 250C, cm, Min, 75/50/40/25
After, thin film oven test 75/50/40/25
22. Group I LOBS

Product Unit
Spec Spec Spec
Sulphur wppm >300 -
Saturates % <90 -
V.I 80-120 95 Min
23. Group II LOBS

Product Unit
Spec Spec Spec
Sulphur wppm < 300 -
Saturates % > 90 -90 Min
V.I 80-120 105 Min

4.5 CDU/VDU CUT POINTS
 PHASE I
 FREAPS would operate with BH Crude.

 FRAPS would operate with Kuwait crude.
 FRVPS, LRVPS, FREVPS would operate with RCO from FRAPS (Kuwait
Crude).
CDU/VDU TBP cut points considered for Phase 1 study are given in table 4.3A,
4.3B and 4.3C.
Table 4.3A: TBP Cut Points for FREAPS( BH crude)
PRODUCT SKO MODE MTO MODE

Gas C1-C4 C1-C4
Lt Naphtha C5-119 C5-124
FBS 119-143 124-164
SR Kero 143-239 164-233
LVGO 239-324 233-326
FRE JBO 324-346 326-400
RCO 346+ 400+
Table 4.3B: TBP Cut Points for FRAPS(Kuwait crude)
PRODUCT FRAPS
Gas C1-C4
Lt Naphtha C5-129
FBS 129-142.5
SR Kero 142.5-238.5
LVGO 238.5-336.5
RCO 336.5+
Table 4.3C: TBP Cut Points for FRVPS,LRVPS,FREVPS( Kuwait Crude)
Product
FRVPS LRVPS FREVPS
XSVGO 336.5-338 336.5-345.7 336.5-343
SPVGO 338-392 345.7-391 343-388.5
SS1 392-424 391-440 388.5-426
SS2 424-521 440-545 426-518
SS3 - - 518-540
Vac Residue 521+ 545+ 540+

 PHASE 2
 FREAPS /VPS would operate with BH crude.

 FRAPS/VPS would operate with Kuwait crude.
CDU/VDU TBP cut points considered for Phase 2 study are given in table 4.4A,
and 4.4B.
Table 4.4A: TBP Cut Points for FREAPS/FREVPS( BH crude)
PRODUCT SKO MODE MTO MODE

Gas C1-C4 C1-C4
Lt Naphtha C5-119 C5-124
FBS 119-143 124-164
SR Kero 143-239 164-233
LVGO 239-324 233-326
FRE JBO 324-346 326-400
RCO 346+ 400+
VGO 346-347
XVGO 347-397 369-399
SS1 397-450 399-498
SS2 450-522 498-599
SS3 522-558 599-651
VR 558+ 651+
Table 4.4B: TBP Cut Points for FRAPS/FRVPS( Kuwait crude)
PRODUCT SKO MODE

Gas C1-C4
Lt Naphtha C5-129
FBS 129-142.5
SR Kero 142.5-238.5
LVGO 238.5-336.5
RCO 336.5+
XSVGO 336.5-340.5
VGO 340.5-361
SPVGO 361-384
SS1 384-444.5
SS2 444.5-530
VR 530+

4.6 EXISTING UNIT CAPACITIES
Design Capacities of existing units are tabulate below in Table 4.4:
Table 4.4-Existing Unit Capacities
SNo. Capacity (MMTPA) to be Licensor

Unit Name
considered Name
Primary Processing Unit
4.26 : Bas/Ku
OPEN
1 FR APS 4.40 for AL/AM
ART
(density: 0.86)
1.086 max OPEN
2 FR VPS
(density: 0.97) ART
1.086 max OPEN
3 LR VPS
(density: 0.97) ART
3.57/3.71 ( OPEN
4 FRE APS
BH/AXL)(Existing) ART
PG:1.39,BH: 1.21 OPEN
5 FRE VPS
(Existing) ART
Residue Processing Units
6 Propane Deasphalting Unit 0.755 KBR
Lube Refinery Units
7 Industrial Oil Hydro-finer 12.2 m3/hr

65/70/76(150N, Spindle, IO
8 Propane Dewaxing Unit 100)/ 70 m3/hr (500N)/ EMRE
48m3/hr(BS)
SPO/150N/500N/DAO:
9 Solvent Extraction Unit-1 EMRE
37/37/45/30m3/hr
SPO/150N/500N/DAO:
37/37/45/30m3/hr
SPO/150N/500N/DAO:
37/37/45/30m3/hr
Raffinate
12 49 m3/hr EMRE
Hydrotreater/MSDW
Secondary Processing Units
13 Old FCC 1.0 EXXON
1.277 (Design case ) /
14 New FCC UOP
1.457(Check case)
Middle Distillate treating Units
15 DHDS 2.27 DuPont
16 DHDT 2.2 UOP
17 ATF Treating Unit 93 m3/hr UOP
18 MTO Dehazing Unit 35 m3/hr
Light End Processing Units

SNo. Capacity (MMTPA) to be Licensor

Unit Name
considered Name
19 NSU 1.222
0.545/0.046 (100% AM
20 NHT-CCR/PSA UOP
Case)
0.475 (Design) // 0.584
21 Prime G (Actual with max. feed Axens
sulfur of 680 ppm)
22 NHT-ISOM 0.250 Axens
23 FCC Naphtha Splitter 100 m3/hr
LPG Treating Unit Old cracked : 38 m3/hr
(used for virgin LPG)
24 New cracked:439 KTPA
(Presently Used)
VIRGIN LPG Treating Unit 19m3/Hr(Not Used)
25 Hexane Unit 0.3836
12.35 m3/hr of treated Vr.
26 Propane Unit
LPG
Other Units
Haldor
27 HGU 14.5 (+25% revamp) Topsoe,
Denmark
28 DHDS-SWS 408 T/D
29 DHDS-ARU 2400 T/D
30 DHDT-SWS 25 m3/hr
31 DHDT-ARU 107 m3/hr
Ortloff
(DHDT
DHDT SRU : 65 X 2 TPD; SRU) //
32 SRU
OLD SRU : 65 X 2 TPD Technimont
KT (Old
SRU)
Attached to Old FCCU:
7.2TPH of feed;
33 Fuel Gas treating unit
Attached to New FCCU:
12.05TPH of feed
Attached to Old FCCU:
80TPH ;
34 Flue Gas Scrubbing unit
Attached to New FCCU:
159TPH .
On-stream hours of 8000 shall be considered in the model and capacities in MTD
shall be adjusted accordingly.
Existing unit details like unit capacities, feed definition, Product yields and
Properties, utility data, which are used in LP modeling to develop the Base Case
are given in Attachment 4A at the end of this chapter.

ATTACHMENT 4A: EXISTING UNITS DETAILS

EXISTING UNITS
Unit wise details like unit capacities, feed definition, Product yields and Properties,
utility data, steam and power balance for the existing units is given as under:
4A.1 Crude and Vacuum Distillation Units (FR CDU/VDU)
FR APS
4.26 : Bas/Ku
CAPACITY(MMTPA) 4.40 for AL/AM 6.0 (POST Expansion)
(density: 0.86)
LICENSOR OPEN ART
FEED PG CRUDE
ON-STREAM HOURS 8000
LR VPS
Corresponding to 50% RCO
CAPACITY(MMTPA) from FR APS (PRE
140 m3/hr 1.09 MMTPA
REVAMP)
FEED PG CRUDE
FR VPS
Existing FR/LR VPS will be
dismantled and a New VPS will be
constructed with 100% RCO from FR
1.086 max
CAPACITY(MMTPA) VPS in DFR case 1..
(density: 0.97)
FR/LR VPS will remain intact in DFR
case 2 which is to be implemented in
phase 1.
LICENSOR OPEN ART
FEED PG CRUDE
Yields of FRAPS (considered in Phase 1 & 2 Expansion) & New VPS in Phase 2
expansion for Kuwait crude:
Yields,
Product Stream Disposition for FR APS/FRVPS cuts
wt%
Gas - Fuel Gas System
Virgin LPG 1.17 LEU
Lt Naphtha 10.25 NSU
FBS 2.42 Power Generation/ DHDT Feed pool/LAN Pool/Diesel Pool
ATF/Kero 14.29 ATF /DHDT
LVGO 15.02 DHDS/DHDT/Diesel Pool
XSVGO 3.38 DHDS/DHDT
VGO 0.65 DHDS/DHDT
SPVGO 3.68 DHDS/DHDT/ IFO/FCCU
SS I 9.21 FCCU/SEU
SS II 11.37 FCCU/SEU
SS III 0 FCCU
Vac 28.14 PDA
Residue
Yields of FRAPS (considered in Phase 1,2 Expansion) & New VPS in Phase 2
expansion for Arab Light crude:

Yields,
Product Stream Disposition for FR APS/FR VPS cuts
wt%
Gas 0 Fuel Gas System
Virgin LPG 1.16 LEU
Lt Naphtha 11.08 NSU
FBS 2.12 Power Generation/ DHDT Feed pool/LAN Pool/Diesel Pool
ATF/Kero 16.86 ATF/DHDT
LVGO 17.06 DHDS/DHDT/Diesel Pool
XSVGO 3.43 DHDS/DHDT
VGO 0.67 DHDS/DHDT
SPVGO 4.17 DHDS/DHDT/ IFO/FCCU
SS I 7.59 FCCU/SEU
SS II 15.06 FCCU/SEU
SS III 0 FCCU
Vac 18.36 PDA
Residue
Yields of LRVPS ( for Phase 1 expansion)

100% arab mix 100 % Kuwait Stream Disposition
Product
Yields, RCO vol % Yields, RCO vol % LR VPS cuts
RCO Feed Feed LR VPS
VGO 4 3 DHDS/DHDT
XVGO DHDS/DHDT/ /FCCU
TOBS 14 14 FCCU/SEU
SS I 16 14 FCCU/SEU
SS II 26 25 FCCU/SEU
SS III FCCU
Vac 40 44 PDA
Residue
Yields of FRVPS (considered for Phase 1) as per FR test run provided by HPCL as
follows :
Product Yield (Wt%)-AL crude Yield (Wt%)-Kuwait crude
RCO 45.43 54.1
VGO 2.18
XVGO 6.28
SS I 6.08 4.3
SS II 12.08 11.42
SS III 1.38 0
Vac Residue 17.43 38.38

UTILITIES
Utilities for FR APS/FR VPS/ LR VPS (PG Crude)
Utilities FR APS FR VPS LR VPS

0.07374 0
MM KCAL/T .07433
Fired duty ( MMkcal/ MT of (For 6 MMTPA MMKCAL/T (For
Feed) feed) 423.37 TPH)
4.166 (2293 2.68 (364.5 KWH 3.4
KWH wrt 550 wrt 135.8 t/h of
Power (KWH/MT of feed) t/h feed) feed).
0. 0.0330 (18.2 0.0805 0.095
Tons/h steam (10.94tons/h
Steam Consumption (T/MT of for feed of 550 (steam for feed of
feed) t/h) 135.8)
Cooling Water(m3/T of feed) 5.71 8.86 14.35
Steam Generation (T/MT of 0.065
feed)
FR VPS LR VPS
FR APS
(considering (considering
(considering
Utilities throughput of throughput of 50%
throughput of
50% RCO=1.09
4.4 MMTPA)
RCO=MMTPA) MMTPA)
79.48 mmkcal/h
(design) 12.56 (current
24
67-68 MMkcal/h and design)
Fired duty ( MMKcal/ hr) current
Power (KW) 2293 364.5 464
Steam cons (TPH) 18.2 10.94 13
Steam gen (TPH) - 1.50 9
Cooling Water(m3/HR) 3390 1800 1958

4A.2 Crude and Vacuum Distillation Units (FRE)
FRE APS
CAPACITY(MMTPA) 3.57/3.71 ( BH/AXL)(Existing) 4.0 (POST Expansion)
LICENSOR
FEED PG/BH CRUDE
FRE VPS
PG: 1.90, BH:1.41 (POST
CAPACITY(MMTPA) PG:1.39,BH: 1.21 (Existing)
Expansion)
LICENSOR
FEED PG/BH CRUDE
Yields, Yields, Yields, Yields,

wt% wt% wt% wt% Stream Disposition for
Product
AL Kuwait BH MTO BH SKO FRE APS/FRE VPS cuts
(Note 1) (Note 1) (Note 2) (Note 2)
Gas 0.33 0.44 0.2 0.28 Fuel Gas System
Virgin LPG 1.55 0.99 1.39 1.5 LEU
Lt Naphtha 10.76 9.42 15.8 15.8 NSU
Power Generation/
FBS 3.98 2.58 7.74 8.74 DHDT Feed pool/LAN &
HAN Pool/Diesel Pool
MTO/Kero Kero/DHDT/MTO/Diesel
14.13 15.98 13 18.1
Pool
LVGO 18.63 14.05 24.3 18.2 DHDS/DHDT/Diesel Pool
JBO Diesel
3.56 3.69 3.68 3.68 Pool/IFO/FO/DDHT/DHD
S/FCCU
RCO 47.08 52.88 33.68 33.68 FRE VPS
VGO 0.08 0.1 .08 .08 DHDS/DHDT
XVGO Diesel
6.01 6.84 4 4
Pool/IFO/DHDS/DHDT
SS I 7.76 5.38 10.5 10.5 FCCU/IFO
SS II 9.43 11.82 10.7 10.7 FCCU/SEU/ IFO
SS III 1.01 2.66 1.44 1.44 FCCU
Vac BH VR to RFO/ PG VR
22.75 26.05 6.98 6.98
Residue to PDA
Notes:
1. The yields have been considered for FREVPS in Phase I expansion. The same was
furnished by HPCL based on test run data.
2. The yields have been taken from the assays in the HPCL ITS model. The same
have been used for FRAPS in Phase I and II, and for FREVPS in Phase II
expansion.

3. UTILITIES
Utilities for FRE APS/FRE VPS (BH and PG Crude):
FRE APS FRE VPS

Fired duty ( MMKcal/ MT of
0.08538 0.10782
Feed)
Power (KWH/MT of feed) 6.065 6.649
Steam consumption (T/MT of
0.033 0.050
feed)
Steam generation (T/MT of
0 0.011
feed)
Cooling Water(m3/T of feed) 6 16
FRE APS FRE VPS

(considering (considering
throughput of throughput of
3.57MMTPA) 1.21MMTPA of RCO)
Fired duty ( MMKcal/ hr) 38.10 16.31
Power (KW) 2706.51 1005.66
Steam consumption (TPH) 14.93 7.59
Steam generation (T/MT of
0.00 1.69
feed)
Cooling Water(m3/HR) 2677.50 2420.00
*(considering calorific value of fuel oil = 9500kcal/kg)

4A.3 NHT/ISOM
NHT/ISOM
CAPACITY(MMTPA) 0.250
LICENSOR Axens
FEED TO NHT 100% BH Naphtha
100% AM Naphtha
100% Mix (AM and BH) Naphtha
Hydrogen
FEED TO ISOM Hydrotreated Light Naphtha from NHT
LPG from Reforming
NHT YIELD PATTERN
Components WT% Destination

BH Case AM Case Mix Case
Feed 100 100 100
Hydrogen 0.0384 0.0448 0.0416
TOTAL 100.0384 100.0448 100.0416
Products
H2S 0.0158 0.016 0.0159
Stripper Off Gas 0.455 0.451 0.442 To FGDS
99.568 99.578 99.584 To ISOM Unit

Hydrotreated Naphtha
TOTAL 100.0388 100.045 100.0419
YIELD PATTERN FOR ISOM
WT%
Components AM Mix Case Destination
BH Case
Case
ISOM Feed 100 100 100
Hydrogen 1.86 0.71 1.231
TOTAL 101.86 100.71 101.231
Products
Fuel Gas 0.88 1.427 0.96 To FG System
LPG 4.982 8.164 6.25 To LPG Rundown
Isomerate 96.067 91.182 94.083 MS Pool
TOTAL 101.93 100.773 101.293

PRODUCT PROPERTIES
Stream Isomerate
Properties
BH case AM Case Mix Case
Specific Gravity 0.665 0.653 0.653
RVP @ 37.8°C, kg/cm2(a) 0.72 (0.93) 0.83
Benzene vol% 0 0 0
RON 84 84 84
UTILITIES: FOR NHT/ISOM/LPG RECOVERY
(Per ton of feed basis)

Cooling water 712.35m3/hr 22.8 m3/T
Power 2390 KW 76.48 KWH/T
Total Steam (53.589) 1.715 / 14.19 MT/MT
(VHP/HP/MP/LP): 16.308/2.431/20.66
Fired duty 1.75 MMKcal/hr 0.056 MMKcal/T
REMARKS:
 Max sulphur in NHT ISOM Feed (Hydrotreated Naphtha) shall be 0.5 wppm and 0.1 ppmw
nitrogen.
 As per operating data of Client, the RON of isomerate achieved is 83.2, with yield of
Isomerate as 93.5 wt%.
 NHT feed should have max 500 ppmw Sulphur and 2 ppmw Nitrogen.

4A.4 NHT/CCR/PSA UNIT
NHT/CCR
LICENSOR UOP
FEED TO NHT 100% BH Naphtha (Design Case 1)
Blend of 90% SR Naphtha and 10% Lube HT
Naphtha (Design Case 2 )
100% Arab Mix Naphtha (Design Case 3)
Hydrogen
FEED TO CCR Hydrotreated Heavy Naphtha from NHT
NHT YIELD PATTERN
WT%
Blend of 90% SR
Components 100% BH Destination
Naphtha and 10%
Case
Lube HT Naphtha
Feed
NHT Feed 100 100
Make-up gas 0.116 0.155
TOTAL 100.116 100.155
Products
H2S 0.051 0.050
Stripper Off Gas 0.19 0.215 To FG System
Hydrotreated Naphtha 99.875 99.89 To CCR Unit
TOTAL 100.116 100.155
YIELD PATTERN FOR CCR
WT%
Blend of 90% SR
COMPONENTS DESTINATION
100% BH Case Naphtha and 10%
Lube HT Naphtha
Feed
Hydrotreated
naphtha (CCR 100 100
feed)
TOTAL 100 100
Products
4.97 6.624
Net Gas (94.6 mole% H2) (94.3 mole% H2) PSA
Unstabilised
LPG 1.732 2.275 To LPG Recovery
Reformate 93.30 91.10 MS Pool
TOTAL 100 100
FEED SPECIFICATIONS FOR NHT
(Design Case 2 ) Blend of 90%

(Design Case
(Design Case 3) SR Naphtha and 10% Lube HT
1)
Naphtha
Lube HT
100% BH 100% Arab Mix
SR Naphtha Naphtha
Naphtha Naphtha
(not used)
Paraffins vol% 44.9 73.1 58.7 50
Olefins vol% 0 0 0 0
Naphthenes
26.3 18.6 22.5 46
vol%
Aromatics
28.8 8.3 18.8 4
vol%
ASTM D86
Distillation (°C)
LV 1% 104 99 101 100
5% 105 100 102
10% 106 101 103
30% 112 106 109
50% 117 111 114 140
70% 123 117 121
90% 133 128 128 190
95% 138 134 135
98% 145 138 142 205
Specific gravity 0.772 0.728 0.751 0.78
Sulphur
500 500 500 15
(ppmw)
Nitrogen
3 3 3 1
(ppmw)
PRODUCT STREAM PROPERTIES
Reformate
Stream 100 % BH case Blend of 90% SR
Properties (this case is not Naphtha and 10%
running) Lube HT Naphtha
Specific Gravity 0.833 0.832
ASTM D86 Distillation
IBP (deg C) 85 78
10% 115 112
30% 122 123
50% 128 129
70% 135 138
90% 145 153
EP 162 190
RVP @ 37.8°C, kg/cm2(g) 0.15 0.16
Aromatics vol% 78.6 78.6
Benzene vol% 0.37 0.46

Total Sulphur wppm <1 <1

RON 103 103
MON 90.9 90.9
Chlorides, wppm <1 <1
Olefins, vol% 1.04 1.1
PSA UNIT CAPACITY
i) 100% BH case flow rate (kg/hr)
Net gas flow rate = 3311
ii) 90% AM+BH/10% LHN case flow rate (kg/hr)
iii) 100% AM case flow rate (kg/hr)
UTILITIES
NHT
Cooling water 133m3/hr 1.952m3/T
Power 519.7 KW 7.629 KWh/T
Total Steam (VHP/MP/LP): 10.5 (10.3/0.2/-) TPH 0.154 T/T
Fuel (fuel-off gas) 2.23 MMKcal/hr 0.0327 MMKcal/T
CCR (including Cyclemax)

(Per Ton of feed basis)
Cooling water 1096 m3/hr 16.097m3/T
Power 6764.6 KW 99.297KWh/T
Total Steam Generation 14.8 (10.3/8.2/3.7) TPH 0.217 T/T
(VHP Generation/MP
Generation /LP
Consumption):
Fuel (Duty Generated from 16.2 MMKcal/hr 0.238 MMKcal/T
PSA off gases)
REMARKS
 Max sulphur in NHT Product (Hydrotreated Naphtha) shall be 0.5 wppm
 Max RVP of NHT product (Hydrotreated Naphtha) shall be 1.39 kg/cm2 (g) for 100%BH
case and 1.42 kg/cm2 (g) for 90%SR Nap+10%Lube HDT Nap case
 Purity of product Hydrogen is 99.99 mol% (min) on dry basis
 Min Hydrogen recovery efficiency is 90%
4A.5 NAPHTHA SPLITTER UNIT
UTILITIES
For feed throughput of

1.222 MMTPA
Cooling water, m3/hr 262 1.72
Power, KW 958 6.27
Total Steam consumption
0 0
(MP/LP), T/hr :
Duty (MMkcal/hr) 33.2 0.217
4A.6 DIESEL HYDRODESULPHURISATION UNIT
DHDS
LICENSOR DuPont
FEED BH/HS LVGO, JBO, VGO & XVGO
FCCU LCGO
VRDS & VBU GAS OIL
YIELD PATTERN
WT% (SOR Case-

Destination
From Stream Data)
Feed
DHDS Feed 100
Hydrogen 0.80
TOTAL 100.80
Products
H2S 1.42
C1 0.11
C2 0.11
0.90 To Old FCCU/New
DHDS Wild Naphtha FCCU/Naphtha
Tanks
Hydro-De-Sulphurised Diesel 97.9 To HSD POOL
Loss 0.36
TOTAL 100.80

DHDS Wild
Stream Hydro-desulphurised
naphtha
Properties diesel (design basis)
(Design basis)
Specific Gravity 0.820-0.845
Paraffins, vol%
Olefin vol%
Aromatic vol%
Total Sulphur (Wt%) 0.001
RON
Cetane Index (CBI) - Feed + 1.8
Recovery at 360 deg C 95 % @ 340 C
Pour point (deg C) Not given
Flash point (deg C) Not given
End point (deg C) 190 -
UTILITIES
(utility summary) (Per ton of feed basis)

Cooling water 1014m3/hr 3.6 m3/T
Power 4200 KW 14.8KWh/T
Total Steam (VHP/MP/LP) 3 TPH 0.011T/T
Fuel oil = 0.00164 T/T
Fuel 3.6MMKcal/hr(abs) i.e. Fired
duty=0.0126MMKcal/T**
** (considering calorific value of fuel oil = 9500 kcal/kg, furnace efficiency 81 %)

4A.7 DIESEL HYDROTREATING UNIT
DHDT
CAPACITY (MMTPA)2.2
LICENSOR UOP
FR FBS, FR KERO, FR LVGO, FR JBO, FR VGO,
FEED BLEND
FR/LR XVGO, FRE LVGO, FRE XVGO, NEW & EXISTING FCC LCO
ON-STREAM HOURS 8000 hr
FEED BLEND SPECIFICATION
1. Sulphur = 1.33 wt%

2. Cetane Index (by D4737)= 42
3. Specific gravity = 0.859
4. Nitrogen = 294 ppmw
5. D86 ASTM 95% = 340°C
6. % of cracked feed in FEED BLEND = 27.24 wt %
7. % of FBS in feed blend = 5.21 wt%
8. % of KERO in feed blend = 0.22 wt%
9. Aromatics = 37.3 wt%
YIELDS OF DHDT
Wt%
Feed
DHDT Feed 100
Hydrogen 1.075
Total 101.075
Products
H2S 1.439
C1 0.1655
C2 0.1655
DHDT Naphtha 2.755
DHDT Kero 4.975
DHDT Diesel 91.545
YIELDS OF VGOHDT
Wt%
Feed
VGO HDT Feed 100
Hydrogen 1.35
Total 101.35
Products
H2S 2.9
C1 0.061

Wt%
C2 0.084
VGO HDT LPG 0.219
VGO HDT Naphtha 0.823
VGO HDT Diesel 7.15
Hydro treated VGO 89.91
LOSS 0.196
PRODUCT PROPERTIES
Product
Stable naphtha Kero Diesel
Properties
Flash Point, °C 38 76
Paraffins, vol% 62
Polyaromatics :
11 13
Aromatic vol% 2.4 wt%
Sulphur, wppm <10 <10 8
Viscosity @ 40 Deg
3.7
C(cst)
Smoke point, mm >25
Nitrogen, ppmw <1
Olefins, vol% <1 <5
Naphthenes, vol% 27
RVP, kg/cm2 A <0.5
RON 63
MON 65
Cetane Index (D4737) 52
Naphthalenes (vol%) <3
ASTM D86 Distillation
IBP 51 153 183
5% 84 160 222
10% 97 163 235
20% 116 165 251
30% 126 167 260
50% 131 172 275
70% 137 175 291
80% 139 183 305
90% 144 191 326
95% 148 197 339
FBP 159 208 360

UTILITIES OF DHT PROJECT (As furnished by HPCL)
DHT DHT Total

SW Utilities/ Total
Utilities (initial (final ARU SRU (Normal
S Offsites )
(Max)
case) case)
Sea Cooling
863.4 1006.2 295 55 152 241 1749 1822
water (m3/hr)
VHP Steam
4768 5424 -15889 -11121 -12327
(kg/hr)
HP Steam
(kg/hr)
MP Steam (Require
(kg/hr) d only
during
69 69 69
DHT
boiler
start up)
LP Steam 1010
2632 2632 4817 -1798 15751 27851
(kg/hr) 0
Fuel Oil
(kg/hr) 4959 4959 9554 14513
(100%)
Fuel gas
(RLNG) 516
(kg/hr) 4222 4222 +100 7731 12569
(100%)
Power (MW) 15.334* XXX 0.2 0.06 0.58 XXX XXX XXX
*(As per in house data with EIL)
DHDT UTILITIES
For throughput of 2.2

MMTPA
Cooling water 863.4m3 3.14 m3/T
Power 16630** 30.18 KWh/T **
Total Steam 7.469TPH (
(VHP/MP/LP): 0.02716T/T
4.768/0.069/2.632)
Fired duty 27 MMKcal/hr 0.098 MMKcal/T
** As per client vide e-mail dated 19.03.2013.

4A.8 Existing Fluid Catalytic Cracking Unit
OFCCU
CAPACITY(MMTPA) 1.0 (Existing) 1.0 (Post Expansion)
LICENSOR EXXON
FEED FR/FRE- SS I, SS II
FR/FRE- JBO
Wax from PDU
Extract from SEU’s
YIELD PATTERN
FOR FR/LR SS, FOR FRE ss,

FOR
FR XVGO, FR FRE JBO,
Components Hydrotreated Destination
JBO EXTRACT WAX FEED,
VGO
FEED, WT% WT%
Feed 100 100 100
TOTAL 100 100 100
Products
C1 ATG
3.4 2.1 3.03
C2
TOTAL LPG 18.2 19.0 21.68 LPG POOL
TOTAL CYCLE Prime G Unit/ MS
32.5 36.0 31.74
NAPHTHA POOL
FCC LCGO 26.1 26.5 29.71 DHDS
FCC RESID
16.3 13.1 10.34
(CLO+HCGO) IFO POOL
COKE 3.5 3.1 3.5
TOTAL 100 99.8 100
Stream Total Cycle

LCGO CLO
Properties Naphtha
RVP @ 37.8°C, psi 8.9 - -

Pour Point, °C - 6 45
Flash Point, °C - 55 100
Paraffins, vol% 30.5
Olefin vol% 45
Aromatic vol% 17
Benzene, vol% 1
0.04*FCCU feed 1*FCCU feed
Total Sulphur (% wt.) 2*FCCU feed sulphur
sulphur sulphur

RON 91 -
MON 80 - -
CCR (% wt.) - - 6
Cetane Index (CBI) - 32.19 -
Viscosity @ 100 Deg 9.429
C(cst)
Viscosity @ 50 Deg 5 68
C(cst)
Recovery at 70deg C 50
(vol%)
Recovery at 75deg C 55
(vol%)
Recovery at 100deg 75
C (vol%)
C (vol%)
C (vol%)
C (vol%)
C (vol%)
UTILITIES
Considering FCC feed per Ton of feed basis

= 1 MMTPA
Cooling water 2630 M3/HR 21.04 m3/T
Power 7774 KW 62.16 KWh/T
Total Steam 2.08 TPH 0.016 T/T
(VHP/MP/LP):
Fired duty 9.68 MMKcal/hr 0.082* MMKcal/T
*(considering fuel oil calorific value = 9500 Kcal/kg)
REMARKS
 CCR in FCCU is kept in range- 0.2 to 0.5 wt%

 For PG VGO case the max feed rate possible is 100 m3/hr at feed CCR of 0.8 wt % as per
test run conducted and yield also given on that basis.
 Design Feed metal factor is 2.2, whereas in actual operation it is <1
 DHDS Wild Naphtha is also to be processed in FCCU Main fractionators
 Minimum capacity to be considered in LP modeling is 90 m3/hr.
 Maximum operating capacity of Old FCC considered is 0.95 MMTPA

4A.9 New Fluid Catalytic Cracking Unit
NFCCU
CAPACITY(MMTPA) 1.277 (Design case ) / 1.457(Check case)
LICENSOR UOP
FR/LR XVGO; FR/LR- SS I, SS III; FRE SS I,FRE JBO, FRE
FEED (Design Case) VTB; SP EXTRACT, S1 EXTRACT, S2 EXTRACT; BS
EXTRACT; DAO FROM PDA UNIT
FEED (Check Case) FR/LR SS I; BS EXTRACT; SDA DAO & SDA Resin
ON-STREAM
HOURS 8000
FEED SPECIFICATIONS
Design case Check case

Feed rate, MT/hr 159.625 182.125
Feed rate, BPSD 25917 30157
API gravity 20.56 23.58
Sulfur content, wt% 2.20 1.38
Nitrogen content, ppmw
Basic 123 5
Total 865 815
Ni/V content, ppmw 0.9/3.2 1.2/2.9
CCR, wt% 4.2 3.4
Volume average boiling
point, °C 469 501
YIELD PATTERN
Design case Check case feed,

Components Destination
feed, WT% WT%
Feed 100 100
TOTAL 100 100
Products
FUEL GAS 3.71 3.09
TOTAL LPG 13.58 16.96 LPG POOL
GASOLINE (C5-
180) 37.60 40.62 Prime G
LCO (180-360) 23.49 20.58 DHDS
HCO (360-425) 5.64 4.84 IFO POOL
CSO (425+) 8.84 7.52 IFO POOL
COKE 7.14 6.40
TOTAL 100 100

Stream Gasoline (C5-180) LCO(180-360) HCO(360-425) CSO (425+)

Properties
Design Check Design Check Design Check Design Check
Case Case Case Case Case Case Case Case
Specific 0.733 0.720 0.925 0.917 1.038 1.007 1.091 1.048
Gravity
D86 ASTM Distillation, Deg C
IBP 46.0 46.0 177.0 177.0 357.0 357.0 260.0 260.0
5% 51.0 51.0 185.0 185.0 361.0 361.0 431.0 431.0
10% 55.0 55.0 192.0 192.0 364.0 364.0 438.0 438.0
30% 76.0 76.0 219.0 219.0 379.0 379.0 466.0 466.0
50% 96.0 96.0 261.0 261.0 392.0 392.0 492.0 492.0
70% 125.0 125.0 292.0 292.0 406.0 406.0 518.0 518.0
90% 160.0 160.0 333.0 333.0 418.0 418.0 552.0 552.0
95% 171.0 171.0 348.0 348.0 422.0 422.0 556.0 556.0
FBP 183.0 183.0 363.0 363.0 427.0 427.0 560.0 560.0

RVP @
37.8°C, kPa
Paraffins, vol% 28.0 35.8
Olefin vol% 40.6 38.2

Naphthenes, 10.7 9.1
vol%
Aromatics, 20.7 16.9 75.0 65.0
vol%
Total Sulphur 0.227 0.116 2.35 1.45 2.93 1.79 3.85 4.03
(wt%)
Benzene, vol% 0.89 0.73
RON 92.3 90.8
MON 80.4 79.9

Cetane Index 26.5 28.1
(D976 )
Viscosity @ 50.0 45.0
100 Deg C(cst)
Nitrogen, 50 40
ppmw

UTILITIES
Considering FCC feed

of 1.456 MMTPA
Cooling water,
3988 24.98
m3/hr
Power, KW/hr 19571 122.61
Total Steam
Generation
72 0.451
(HP/MP/LP),
TPH:
Total steam
Consumption 22 0.137
TPH
Fired duty, 0 (Fired heater not
MMKcal/hr required for design 0.0465
case)
REMARKS
 Unstabilised Naphtha from Group II LOBS facility shall be processed in New FCCU
fractionator.
 Minimum capacity to be considered in LP modeling is 140 m3/hr.
 DHDS Naphtha, RHDS/MSDW Naphtha when processed in NFCC, produces Fuel Gas,
LPG & FCC Naphtha. The yields of Fuel Gas, LPG & FCC Naphtha is same as offgas,
LPG & stabilized Naphtha produced after unstabilized Naphtha is fed in debutanizer as per
NFCC BDEP.

4A.10 FCCU Naphtha Splitter
FSU
CAPACITY 100 m3/hr (with feed sulfur upto 700 ppm)
LICENSOR
FEED FCCU TOTAL CYCLE NAPHTHA/ GASOLINE
HYDROGEN
YIELD PATTERN
Streams Wt% Destination

Feed
FCC gasoline 99.77
H2 make-up 0.23
TOTAL 100
Products
Off Gas 1.12 NFCCU- WGC
Light gasoline 44.56 MS Pool/
Heavy gasoline 54.32 MS Pool
TOTAL 100.12

4A.11 Prime G Unit
ISL
CAPACITY(MMTPA) 0.584 with feed sulfur upto 700 ppm
LICENSOR Axens
FEED FCCU TOTAL CYCLE NAPHTHA/ GASOLINE
HYDROGEN
FEED SPECIFICATIONS
FCC Gasoline
BH Case (this
AM Case Mix Case
Characteristics case is not run)
Max available rate, kg/hr 59375 59375 73000
Max available rate,st m3/hr 79 82.3 100
Density at 15°C, g/cc 0.7518 0.7218 0.730
Distillation (ASTM – D86)
IBP 43 43 35
10% 52 52 49
30% 68 68 70
50% 91 91 91
70% 122 122 118
90% 157 157 163
95% 175
FBP 181 181 205
Paraffins, vol% 27 26 26
Olefin vol% 39 41 55
(Diolefins wt%) (4.0) (2.0) (2.0)
Naphthenes, vol% 10 10 8
Aromatics vol% 24 23 11
(Benzene vol%) (1.5) (1.5) (1.2)
700 / 62(basis last
2800 / 840 280 / 90
Total Sulphur, wppm/RSH 6 months average)
RON 92 92 91
MON 80 80 80
YIELD PATTERN
AM Case, BH Case
Streams Mix Case ,Wt% Destination
Wt% ,Wt%
FEED
FCC (Last 6 months
100 100 99.73
gasoline average)
H2 make- (Last 6 months
0.53 0.22 0.0.23
up average)
TOTAL 100.53 100.22 100.23

PRODUCTS
(Last 6 months
0.31 0.04
H2S 1.12 average)
Off Gas 1.6 0.98
MS Pool (Last
Light 27.94 34.0 44.56 6 months
gasoline average)
Heavy MS Pool(Last 6
hydrotreate 70.68 65.23 54.32 months
d gasoline average)
TOTAL 100.53 100.21 100.0
Stream
Light Gasoline Heavy Gasoline Benzene Heart-cut*
Properties
AM Mix
AM BH Mix AM BH Mix BH
Cas Cas
Case Case Case Case Case Case Case
e e
Density at 706. 692.
653.7 649.7 656.2 798.9 765.8 774.9 681.0
15°C, g/cc 1 2
MW, kg/kmol 71.6 73.4 73.7 104.6 110.7 110.4 91.9 85.2 85.9
Distillation (ASTM D-86)
IBP 18.1 19.7 20.3 85.2 91.1 90.9 46.3 48.7 49.7
5% 32.5 34.1 34.6 89.2 96.3 97.0 50.9 53.2 54.5
10% 33.7 35.6 36.5 91.9 99.1 96.4 53.5 56.9 57.9
30% 36.0 37.8 38.7 104.9 111.4 109.0 66.2 71.0 73.4
50% 38.2 41.8 42.3 121.9 126.9 123.1 70.8 76.2 78.3
70% 40.8 47.6 50.5 140.7 144.1 143.1 74.8 80.2 82.2
90% 52.7 58.3 60.3 163.5 165.1 173.6 80.7 85.5 88.0
95% 55.8 61.9 63.8 171.1 172.1 187.9 84.3 89.0 91.0
FBP 60.7 66.2 68.7 176.8 177.6 201.0 91.9 95.6 97.8
RVP, psia 18.8 16.9 16.4 2.1 1.6 1.6 - - -
Paraffins, v% 48.78 48.26 38.39 31.9 18.30 36.20 35.8 28.4 24.0
Olefin v% 49.91 49.09 59.45 17.7 28.90 33.80 48.6 52.0 61.4
Naphthenes,
8.5 11.2 6.5
v% 0.85 1.41 0.94 14.87 15.92 12.98
Aromatics
7.1 8.4 8.1
v% 0.44 1.24 1.22 35.58 36.92 17.01
(Benzene (2.03
(7.0) (8.2) (7.9)
v%) (0.44) (1.24) (1.22) ) (1.67) (1.20)
Total Sulphur
940 92 300
(wppm) 100 30 100 100 140 100
RON 94.9 94.6 95.8 84.5 89.0 83.5 - - -
MON 82.8 82.4 81.8 76.6 78.0 76.5 - - -

UTILITIES

Cooling water 382.5 m3/hr 59.375 m3/T
Power 1071.6 KW 18.048 KWh/T
Total Steam (VHP/MP/LP): 13.32TPH(16.69/2.503/- 0.2245 T/T
0.863 TPH)
Fuel 2.1 MMKcal/hr 0.0354 MMKcal/T
REMARKS
A Benzene heart-cut shall be withdrawn at the splitter in order to meet the 1% vol benzene
content in pool in case of any benzene upset in the feed (up to 2.2 vol%). This heart-cut is not
used in normal operation.

4A.12 PROPANE DEASPHALTING UNIT
PDA
LICENSOR KBR
FEED FR/LR VR
YIELD PATTERN (WITH ONLY PROPANE AS SOLVENT)
Light bright stock DAO FCCU feed DAO

Components WT% Destination WT% Destination
DAO 22 SEU 25 FCCU
Pitch 78 Asphalt sales 75 Asphalt sales
Total 100 100.0
As per MOM dated March 13, 2013; Propane consumption in PDA = 2 TPD
YIELD AND PROPERTIES WITH PROPANE AND BUTANE AS SOLVENT (FOR

BOTH FEED CASES)
SNo. Product yield and qualities Feed Asphaltene DAO

Case Lube Bright Stock DAO
1. Yield Wt% 100 82 (78) 18 (22)
lv% 100 80 20
2. Specific
gravity 1.028 1.054 0.926
@15°C
3. API gravity °API 6.1 2.8 21.3
4. Nitrogen Wt% 0.33 0.4 0.06
5. Sulphur Wt% 5 5.5 (5.7) 2.4 (2.4)
6. CCR Wt% 22.8 27.5 (28.5) 1.5 (2.6)
6. Nickel ppmw 28 34 (35.9) <<1 (0.13)
7. Vanadium ppmw 104 125 (133.3) <<1 (0)
8. Viscosity
@100°C Cst 1.621 33
@135°C Cst 230 1190
@150°C cst 522
Asphaltene
9. ppmw <100
content

SNo. Product yield and qualities Feed Asphaltene DAO

Case FCCU feed DAO
1. Yield Wt% 100 68 (75) 32 (25)
lv% 100 64.8 35.2
2. Specific 1.028 1.078 0.936
gravity
@15°C
3. API gravity °API 6.1 -0.3 19.7
4. Nitrogen Wt% 0.33 0.5 0.08
5. Sulphur Wt% 5 5.9 (5.8) 2.9 (2.6)
6. CCR Wt% 22.8 32.4 (28.9) 2.5 (4.6)
6. Nickel ppmw 28 41 (37.3) <1 (0.2)
7. Vanadium ppmw 104 155 (138.7) <1 (0)
8. Viscosity
@100°C Cst 1.621 45
@135°C Cst 230 4720 16
@150°C cst 1770
Asphaltene <200
9. ppmw
content
Note: - Values in ( ) are as per predicted based on revised yield considering only
Propane as solvent.
UTILITIES

Power, KW 1443 15.59
Total Steam
35.7 0.386
(HP/MP/LP),TPH:
Fired duty, MMKcal/hr 10.7 0.116

4A.13 SOLVENT EXTRACTION UNIT # 1
SEU1
CAPACITY, m3/hr 37/37/45/30
FEED SPO/150N/500N/DAO
As per MOM dated March 13, 2013; HPCL confirmed that 180 kg/hr of LPG to be
used as stripping gas in each SEU.
YIELD PATTERN AS PER EXISTING DATA (FROM HPCL)
a) SS II Feed (45 M3/HR)
Components WT% DESTINATION

500 n raffinate 58 PDU/LOUP
/FCCU/NFCCU/RPO
500 n extract production/Flux in
42 asphalt.
Total 100.0
Stream Spindle
150 N Extract 500 N Extract DAO Extract
Properties Extract
Specific 1.0057
NA 1.044 (Typical) 1.011 (Typical)
Gravity (Typical)
Pour Point,
NA 27(Typical) 27 (Typical) 32 (Typical)
°C
Flash Point,
NA 208 246 292
°C
Aniline Point,
NA NA 45-50 65.70
Deg F
Sulphur, wt% NA 5.8-5.9 4.5-4.7 5.2-5.36
CCR (% wt.) NA 0.4-0.50 5.8-7.0 8.5-8.6
Viscosity @
21.95 71.40
100 Deg NA 9.77 (Typical)
(Typical) (Typical)
C(cst)
Viscosity @
50 Deg
NA NA NA NA
C(cst)
NA: Not Available

UTILITIES
Per Ton of feed basis

36
37m3/ 37m3/ 45m3/ 30m3/h
m3/hr
hr of hr of hr of r of SPVGO SS I SS II SS III DAO
of SS
SPVG SS 1 SS II
II
DAO feed feed feed feed feed
O feed** feed** feed**
feed**
feed**
Cooling
1163. 1188. 1429. 1225. 35.2 33.8 36.2 36.2
water, 1006 35.27
4 5 3 1 6 2 4 5
m3/hr
Power, 867.1 18.6 22.6 24.2 31.2
627.7 628 957.7 820.8 19.03
KW 8 3 6 8 5
Total
steam
generati
0.11 0.10 0.11 0.14
on 31.1 31.1 31.1 31.1 31.1 0.121
8 6 8 4
(VHP/M
P/LP),
TPH:
Fired
duty , 0.36 0.38 0.39 0.47
15.11 13.44
MMKcal 11.68 12.15 13.3 0.354* 0* 3 7 9
/hr**
** Heater efficiency to be considered as 90 % instead of 77% )

*(considering calorific value of fuel oil = 9500 kcal/kg)
Specific gravity of SS1 considered = 0.9108
Specific gravity of SPVGO considered = 0.8915
Specific gravity of SSII considered = 0.9389
Specific gravity of DAO considered =0.925

SEU-II
FEED SPO/150N/500N/DAO
YIELD PATTERN
a) SP VGO Feed (37 M3/HR)
COMPONENTS WT% DESTINATION
SPINDLE Raffinate 72 PDU/LOUP
SPINDLE Extract 28 /NFCCU
Total 100.0
b) SS I Feed (37 M3/HR)

150 N Raffinate 74 PDU/LOUP
150 N Extract 26 /NFCCU
Total 100.0
Product Stream Properties: Same as that for SEU # 1

Utilities: Same as that for SEU # 1
SEU3
SPO/150N/500N/DAO
FEED -SPO/150N/500N/DAO
-
-
YIELD PATTERN
a) SS II Feed (45 M3/HR)

/NFCCU/Flux in
500 N Extract
42 asphalt/RPO production.
Total 100.0

b) SS I Feed (37 M3/HR)

Components Wt% Destination
150 N Extract 26 /NFCCU
Total 100.0
c) DAO Feed (30 M3/HR)

BS Raffinate 72 PDU/LOUP
/NFCCU/FCCU/For
BS Extract
28 TRAE production
Total 100.0
Product Stream Properties: Same as that for SEU # 1
Utilities: Same as that for SEU # 1
4A.16 Industrial Oil Hydrofiner
IOH
CAPACITY(m3/hr), Max 12.2 m3/hr
FEED Distillate from LR VPS
HYDROGEN
YIELD PATTERN
Feed Wt%
SPVGO Feed 100
Hydrogen 0.72
Total 100.01
Products Wt% Destination
IO-100 97.2 To PDU
Loss 3.52
Total 100.72

4A.17 PROPANE DEWAXING UNIT (FOR GROUP-1 LOBS)
PDU
CAPACITY
SPO/150N/500N/IO-100/DAO: 70/65/70/76/48m3/hr.
FEED RAFFINATE STREAMS FROM SEU’S
HYDRO-FINED SS I STREAM FROM IOH
PROPANE FROM PROPANE UNIT
YIELD PATTERN AS PER EXISTING DATA (FROM HPCL)

a) For 150 N Raffinate Feed (65 M3/HR)
Feed
150 N Raffinate 100
Propane 220 LV % of feed
TOTAL 100. 6
Products
150 N LOBS 75 Sales
150 N Wax 25 /FCCU/LOUP
Loss
TOTAL
b) For 500 N Raffinate Feed (70M3/HR)

Feed
500 N Raffinate 100
Propane 230-240 LV % of feed
TOTAL
Products
500 N LOBS 76 sales
500 N Wax 24 FCCU/LOUP
Loss
Total
c) For Spindle oil Raffinate Feed (70M3/HR)

Feed
Spindle Oil Raffinate 100
Propane 210-220 LV% of feed
TOTAL
Products
Spindle oil 75
Wax 25 FCCU/LOUP
Loss
TOTAL

d) For Hydrofined IO-100 Feed (76M3/HR)

Feed
Hydrofined IO-100 100
TOTAL
Products
IO-100 78 sales
Wax 22 FCCU/LOUP
Loss
TOTAL
e) For BS Raffinate Feed (48M3/HR)

Feed
BS Raffinate 100
TOTAL
Products
BS 76 sales
Wax 24 /FCCU/LOUP
Loss
TOTAL
As per MOM dated March 13, 2013; Propane consumption in PDU is 3.8 TPD
Spindle Oil/150 150 N Wax/

Stream Lube Base/500 Spindle 500 N IO-100/IO-
Properties Lube Base/DAO Wax/DAO Wax Wax/1300 N 1600
Lube Base oil Wax
Specific 0.8547/0.878/ 0.82/0.856 0.842/0.861/N 0.84/NA
Gravity 0.895/0.906 (Typical) A (Typical) (Typical)
50/59/NA 60/NA
Pour Point, °C -6/-1/-1/-6 44/60 (Typical)
(Typical) (Typical)
Flash Point,
165/202/238/298 154/NA (Typical) NA NA
°C
Paraffins,
NA NA NA NA
vol%
Aromatic vol% NA NA NA NA
Aniline Point,
NA NA NA NA
Deg F
0.29/0.53 0.40/0.61/NA
Sulphur, wt% 0.72/0.95/1.30/NA NA
(Typical) (Typical)
0.025/0.0085/
0.0016/0.0023/0.05 0.002/0.01
CCR (% wt.) NA NA
/NA (Typical)
(Typical)

Viscosity @
2.8/4.5/10.5/ 2.76/14.55 3.365/7.38/NA
100 Deg NA
30.5-32.5 (Typical) (Typical)
C(cst)
Viscosity @ 50
NA NA NA NA
Deg C(cst)
NA: Not Available
UTILITIES
500 N
For For 70 For Spindle
For 65 For 48 Raffinat
70m3/h m3/hr 76m3/h Raffina Bright
m3/hr m3/hr e,
r of of r of IO te, 150- Stock
of 150N of BS Hydro-
500N spindle 100 T/N raffinat
raffinat raffinat fined
raffinat raffinat raffinat Raffina e
e* e* SS I &
e* e* e* te
SS III
Cooling
1420.8
water, 1841.8 1710.3 1841.8 30.54
35.42 37
m3/hr
Power,
6277.6 6115.2 6277.6 6553.4 109.20 170.66
KW 120
Total
Steam
(VHP/M 31.65 31.65
31.65 31.65 0.608 0.565 0.824
P/LP),
TPH:
*(considering specific gravity of feed as 0.8)

4A.18 LOUP (Raffinate Hydrotreater/MSDW Unit)
RHDT
CAPACITY(m3/hr) 49
LICENSOR EMRE
FEED 500 N Raffinate
150 N Raffinate
Spindle Raffinate
MSDW
CAPACITY(m3/hr) 49
LICENSOR EMRE
FEED Hydrotreated 500 N Raffinate
Hydrotreated 150 N Raffinate
Hydrotreated Spindle Raffinate
Hydrogen
YIELD PATTERN (RHDT/MSDW UNIT)
Kuwait Group I HDT/MSDW Unit Overall Product Yields (EOR)
Overall Unit yields , Spindle 150N 500N Feed Destination

wt% Feed Feed
Feed 100 100 100
H2 1.14 0.8 0.81
TOTAL 101.14 100.80 100.81
Products
H2S 1.7 1.40 1.46
NH3 0.01 0.01 0.02
C1 0.12 0.04 - FG Network
C2 0.17 0.06 - Sour Gas is routed
C3 0.61 0.3 - to FGTU via FGRC
C4 1.11 0.64 - d/c.
Offgas and light - - 2.52 H2 purge gas is
hydrocarbons sent to SEU
hydrofiners
Unstabilized Naphtha 6.7 2.11 0.3 TO new FCCU
(C5-150°C) fractionator
Premium Diesel 37.36 16.19 6.01 Diesel Pool
Light Lube 0 23.20 45.14 Sales**
Heavy Lube 53.36 56.85 45.36 Sales
TOTAL 101.14 100.80 100.81

Arab Light Group II HDT/MSDW Unit Overall Product Yields (SOR)
Overall Unit yields , Spindle 150N 500N Feed Destination

wt% Feed Feed
Feed 100 100 100
H2 1.31 1.07 1.19
TOTAL 101.31 101.07 101.19
Products
H2S 139 1.49 1.70
NH3 0.02 0.01 0.01
Offgas and light 3.22 2.75 3.15 FG network
hydrocarbons Sour Gas is routed
to FGTU via FGRC
d/c.
H2 purge gas is
sent to SEU
hydrofiners
Unstabilized Naphtha 3.37 0.87 0.65 TO new FCCU
fractionator
Premium Diesel 39.27 17.08 13.72 Diesel Pool
Light Lube 0 8.75 14.91 Sales**
Heavy Lube 54.04 70.12 67.05 Sales
TOTAL 101.31 101.07 101.19
** During 500 N raffinate processing in LOUP , 500 N DWO and 150 N Heavy
distillate or Light Lube is produced. Quality of 150 N Heavy distillate or Light Lube
is equivalent to 150 N DWO and is routed to product tank.
During 150 N raffinate processing in LOUP , 150 N DWO and Spindle Heavy
distillate or Light Lube is produced.. Quality of Spindle Heavy distillate or Light
Lube is varied as per market demand. Quality of Spindle Heavy distillate is
equivalent to SPO DWO 90 N.
During Spindle raffinate processing in LOUP , Spindle DWO is produced and no

Heavy distillate or Light Lube is produced.
PRODUCT PROPERTIES
Unstabilized Naphtha
Arab Light Group II Kuwait
Spindle 150 N 500 N 500 N
Distillation
ASTM D-86
IBP -93 -92 -97 -89
5 -6 -4 5 3
10 15 15 14 18
30 66 58 35 50
50 93 70 66 48

70 142 75 65 53
90 215 86 76 75
95 247 108 84 90
EBP 290 137 112 115
Premium diesel
Arab Light Group II Kuwait
Spindle 150 N 500 N 500 N
Distillation
ASTM D-86
IBP 118 134 135 146
5 181 198 187 182
10 207 222 203 205
30 261 270 253 248
50 286 301 291 269
70 300 318 312 291
90 317 337 330 311
95 323 346 344 323
EBP 336 356 358 336
UTILITIES

Spindle 150 N 500 N
(sp gr = (sp gr = (sp gr =
0.861) 0.87) 0.886)
Cooling water, m3/hr 1343 31.83 31.5 31.935
Power, KW 4209.7 99.78 98.75 96.97
Total Steam 6.536
consumption(VHP/M (4.894/0.2/1.44 0.155 0.153 0.151
P/LP), TPH: )
Fuel, MMKcal/hr 10.04 0.24 0.238 0.234
The above mentioned yield data is as per Process package. However present operating
yield and specification is also being provided below
Cumulative Yield wt% 2012-2013
500 N 150N SPO

Target Actual Target Actual Target Actual
DWO. 64 57 63 55 66 73
Heavy 21 27 23 27 0 0
Distillate
Light 11 12 10 13 29 22
Distillate
Naphtha 1 1 1 1 1.5 1.5
H2S + 3 3 3 3 3.5 3.5
light HC
Total 100 100 100 100 100 100
 Feed/DWO properties: 500 N

Properties Target Actual

Feed
Viscosity, SSU 100 deg. C 60-62 58-60
DWO 500 N
Viscosity, cst@100 deg. C. 10.5-12 10.5-11.0
Pour Point -15 -15 to -24
Flash, deg. C. 240 (min.) 254-258
VI 105 min. 105-107
Color <0.5 <0.5
Light Distillate (Diesel)
Flash >40 15-35
Recovery 95% 360 max 340-345
 Feed/ DWO properties: 150 N

Feed
DWO 150 N
Viscosity, cst@40 deg. C. 28-32 30-33
Flash, deg. C. 210 (min.) 210-220
VI 105 min. 105-107
Color <0.5 <0.5
Flash >40 -
Recovery 95% 360 max 340-345
 Feed/DWO properties: SPO N

Feed
DWO SPO N
Viscosity, cst@40 deg. C. 9-11 9-11
Flash, deg. C. 162 (min.) 170-180
VI 100 min. 98-102
Color <0.5 <0.5
Flash >40 -
Recovery 95% 360 max -
As per MOM dated March 13, 2013; HPCL confirmed that design yields are to be
considered for RHDT/MSDW unit.

4A.19 HEXANE UNIT
HEX
CAPACITY(MMTPA), Max 0.386
LICENSOR
FEED SR Naphtha from PG Crude
YIELD PATTERN
WT% DESTINATION
Feed
SR Naphtha 100
TOTAL 100
Products
Hexane 18.0 Hexane Sale
LAN Raffinate 80.0 To LAN Pool
Aromatic rich Raffinate 2.0 To HAN Pool
TOTAL 100.0
PRODUCT PROPERTIES
Hexane LAN raffinate Aromatic rich raffinate

Specific gravity 0.695 0.695 0.695
Sulphur (wt%) 0.00008 0.00008
Paraffins (vol%) 81 45
Aromatics(vol%) 0.50 max 20
IBP deg C 63 min
FBP deg C 70 max
UTILITIES

0.386 MMTPA
Cooling water, m3/hr 1280
Power, KW 498.4
Total Steam Consumption
19.0
(VHP/MP/LP), TPH:

4A.20 PROPANE UNIT
PRO
CAPACITY(m3/hr) 12.35 of treated Virgin LPG feed
LICENSOR
FEED Virgin LPG, URAN LPG
YIELD PATTERN
Virgin LPG
COMPONENTS DESTINATION
Feed, WT%
Feed
LPG feed 100
TOTAL 100
Products
Propane 13.3 Propane
LPG 86.7 LPG Pool
TOTAL 100
Note : Uran LPG is obsolete. Propane unit operates only on Vr. LPG
UTILITIES

12.35m3/hr (6.25 TPH)
Cooling water, m3/hr 168.675 24
Total Steam Consumption
2.125 0.34
(VHP/MP/LP), TPH:
Electricl power KW 86

4A.21 HYDROGEN GENERATION UNIT
HY1
CAPACITY(KTPA) 14.5 (+25% revamp)
LICENSOR Haldor Topsoe, Denmark
FEED SR Naphtha from PG/LS Crude, Natural gas
YIELD PATTERN
WT% (Feed HAN from

stream data)) DESTINATION
Feed (Naphtha) 100
TOTAL 100
Products
Hydrogen 26.62
H2S 0.03
Off-gas 0.61
Loss 72.74
TOTAL 100.0
UTILITIES
For HGU capacity of

18.125 KTPA
Power, KW 1030 121.2
Total Steam
Generation 34.4 4.0
(VHP/MP/LP), TPH:
FEED TO PDS
Quality considered in the original Streams to be considered

design of HGU for revamp
Light
LAN HAN
Naphtha Light naphtha available
(Design) (Design)
(Design)
MIX case
Arab Mix
Case (Arab+
case
Bombay High)
Sp.gravity @
0.71 0.74 0.63 0.665 0.687
60 F
C/H ratio,
5.6 5.9 5
w/w
PONA vol%
Paraffins 72 57.6 100 89.4 76.2
Olefins 0 0 0 0 0
Naphthenes 20 26 0 8.9 16.2

Aromatics 8 16.4 0 1.7 7.6
LHV in
10530 10412 10711
Kcal/kg
ASTM
distillation,
deg C
IBP 36 42 28 38 40
5% 54 73 - 45 46
10% 60 78 29 47 50
50% 85 95 34 63 70
90% 114 113 48 78 82
95% 134 135 53 82 84
FBP 166 166 60 84 87
H2O ppmw 200 200 5 0 0
Total sulfur
1000 200 10 500 500
ppmw
Mercaptan
50 9 nil 90 90
ppmw
H2S, ppmw nil
Chloride
2-5 2-5 2-5 2 max 2 max
ppmw
Total
Nitrogen 110 90 0.5 2 max 2 max
ppmw
Oxygen,
0.5 - 0.1 max 0.1 max
ppmw
Metals ppb
3 ppbw
Pb 20 20 20 3 ppbw max.
max.
10 ppbw
As 30 30 25 10 ppbw max.
max.
V 15 15 nil
Na 600 600 nil
20 ppmw
Cu 35 35 nil 20 ppmw max.
max.
K 6000 6000 nil
20 ppmw
Ni 20 ppmw max.
max.

4A.22 SULPHUR RECOVERY UNIT- DHDS
SRU
CAPACITY(TPD), MAX 65*2
FEED H2S REMOVED FROM AMINES
MOLE % RECOVERY 98.75
UTILITIES
For SRU capacity of 65*2 TPD (Per Ton of feed basis)

Cooling water, m3/hr 5 ( SRU); 90 (SWS); 200(ATU) 57.39
Power, KW 1557 302.9
Total Steam 17.28 3.36
Generation
(VHP/MP/LP), TPH:
Fired duty, MMKcal/hr 3.5 0.0679
(*considering calorific value of fuel oil= 9500 kcal/kg)
As per MOM dated March 13, 2013; HPCL confirmed that recovery shall be increased
to 99.9 mole% as new TGTU is being implemented.
4A.23 SULPHUR RECOVERY UNIT- DHDT
SRU
CAPACITY(TPD), Max 65*2
Amine acid gas (from ARU) and
FEED sour water stripper gas (from SWS unit)
On-stream Hours 8000
Wt % recovery 99.8
UTILITIES
For SRU capacity of 65*2 TPD (Per Ton of feed basis)

Power, KW 584.3 91.04
Total Steam
Generation (VHP
17.68 (15.9/-/1.79) 2.755
generation/MP/LP
generation) TPH:
Fired duty , MMKcal/hr 5 0.78

ATTACHMENT 4B: OFFSITE FACILITIES

1. EXISTING STORAGE TANKS
Details of existing storage tanks is given as under
Capacity Net
S.No Tank No Service COMMENTS
KL Capacity KL
1 105 CRUDE 17800 15904 (Tank Dismantled)
2 106 CRUDE 19439 (Tank Dismantled)
3 109 CRUDE 32600 (Tank Dismantled)
4 110 CRUDE 89323 74458
5 111 CRUDE 89152 72468
6 112 CRUDE 89602 77230
7 113 CRUDE 89134 76575
8 114 CRUDE SLOP 869 920
9 115 CRUDE 89385 78879
10 116 CRUDE SLOP 912 920
11 117 CRUDE 89327 77012
12 118 CRUDE 15223 12778
13 119 CRUDE 15265 13290
14 608 CRUDE SLOP 820 (Tank Dismantled)
15 609 CRUDE SLOP 1700 795 (Tank Dismantled)
16 MPPL-2 HSD/KERO 15
17 103 MS 26522 22947
18 305 KERO 1708 1560 (Tank Dismantled)
19 306 HSD 9299 8754
20 308 HSD 5136 4983
21 351 KERO 5250 (Tank Dismantled)
22 352 KERO 4930 (Tank Dismantled)
23 371 KERO 11800 9969 In Service
24 372 KERO 11800 10005 In Service
25 373 KERO 11800 9964 In Service
NO SUCH TANK
26 201 HSD 6590
EXISTING
27 264 HSD 5312 4994
28 301 HSD 6555 6058
29 307 HSD 8987 8621
30 309 HSD 5299 5023
DHDS/DHT FEED
31 354 6977 6753
(SOUR HSD)
DHDS/DHT FEED
32 360 7227 6681
(SOUR HSD)
DHDS/DHT FEED
33 362 7079 6723
(SOUR HSD)
34 760 HSD 7147 6702
35 313 HSD 4970 5915
36 314 HSD 4970 5965
37 315 HSD 4970 7300
38 353 ATF 6194 (Tank Dismantled)
39 361 KERO 6386 5939
40 363 ATF 9178 7730 In Service
41 364 ATF 9165 7672 In Service
42 365 ATF 9136 7762 In Service

Capacity Net
KL Capacity KL
43 366 ATF 9163 7692 In Service
44 367 ATF 5851 4903 In Service
45 368 ATF 5850 4876 In Service
46 369 ATF 825 550 In Service
DHDS/DHT FEED
47 457 5030 4320
(SOUR HSD)
48 370 SCN/FBS 11800 9964 In Service
49 311 MS 3876 3363
DHDS/DHT FEED
50 304 1753 1604
(SOUR HSD)
51 451 ATF 6695 6348
52 461 IDO/LDO 5047 4691
53 462 BITUMEN 5079 4701
54 359 CATFEED 6514 5915
55 554 CATFEED 10302 9573
56 406 CATFEED 3806 (Tank Dismantled)
59 404 FUEL (LFO) 252 1678 Tank not dismantled
60 404B FUEL (HFO) 253
61 405 FUEL 1707 1567 Tank Dismantled
62 551 IFO 2566 (Tank Dismantled)
65 555 CATFEED 8349 7674
66 556 IFO 8379 7785
67 571 CATFEED 8614 7999 (Existing Tank)
68 463 VTB 7074 6710
69 606 VGO 1646 1530 (Tank Dismantled)
70 607 VGO 1652 1535 (Tank Dismantled)
71 572 LSHS 9229 8757
72 573 LSHS 9249 8781
73 574 LSHS/IFO 7100 6751
74 750 ASPHALT 1423 1310
75 751 ASPHALT 2035 610
76 752 ASPHALT 2035 1881
77 753 ASPHALT 2035 1878
78 754 ASPHALT 1988 1875
79 755 ASPHALT 1965 1852
80 756 ASPHALT 1149 1070
81 757 ASPHALT 1010 1071
82 758 ASPHALT 15500 (Tank Dismantled)
83 759 DRUMS 31497 (Drums Dismantled)
84 101 MS 18789 14255
85 302 MS 6526 4747
86 310 MS 8878 (Tank Dismantled)
87 312 FBS/SCN 3559 3406
88 104 MS 18951 14655
89 102 HSD 26696 23121
90 107 MS 6661 5774
91 108 MS 6814 5922
92 209 GASOLINE 1582 (Tank Dismantled)

Capacity Net
KL Capacity KL
93 212 GASOLINE 1976 (Tank Dismantled)
94 261 MS 8797 7637
95 MPPL-1 MS 20 Tank in Mahul
96 1002 PRIME G FEED 3300
97 203 NAPHTHA 1959 (Tank Dismantled)
100 250 NAPHTHA 9022 7838
101 251A NSU FEED 6761 5883
102 251B NSU FEED 6739 5817
103 252 NAPHTHA 16753 15578
104 253 NAPHTHA 16400 15278
105 254 NAPHTHA 16499 15336
106 262 NAPHTHA 862 (CPP tank)
107 263 NAPHTHA 884 (CPP tank)
CP-TK-
108 NAPHTHA 100 (CPP tank)
001
109 612 SLOP 1414
110 1001 CCR FEED 3300
NHT FEED (CCR /
111 1003 2570
ISOM)
112 1004 ISOM FEED 3300
113 1005A ISOMERATE 3200
114 1005B ISOMERATE 3200
115 213 HEXANE 2760 2410
116 214 HEXANE 2740 2363
117 256 NAPHTHA 1600 1453
118 257 HEXANE 2787 2381
119 260 SOLVENT 1425 2778 2479
- 259 SOLVENT 1425 2207 2381
120 561 MTO 1398 1236
121 562 MTO 1317 1232
122 349 LDO 4906 4647
123 D-101 LPG 205 (Sphere Dismantled)
126 D-207 LPG 2554 2285
127 D-212 LPG 1335 1133 PLANNED TO BE
DISMANTLED; NOT
128 D-213 LPG 2571 2311 TO BE CONSIDERED
129 D-214 LPG 2368 2115
132 D-215 PROPANE (Sphere Dismantled)
133 D-216 PROPANE (Sphere Dismantled)
134 D-217 PROPANE 523
135 D-218 PROPANE 523

Capacity Net
KL Capacity KL
NEW SPENT ACID
136 1458
TANK
LP-TK
137 MEA SOLUTUION 72
821
138 NF-D-610 FR. ACID 20550
139 NF-D-609 FR. ACID 20550
140 NF-TK-1 FR. ACID 62536
141 GK-D-4 DILUTE CAUSTIC 70440
142 GK-D-1 CAUSTIC DILUTE 63
143 GK-D-3 REUSE CAUSTIC 54
144 GK-D-2 CAUSTIC FRESH 63 (Sl No. 136 TO 155)
145 GK-TK-1 NH3 HCO3 12 ISBL Tanks; not to be
considered by EIL for
146 1 SALT WATER OSBL feed & product
147 TK-1262 SALT WATER 8975 storages
148
149 2 TREATED WATER 8702
152 FR. WATER TANK
153 260
TANK NEAR DM
154 821
PLANT
WATER TANK NEAR
155
TK-253
156 1101 SLOP OIL 252
SLOP OIL /WASH
157 1303 88.6
OIL
158 1301 RCO 4170.5
159 1302 WASH OIL (826) UNDER M/ce
160 1304 150N DIST (1570) UNDER M/ce
161 1318 150N DWO 2980.9 UNDER M/ce
162 1324 SPO DWO 1880
163 1330 DAO DIST. 2064.4
164 1384 150/500N 319.9 (Tank Dismantled)
165 1305 150N DIST 3108.8
166 1306 DAO RAFF 3050 UNDER M/ce
167 1319 IO - 100 1383
168 1363 500N DWO 1870 UNDER M/ce
169 1386 1300/500N 722.1 (Tank Dismantled)
170 1307 500N RAFF 5341.4
171 1316 500N DWO 6000
172 1322 BS DWO 835.3
173 1323 150N DWO 4911
174 1332 500N DIST. 6001.9 UNDER M/ce

Capacity Net
KL Capacity KL
175 1333 500N DIST. 3200
176 1335 500N DIST 7123.9
177 1361 500N DWO 1800
178 1381 500N 53.6 (Tank Dismantled)
179 1308 500N RAFF 4446
180 1321 150N DWO 3359.3
181 1331 500N DIST 8109.2
182 1382 IO-100/1600 180.2 (Tank Dismantled)
183 1317 SPO DWO 1795.2
184 1309 150N-RAFF 4311
185 1312 DAO RAFF 2448
186 1310 500N RAFF 2628
500N RAFF / DAO
187 1311 1540
DIST
188 1313 SPO RAFF 2546
189 1314 SEU SLOP 902.9
190 1315 BS DWO 725.8
191 1320 500N DWO 1966.9
192 1326 TOBS (SPO) DIST 2673.5
193 1327 TOBS (SPO) DWO 2977
194 1325 PDU SLOP 779.8
195 1328 RPO 1486.8
196 1337 RPO 1479
197 1329 RPO 1479.7
198 1336 RPO 1507.9
199 1385 CBFS 423
200 1334 500N DIST 3896.7
201 1341 FUEL OIL 1542.4
202 1383 6500N 832.9 (Tank Dismantled)
203 1387 DIANA 396.2
204 1260 FRESH WATER 1193 ISBL Tanks; not to be
considered by EIL for
DRINKING WATER NOT OSBL feed & product
205 1261
AT LR AVAILABLE storages
206 1401 BS DIST 3458 UNDER M/ce
207 1402 BS DIST 3460 UNDER M/ce
208 1403 BS DIST 3461
209 1405 500N DWO 3387
210 1406 500N DWO 3462
211 1407 500N DWO 3408
212 1408 150N DWO 3466
213 1409 150N DWO 3377

Capacity Net
KL Capacity KL
214 1410 150N DWO 3377
215 1411 500N DWO 3377
216 1404 FLUX OIL 1288 UNDER M/ce
217 10 PORTABLE WATER
ISBL Tanks; not to be
218 11 PORTABLE WATER considered by EIL for
219 12 PORTABLE WATER OSBL feed & product
storages
220 702 TANK NEAR D-302
221 1412 500N DWO 1868 Note-2
222 1413 500N DWO 2387 Note-2
223 1414 BS DWO 2034 Note-2
224 1415 BS DWO 2034 Note-2
225 560 ASPHALT (IFO) 9740 8432 Note-2
226 558 ASPHALT(IFO) 9730 8432 Note-2
227 559 ASPHALT(IFO) 9740 8432 Note-2
228 575 ASPHALT(IFO) 9748 8432 Note-2
229 1010A SLOP 250
230 1010B SLOP 250
231 611 SLOP 2040 1872
CONSIDER ONLY
232 605 SLOP 443 834
ONE TANK
233 610 SLOP 3908 3701
CONSIDER ONLY
234 604 LFO 452 385
ONE TANK
TANKS NEAR NEW
235 603 ETP
TANKS NEAR NEW
236 94 ETP
TANKS NEAR NEW
237 93 ETP
Not to be considered
TANKS NEAR NEW
238 258 ETP
by EIL for OSBL feed
TANKS NEAR NEW & product storages as
239 458 ETP per Refinery records;
TANKS NEAR NEW Seems to be under
240 255 ETP Mahul (Mktg)
TANKS NEAR NEW
241 356 ETP
242 452 TANKS NEAR TK-252
245 455 HSD 5534 6240 Note-2
TANKS NEAR TK- & product storages as
246 456
252 per Refinery records;
Seems to be under
Mahul (Mktg)

Capacity Net
KL Capacity KL
247 459 SKO 6180 5685 Note-2
248 557 SKO 3100 2927 Note-2
TANK NEAR FW & product storages as
249 1265
AUG. PUMPS per Refinery records;
Seems to be under
Mahul (Mktg)
Notes:
1) HPCL to confirm if these tanks are existing or dismantled already
2) HPCL to furnish details (capacity and service) of these tanks which have been located
in plot plan (DRAWING NO. K-3805)

ATTACHMENT 4C: FINANCIAL PARAMETERS

FINANCIAL PARAMETERS
Following financial parameters shall be considered for the financial analysis.

SNO FINANCIAL PARAMETERS
1 Construction Period 36 months
2 Project Life 25 years
3 Debt/ Equity Ratio 2:1
4 Expenditure Pattern Equity concurrent to Debt
5 Loan Repayment period After moratorium period in 1 year
6 Moratorium Period 10 Years
7 Interest on Long Term Debt 9.04%
Interest on Short Term / Working
8 Capital Loan 9.04%
9 Capital Phasing (Total Capital)
1st Year (03 Months) 3.0%
2nd Year 20.0%
3rd Year 42.0%
4th Year (09 Months) 35.0%
10 Capacity Build – up
1st year 90%
2nd year onwards 100%
30% + Surcharge @10% + 3%
10 Corporate Tax Rate E.Cess
18.5% + Surcharge @10% + 3%
11 MAT E.Cess
* Finance term meaning repayment of loan at the end of 5 years (no installment
payment)

ATTACHMENT 4D: ASSAYS


Bombay High assay provided by HPCL in their model has been considered for DFR.

ATTACHMENT 4E: EXISTING UTILITY SYSTEMS

A. Existing Utility Systems
1.0 STEAM AND POWER
STEAM
Quantity of steam generated

Quantity of
Design Maximum Steam
Fuel fired in Remarks
(TPH) (TPH) Level
boilers
Utility Boilers
SG-5 Not operational
Design oil:
3220 kg/hr
(NCV=9795
kcal/kg)
HP Steam OR
SG-9 50 42 (14 Design gas
Kg/cm2g) (refinery gas):
3320 kg/hr
(NCV=9572
kcal/kg).
Not to be
considered as
operational
Design Fuel oil
CO-BOILER 30 30 HP Steam since this boiler
: 2.1 T/hr
will be
scrapped
shortly.
LR Boiler F-1200
Not operational
C
Design: 9.3
T/hr fuel oil
The design fuel
(NCV =9500
requirements
SG-10 140 120 VHP Steam kcal/kg) OR 8.2
are at design
T/hr of fuel gas
boiler load.
(NCV=11278
kcal/kg)
Design: 9.3
T/hr fuel oil
The design fuel
(NCV =9500
requirements
SG-11 140 120 VHP Steam kcal/kg) OR 8.2
are at design
T/hr of fuel gas
boiler load.
(NCV=11278
kcal/kg)
Total Steam
Generation, 360 312
TPH

Maximum
Maximum Design Aux
Design (TPH)
CPP (TPH) firing (T/hr)
(T/hr) (without
(with aux) (Fuel Gas)
aux)
HRSG-1 35 26 21 0.3
HRSG-2 35 26 19 0.3
HRSG-3 35 23 18 0.3 HP Steam

generation.
Aux firing is
HRSG-4 35 32 26 0.3 additional fuel
48.9 gas firing in
63.8 HRSGs for
(@75% GT
(@75% GT 63.8 steam
load without
load with full (@75% GT generation.
aux firing)
aux firing) load with
HRSG-5 and 61 1.0
61 (@100% full aux
(@100%
GT load firing)
GT load
without aux
without aux
firing)
firing)
Total Steam
Generation, 203.8 170.8
TPH
Quantity of
Design Maximum Steam
DHT Project Fuel fired in Remarks
(T/hr) (TPH) Level
boiler
Design: 8.53
T/hr fuel oil OR
SG-12 125 (Gross) 100 (Net) VHP Steam
6.9 T/hr of fuel
gas (RLNG)
POWER
Design
ISO
Naphtha Max. Load,
Rating, Remarks
Consumption MW
MW
(T/hr)
CPP
GTG-1 10 2.37 7.18
2.37 Extra Power
GTG-2 10 7.18
Required is met by
2.37 importing power from
GTG-3 10 7.18
grid.
GTG-4 10 2.44 7.18
GTG-5 25 5.80 20.4
Total Power 15.35
49.12
Generation

Naphtha Quality for CPP firing:
Sp gravity at
15 degC 0.78
ASTM D86
Cut point Temp deg C
IBP 93.5 - 110.5
5% 113.3 -122.9
90 172.5 - 195.8
95% 193 - 218.7
FBP 209 - 229
2.0 CONDENSATE SYSTEM
Design Condensate from Units (GFEC+FR block): 247 TPH

Actual Condensate Return (GFEC+ FR block): 140 TPH (Lower than design as steam
consumption is lower than design cases)
Design Condensate from Units (LR block): 45.6 TPH
Actual Condensate Return (LR block): 36 TPH (Lower than design as steam
consumption is lower than design cases)
DHT project condensate generation details: 22.6 TPH (Normal)
Condensate generation Condensate generation

S.No Units TPH TPH
(Normal) (Max)
1 DHT (Future case) 2.69 2.69
2 DHT (Initial case) 2.69 2.69
3 ARU 10.1 12.7
4 SWS 4.817 6.021
5 SRU 5.035 5.035
Total 22.642 26.45

3.0 FRESH/ RAW WATER SYSTEM
Fresh Water Source Treated water from Bombay Municipal

Corporation (BMC)
Raw Water requirement for 250 (Based on actual total consumption within
existing units (FR+LR), m3/hr refinery)
Raw water requirement for new 160 (Based on actual total consumption within
units under GFEC project, refinery)
m3/hr
Total raw water requirement, 410 m3/hr (350 m3/hr fresh water from BMC plus
m3/hr 60 M3/hr IETP recycle water to DM plant feed).
No. of fresh water receiving 3 No’s (FR/LR/GFEC)

sumps
No. of
Capacity
Pumps
FR 4 (2 x 175 m3/hr + 2 x 210

Pumping capacity, m3/hr m3/hr)
GFEC 3 (3 x 320 m3/hr)
LR 2 2 x 108 m3/hr
Raw Water requirement for 135 m3/hr (Quantity applied to BMC. Approval
DHT project, m3/hr yet to be received).
No. of fresh water receiving 1 No

sumps under DHT project
Pumping capacity (DHT), m3/hr Service No. of Capacity

pumps
Utility water 3 Nos. 60 (each)

pumps
DM water 2 Nos. 330 (each)

plant feed
pumps
Remarks:
1) No pre-treatment of BMC raw water is required

4.0 COOLING WATER SYSTEM
4.1 Sea Cooling Water System:
GFEC Sea Cooling Water System (For MS BLOCK, FRE Run down,OFCC,NFCC)
Total Capacity of Sea 15000

Cooling Tower, m3/hr
No. of sea cooling water 6 All cells operating
cells
No. of sea cooling water 8 6 Operating + 2 Stand By
pumps
Max. Pumping Capacity, 2500 Capacity of one pump
m3/hr
FR/FRE Sea Cooling Water System
Total Capacity of Sea 12500 (7500 FR + 5000

Cooling Tower, m3/hr FRE)
No. of sea cooling water
5 (3 FR + 2 FRE) All cells operating
cells
9 (4 FR + 2 FRE) 6 Operating + 3 Stand By
pumps
Max. Pumping Capacity,
2500 Capacity of one pump
m3/hr
DHDS Sea Cooling Water System
Total Capacity of Sea

4800
2 1 Operating + 1 Stand By
cells
pumps
m3/hr
LR Sea Cooling Water System

7500
3 All cells operating
cells
pumps
m3/hr

LOUP Sea Cooling Water System

5000
2 1 Operating+ 1 Stand By
cells
pumps 2 1 Operating + 1 Stand By
2500 Capacity of each pump
m3/hr
DHT Sea Cooling Water System

5000
2 1 Operating+ 1 Stand By
cells
pumps 2 1 Operating + 1 Stand By
m3/hr
4.2 Bearing Cooling Water System

GFEC BCW System
Total Capacity of Bearing

1800
No. of Bearing Cooling
water cells
4 3 operating + 1 Stand By
water pumps
m3/hr
LEU Cooling System

800
water cells
water pumps
m3/hr

DHDS BCW System

250
1
water cells
water pumps
m3/hr
LOUP BCW System

300
2
water cells
water pumps
m3/hr
DHT BCW System

1200
2
water cells
water pumps
m3/hr

5.0 BOILER FEED WATER SYSTEM

Deaerator Details
No. of De-aerators Capacity, TPH
CPP 3 90/60/102
GFEC 1 500
FR 1 100
DHT ID: 4 Meter
1
Length: 13.6 Meter
LR 2 (1 Vac Dea. + 1 Press Dea. ) 82.7/74.6
HP BFW Pumps (in GFEC BH): 2 pumps of 220 m3/hr each

VHP BFW pumps (in GFEC BH): 3 pumps of 190 m3/hr each
HP BFW pumps (in FR BH): 3 pumps of 45 m3/hr each
CPP BFW pumps: 3 pumps of 69 M3/hr each (common for HRSG-I/II/III)

: 2 Pumps of 50 M3/hr each for HRSG-IV
: 2 Pump of 84 M3/hr each for HRSG-V
DHT boiler BFW pumps: 2 pumps of 174 m3/hr (Rated) each. (1 operating + 1
standby)
DHT export to process unit under DHT project BFW pumps: 2 pumps of 57.6 m3/hr
(Rated) each. (1 operating + 1 standby)
LR BFW pumps : 4 pumps of 65 M3/hr each for D-209/3209/4209

: 2 pumps of 26 m3/hr each for VPS
6.0 NITROGEN SYSTEM:
Design Capacity, Operating Max.

Nm3/hr Capacity, Capacity,
Nm3/hr Nm3/hr
Total Nitrogen
System Capacity, 1000 (DHDS) 600 (DHDS) 750 (DHDS)
Nm3/hr
Augmentation of 2400 (GAN) +
2200 (GAN) + 975 2200 (GAN) +
GFEC N2 plant under
(Liq) 975 (Liq) 975 (Liq)
DHT project**
**Two N2 plants are currently available in the refinery (GFEC and DHDS).
GFEC N2 plant will get augmented under DHT project.

7.0 COMPRESSED AIR SYSTEM
FR + FRE Air System
Compressor Design Capacity, Operating Max.

Nm3/hr Nm3/hr
51-C-04 5295 Standby 4435
51-C-07 2726 Standby 1935
51-C-08 2726 2081 1935
51-C-09 5295 4164 4435
GFEC + NFCCU Air System

Nm3/hr Nm3/hr
506-C-1001 5395 2600 4215
506-C-1002 5395 3050 4435
DHDS Air System

Nm3/hr Nm3/hr
87-C-01 A 6000 2978 4400
87-C-01 B 6000 Standby 4400
LR Air system

Nm3/hr Nm3/hr
C – 1230 D/E/F ( two
2150
operating + one 2550 each 1800
standby )
DHT Air System
Design Capacity, Operating Max.

Nm3/hr Nm3/hr
Total Compressed 5395
Air, Nm3/hr (1 Operating + 1 Note 1 & 2 6211
standby)
Note:
1. Capacity of Instrument air drier in DHT project= 3900 Nm3/Hr.

2. Following are the details of Plant air and instrument air requirement of whole DHT
project:
Service Unit Normal requirement Peak requirement

Plant air Nm3/Hr. 189.1 1539
Instrument air Nm3/Hr. 1468 3343
8.0 DEMINERALISED WATER SYSTEM
No. of DM Plants 2
Capacity of DM Plant, m3/hr 65 M3/hr x 2 chains ( DHDS)
265 M3/hr x 2 chains (GFEC)
265 (DHT) Remarks 4
Remarks
1) 3rd chain of DMP of 265 m3/hr proposed under DHT project

2) DHDS DMP is currently idle
3) HPCL to confirm data
4) One additional train of 265 m3/hr is being put up under DHT project.
9.0 FLARE SYSTEM
Present refinery flare system details are given below:
1) Hydrocarbon Flare System – Flare loads from existing units and new/revamped
units under GFEC project + Units under DHT project+ Units under Lube refinery.
2) Sour Flare System – Sour flare loads from DHDS sulphur block and new units
under GFEC project + DHT sulphur block
10.0 FUEL OIL CHARACTERSTICS
Parameter Value
1 Sp.garvity @ 15 deg C 0.95 - 1.01
Supply temperature at burner, deg
2 C 150 - 160
3 Viscosity @100 deg C, SSU 400 - 700
Typically 0.5 wt%, max 1.0
4 Sulfur, wt% wt%
5 Ash, wt% 0.2
6 Nitrogen,ppmw 2000
7 Vanadium,ppmw 10
8 Sodium, ppmw 81
9 Iron, ppmw 8
10 Flash point , deg C 250+
11 Heating value, LHV Kcals/kg 9500
11.0 FUEL GAS CHARACTERSTICS

Burner to be designed for the following three types of fuel gas
FG-1 FG-2 FG-3

Composition VOL% VOL% VOL%
CH4 ( Methane) 61.57 33.96 22.95
C2H6 (Ethane) 7.62 33.85 11.13
C3H8 ( Propane) 2.59 6.00 2.56
C4H10 ( Butane) 1.04 1.52 0.38
C5H12 (Pentane) 1.19 0.31 0.03
C6H14 (Hexane) 0.56 0.00 0.60
C2H4 (Ethene) 5.87 0.00 9.13
C3H6(Propene) 0.62 0.00 3.42
C4H8(Butene) 0.05 0.00 0.02
C5H10 (Pentene) 0.00 0.00 0.01
CO2 1.51 0.00 0.00
H2O 0.00 0.50 0.55
O2 0.05 0.00 0.00
N2 7.87 9.69 8.71
H2S 0.01 0.01 0.00
CO 1.88 0.00 0.35
NH3 0.00 0.01 0.00
H2 7.58 14.17 40.202
Total vol% 100.0 100.0 100.0
LHV (Kcals/Nm3) 9154 10269 7580
M.W 20.88 22.56 16.24
B. Existing Refinery Utility Consumption/Generation Data
These data for individual units are provided in ATTACHMENT 4A.

MARKET STUDY Document No.
SECTION 5
MARKET STUDY

MARKET STUDY Document No.
This section is excluded from the report as per the scope of the work.

PROJECT LOCATION Document No.
SECTION 6
PROJECT LOCATION

PROJECT LOCATION Document No.
6.0 PROJECT LOCATION
The proposed project is expansion of Hindustan Petroleum Corporation Limited

(HPCL), located in Mumbai in Maharashtra. The site is located approximately at
Latitude of 19.01794 and longitude of 72.90321.
The site is well connected by state highways and road network. It is located in
Mumbai. The nearest airport to the site location is Mumbai Airport, which is around
25 Km away from the Mumbai Refinery site and the nearest rail junction is LTT
(Lokmanya Tilak Terminus).
The power required after post expansion is proposed to be met by utilizing existing
CPP to generate 13 MW power and balance shall be imported from external source.
The expansion envisaged for various process units is proposed to be done within
the battery limit or in immediate vicinity of the existing units. Thus the administration
building and other associated facilities shall be kept same as that of existing one.
The overall plot plan prepared for this project is attached in Annexure-2.
HPCL Mumbai site can be visualised in Google map as attached below:

PROJECT CONFIGURATION Document No.
HPCL Mumbai Refinery Expansion Ch 7.1 Page 1 of 4
SECTION 7.1
PROJECT CONFIGURATION

7.1.0 PROJECT CONFIGURATION
The capacity of HPCL Mumbai refinery is increased from 7.5 MMTPA to 9.5
MMTPA. The desired capacity increase is proposed to be achieved by
implementation of the expansion project as below:
 Post expansion, the existing FRVPS and LRVPS units shall be dismantled. A
new VPS unit (VDU) shall be installed for processing the RCO generated from
FRAPS (based on the PCS process package).
 A revamp of 20% shall be done in the MS block units (NHT/ISOM, NHT/CCR
and Prime-G) in order to accommodate the increased light distillates. Also A
new HGU unit is envisaged in post expansion case.
 A new Visbreaker unit, as an option of residue upgradation shall also be
installed in post expansion case.
7.1.1 Process Units
The extent of augmentation in the process units is tabulated below:
Table 7.1.1: Expansion capacity of various units
Units Design Capacity Base Case Expansion Case
4260(Bas/Kuw)
FRAPS/VPS 4000 6000
4400 (AL/AM)
FREAPS 3570 (BH)
3500 3500
/VPS 3710 (AXL)
NAPHTHA SPLITTER
1222 903 939
UNIT
NHT/ ISOM 250 175 300
NHT/CCR 545 445 654
PRIME G+ 475 531 425
NEW FCCU 1456 870 1019
OLD FCCU 950 560 813
DHDS UNIT 2270 940 2034
DHDT UNIT 2200 1140 1100
VGO FEED POOL
0 147
(DHDT)
DIESEL FEED POOL
1081 741
(DHDT)
PDA 755 755 755
HGU 14.5 19.2 14.5
New HGU 36
VBU –New residue
565
upgradation unit
The block flow diagrams for Base Case, refinery expansion case are given in
Annexure 3 of the DFR.

Hence, the major project facilities in the refinery expansion are as follows:
Expansion Case Description

Revamp of FR APS+New FRVPS +VBU + MS Block 20%
revamp + New HGU of 36 KTPA+Revamp of DHDT for VGO
Mode+Utilities and Offsites.
7.1.2 Utilities Systems
The utility facilities for the Refinery consist of the following:

 Cooling water system
 DM water system
 Compressed air system
 Nitrogen system
 Steam, power and BFW system
 Condensate system
 Internal fuel oil and fuel gas system
 Bearing Cooling Water System.
The utility systems are an integral part of the refinery and constructed on the
Refinery site.
The revised utility consumption and the additional facilities required post revamp
of the above facilities have been worked out based on estimation of utility
consumption of the process units.
Following New utility Systems shall come up in Post expansion case.
Table 7.1.2 New Utility Systems

Utility system Description
Bearing Cooling water system
Bearing Cooling Water Cells 1(W) Cells each of 150 m3/hr Capacity.
Bearing Cooling Water Pumps 1W+1S pumps each of 150m3/hr.
Balance all utility systems are adequate in order to cater the additional requirement
post expansion. The details are given in Section 7.5 of DFR.
Major utility systems of refinery are summarized below in table 7.1.2.
7.1.3 Offsite Systems
The offsite facilities of existing refinery consists of
a)Crude Oil storage and transfer

b)Intermediate Feed/intermediate product storage and transfer
c)Finished product storage and transfer.

The existing storage and transfer facilities of the refinery (for the various feed and
product streams) commensurate with the additional quantities to be handled for the
Expansion Project. Thus, in this project no new additional crude and product tanks
shall be considered.
Intermediate tanks viz Raw Diesel Storage Tanks, HGU Feed Tanks, VBU Feed
Tanks, VGO Feed Tanks, Hydrotreated VGO tanks, Diesel back blending
stream tank, Slop/off spec tanks are coming up in Expansion Case. The details
are given in Section 7.6 of the DFR.
Following New Tanks shall come up in Post expansion case.
Table 7.1.3 List of New Tanks

No of
Sl.No Service Type HxD(mxm)
Tanks
Raw Diesel
1 2 Floating Roof 20x30
Storage Tanks
2 HGU Feed Tanks 2 Floating Roof 20x9
3 VBU Feed Tanks 2 Fixed Roof 20x16
Cone Roof with N2
4 VGO Feed Tanks 2 20x25
blanketing
Hydro treated Cone Roof with N2
5 2 20x23
VGO blanketing
Diesel back
6 blending stream 2 Floating Roof 20x13
tank
Slop/Offspec 1 20x20
7 Floating Roof
tanks 2 20x13

REFINERY CONFIGURATION STUDY Document No.
SECTION 7.2
REFINERY CONFIGURATION STUDY

7.2.0 REFINERY CONFIGURATION STUDY
7.2.1 DEVELOPMENT OF REFINERY CONFIGURATION
The development of the refinery configuration is described in the following

sections.
7.2.1.1 Study approach

The approach adopted to develop the refinery configuration for 9.5 MMTPA crude
processing along with various residue up-gradation options is described below.
 Development of base case Linear Programming (LP) model and validation of the
same.
 Development of refinery configuration for expansion of refinery capacity to 10
MMTPA.
 Development of the model considering different Residue Upgradation
technologies along with improvement of distillate yields
 Analysis of configurations for various Residue Upgradation options for Crude
Mix of various Design Cases.
7.2.1.2 LP Model development
General
EIL has used PIMS (Process Industry Modeling Systems) LP Software to develop
a comprehensive LP Model for HPCL Mumbai Refinery Expansion Project.
Liner Programming (LP) is a mathematical technique for determining the most
optimum allocation of resources to achieve a particular objective when there are
alternative uses for the resources. Optimizing the operation of refinery or the
determination of the optimal configuration is a typical application of linear
programming. The refinery is described by a set of given equations and/ or
inequalities (m) involving variables (n), and solved by finding the non negative
values of these variables which satisfy the equations and inequalities and also
maximize the objective function or profit. This analysis involved the creation of a
model that represented nearly 2000 equations and/or inequalities and more than
2000 variables.
The Equations represent: Feed availability, plant capacity and possible stream
routings.
The Variables represent: Amount of feeds purchased and products made,

operating variables and actual stream disposition.
The Objective function is being maximized, typically product value less raw
material and operating costs.

Overview of LP model
The following sections briefly describe the input data (and its source) and
alternate stream dispositions. These greatly affect the final results of the LP
Model.
The LP model developed uses mostly weight based units and some volume
based units to better handle the material balance around the refinery complex.
The whole model operates on a weight basis.
The architecture of the LP model can be broadly defined by the following key
components. As a matter of convention these are labeled as ‘Tables’.
 Buy & Sell tables (Feeds, Products & Utilities)
 Assay tables/Distillation tables (Crude assay and crude unit product yields &
properties)
 Sub-model tables.
 Blends tables(Product blend specifications, Blend mix)
Various other tables for defining various constraints and inputs are available but
are not detailed in this report. The following pages describe briefly the importance
of the above tables in the overall LP optimization.
Buy & Sell Tables
These tables define the maximum & minimum quantities of feeds/utilities
permitted for purchase and also that of products permitted for sales. The prices of
these streams are also defined here. Since as whole the LP model is a weight
based model, all the product prices were given on Rs /MT basis.
Sub-model Tables
Sub-models are the building blocks of an LP model. All the process units and
utility producing units are represented by various Sub-models. The optimizer tool
optimizes the interaction between the various sub-models and other tables and
thereby creates a “flow” between sub-models. This flow between sub-models
eventually results in an optimized configuration scheme.
Given below are the major sub-models in LP.
a) Process Unit Sub-models

Process unit sub-models require yields which are either in weight or volume basis.
Weight based yields have been used for all the process sub-models. Typically the
yields will be given in the following format:
 Base Yield for every unit

 Delta yields as required.
b) Crude Assay & Crude/Vacuum distillation Unit

The Crude/vacuum unit is not a sub-model in LP but is defined in Assay tables.
However, for the sake of simplicity it is described as sub-model.

Aspen Tech’s Crude manager has been used to generate yields and properties
for various cut points as envisaged.
Crude and Vacuum unit units are modeled in single sub-model. Utilities for all the
units are also considered.
c) Utility Sub-model
The Utility sub-model produces all the utilities required by process units. Utility
requirements for each process unit are defined in respective process sub-model.
All the utilities required for each of the configurations are produced in the utility
model. Except for raw water, no other utility purchases are envisaged. Accurate
utility estimates are essential to predict the fuel & oil loss of the refinery complex
and also operating costs. In this study the utility requirements considered are
annualized operating utility requirements.
Utilities typically tracked in by LP model are:
 Power, KWh
 Steam
 Fuel (fuel gas or fuel oil in terms of MMkcal/hr or tons)
 Catalyst & chemicals
 Utility requirement is entered in the LP model in one of the following ways.
 Unit of feed (weight or volume, for example for power KWH/ton of feed
processed)
 Unit of product (weight or volume, for example in H2 plant KWH/ton of H2

produced)
d) Captive Power plant

Power & steam are generated in the captive power plant (CPP) sub-model. Power
plants such as GT and Utility boilers are modeled based on data furnished by
HPCL.
e) Refinery fuel balance

Refinery fuel is another important utility tracked by the LP model. Refinery Fuel
requirement is met by refinery fuel gas, internal fuel oil and is supplemented by
natural gas. Fuel requirement is defined in each process sub-model and hence
total refinery fuel requirement is known in terms of MT of fuel oil
equivalent/Annum.
f) Sulphur Recovery unit

Two Sulphur recovery units (DHDS & DHDT) are modeled to track H2S produced
from various process units. Sulphur recovery of 99.9 % in DHDS SRU and 99.8%

in DHDT SRU are considered for this study along with Tail Gas Treating Unit to
reduce the overall SOx emissions.
Product Blending
The following blend tables are configured as part of LP model development:
 Blend Mix: Defines the streams that are allowed for blending to produce the
desired product.
 Blend properties: Defines the properties of various blend streams identified for
blending in Blend Mix table
 Blend specs: Defines the product specifications required to be achieved by LP

model.
7.2.2 BASE CASE LP MODEL DEVELOPMENT
The first step is to develop an LP model for the exiting refinery using the existing
design and operating data. The schematic sketch of existing refinery is depicted
below:
Figure 7.2.1: Schematic sketch of Existing Refinery
Using this LP model, the performance of the existing refinery has been evaluated.

Key issues that have been considered while developing the base model are listed
below:
 Bombay High, Arab Extra Light, Basrah and Arab Mix crudes of quantity as
given in Table 7.2.1 were considered for Base Case.
 The crude assays were obtained from HPCL existing LP Model. The same
were used in the working LP Model to develop the Base Case.
 Yields, utilities of the existing units are based on the data obtained from
HPCL.
 The TBP cut points of straight run products have been kept same as
considered in the design of existing Crude Units.
 Low sulphur IFO has been used for all units (CDU/VDU, FCCU, DHD, DHDT,
etc) to meet the internal fuel requirements.
 Natural Gas has been considered for the following end uses:
 Fuel for process fired heaters
 Fuel for Boilers
 SOx has been limited to 12.6 MT/Day.
7.2.2.1 Material balance
Material balance for base case (existing refinery configuration) which is validated
by HPCL is tabulated below in table 7.2.1.
Table 7.2.1: Material Balance for Base case
Material Quantity in KTPA Wt%
Feeds
Bombay High 2800 37.2
Arab Extra Light 580 7.7
Arab Mix 725.9 9.7
Basra Light 3420 45.4
RLNG 24 0.5
Products
Liquefied Petroleum Gas 352 4.7
LAN 205 2.7
Special cut naphtha 96 1.2
Treated Hexane 30 0.4
Solvent 1425 8.5 0.2
MS Euro III 808 10.7
MS Euro IV 381.7 5.1


SKO 52.4 0.7
ATF 600 8
MTO 48 0.6
HSD Euro III 1810 24
HSD Euro IV 684 9
LDO 88 1.1
Fuel Oil 591 7.8
Bitumen 707 9.5
LOBS Production
Spindle oil Group I 15
Spindle oil Group II 19.3
150 Neutral Group I 81.8
150 Neutral Group II 38.4
5.8
500 Neutral Group I 205
500 Neutral Group II 7
Bright Stock 60.6
Industrial Oil 100 8.8
Rubber Processing Oil 70 0.9
Sulphur 34 0.5
7.2.2.2 Unit capacity utilization

The design capacities and its utilization in base case is given below in Table 7.2.2:
Table 7.2.2: Unit capacities Utilization in Base case
Existing Units Design Capacity TPA Capacity Utilization KTPA
Primary Processing Units
FR APS/VPS 4400 4353.8
FRE APS/VPS 3000 3375
PDA 755 713
FCCU (Existing +New) 2227 1474
Middle Distillate Treating Units
DHDS 2270 940
DHDT 2200 1140
Light Distillate Treating Units
NSU 1222 937
NHT/ISOM 250 244
NHT/CCR 545 462


FCC GASOLINE
584 549
SPLITTER
PRIME G 475 337
HGU 18.1 12.7
Power Plant
5 Gas Turbines 48 MW 48 MW
7.2.2.3 Economic Summary

Based on the prices of crudes and products as given in the Design Basis (Section
4) and quantities of crude and products as listed above in Table 7.2.1, economic
evaluation for the base case is summarized below in Table 7.2.3
Table 7.2.3: Economic Summary of Base case

Economic Parameters Based on 3 Yr Avg Price (2011-14)
Gross Margin ( Rs Crore / Annum) 759
Power purchase ( Rs Crore / Annum) 237
Net Refinery Margin ( Rs Crore / Annum) 522
US $/ bbl of Crude 2.28

7.2.3 DEVELOPMENT OF EXPANSION CONFIGURATIONS
The schematic sketch which is envisaged for expansion of existing refinery for 9.5-
10 MMTPA crude processing is shown below:
Figure 7.2.2: Schematic sketch for Expansion Refinery
The configuration study involves two parts:
1. Study for Suitability / Adequacy of Existing units for 10 MMTPA crude

processing: This part is described in detail in Section 7.3 (Process
Description) of the DFR.
2. Configuration study considering various options for Residue upgradation
unit
7.2.4 VARIOUS OPTIONS FOR RESIDUE UPGRADATION UNIT
The various options for Residue upgradation which were considered to arrive at
the most optimum refinery configuration are listed below:
 Visbreaker Unit

 Solvent Deasphalting Unit
 Slurry Hydrocracking
 Resid Hydro-cracking (Ebullated Beds)
7.2.4.1 VISBREAKING
The Soaker Visbreaking process is ideally suited for the reduction of heavy fuel oil
product by reducing residue viscosity and maximizing production of distillates.
Key Features
 In soaker visbreaking, the bulk of the cracking reaction occurs not in the
furnace but in a drum located after the furnace called the soaker.
 The oil is held at an elevated temperature for a pre-determined period of time

to allow cracking to occur before being quenched.
 The oil then passes to a fractionator. In soaker visbreaking, lower

temperatures are used than in coil visbreaking.
 Visbreaker tar can be further refined by feeding it to a vacuum flasher. Here

additional heavy gas oil may be recovered and routed either to catalytic
cracking, hydrocracking or thermal cracking units on the refinery.
 The vacuum-flashed tar is then routed to fuel oil blending or for sale as
product.
The yields considered are as follows:
Table 7.2.4: Yields of Visbreaker

Yields (wt%) VBU with flasher VBU without flasher
H2S 0.31 0.11
FUEL GAS 1.64 1.18
LPG 0 0.9
VBU NAPHTHA 4.05 3.7
VBU Diesel 11.18 12.7
VBU VGO 11.78 0
VBU TAR 71.04 81.4
Viscosity @ 50 Deg C of Kuwait VR is 488162 cst

Viscosity @ 50 Deg C of Arab Light VR is 233420 cst

Viscosity @ 50 Deg C of Arab Light VBU Tar is considered as 80997 cst.
Viscosity @ 50 Deg C of Kuwait VBU Tar is considered as 127044 cst.
7.2.4.2 SOLVENT DEASPHALTING
Key features of High Lift SDA
Solvent Deasphalting process is a heavy oil residue upgrading and solvent de-
asphalting technology used to separate low value asphaltene components from
higher value resin and oil products.
 This unit is a three stage unit producing DAO as incremental feedstock to the
FCC unit, Resin as a blendstock for road bitumen, and Asphaltene as a
blendstock for road bitumen or as a pelletized solid product.
 Normal butane is the selected solvent in order to provide adequate lift of DAO
and Resin to produce a sufficiently hard asphaltene.
 In this unit, the solvent extractors’ operating conditions are adjusted to lift the
resinic molecules in the DAO. The resinic molecules are then recovered from
the DAO by partially expanding the solvent under supercritical conditions.
 In High-Lift SDA, DAO recovered after separation of resin is processed in the

FCC unit and formation of bright stock.
 The resin product is a relatively low metal, low sulphur residuum that is high in
asphaltene free CCR.
 The asphaltene which gets produced after separation of DAO and resin product
is a high viscosity liquid which solidify at ambient temperature. The pitch in solid
form can be pelletized and can also be used as solid fuel for cement kilns, the
steel industry or the utility industries.
 For High-Lift SDA, the product yields are tabulated below:

Table 7.2.5: Yields of SDA
Yields Wt%
Asphaltene 33
Resin 15
DAO 52

Key features of Low Lift SDA
 A Low-lift SDA is also considered for evaluation in this configuration study. The
lift considered is same as that of existing PDA ( 22% for Bright stock production
and 25% for FCC feed). This is a typical 2-cut SDA. The SDA pitch is routed to
bitumen blending and DAO is routed to FCC feed and Bright stock production.
7.2.4.3 SLURRY HYDROCRACKING
Slurry hydrocracking is the latest technology which involves high conversion

thermal cracking in the presence of hydrogen and catalyst/ additive. Commercial
operating reference is not available for this option, though extensive pilot plant
studies have been done which is quite expensive. Also there are issues related to
Pitch disposal which is residual material from the SHCU.
Key Features:
 Slurry hydrocracking is the latest technology which involves high conversion
thermal cracking in the presence of hydrogen and catalyst/ additive.
 Commercial operating reference is not available for this refinery, though

extensive pilot plant studies have been done.
 For evaluation of SHCU, the data from licensers like M/s UOP and M/s KBR are
obtained. Reactor configuration, its pressure etc are specific to licensor.
 The product yields as furnished by licensors are tabulated below:

Table 7.2.6: Yields of Slurry HCU
Yields Wt%
C1/C2 2.2-4.6
C3/C4 3-5.6
Lt naphtha (C5-135) 8-12.4
Hy Naphtha (135-155) 3-4
Diesel (155-370) 50-51
VGO (370-525) 14-15
pitch (525+) 6-10
 Slurry hydrocracker is integrated with hydro-treater unit. No further treatment

of SHCU products is required.

Slurry Pitch Disposal

Slurry pitch which is residual material from the SHCU is a high energy content
pitch having residual iron material and feedstock metals. Slurry pitch generation is
in viscous liquid form which can be solidified and can be converted into the
transportable granules. Slurry pitch can be considered as economical Alternative
fuel because of its controlled properties and ease of bulk handling. There are
various value upgrading options for slurry pitch. The options where Slurry pitch
can be utilized, are as follows:
Solidification of liquid pitch by Belt Conveyor SANDVIK:

Solidification by indirect water cooled conveyor belt followed by simple finger
crushing unit.
Solidification of liquid pitch by Extrusion Process of Rutgers:

A mixture of steam and water, adjusted to a certain temperature, will be added to
the liquid pitch - stream in a nozzle, cooling the pitch down to a moderate
solidification temperature.
Cement Industry:
Slurry pitch in the form of solid can be co-fired with coal at up to 30 wt% of the fuel
requirement in the cement kilns. Since India has a large demand for low fuel
source for its relatively large Cement industry, this market should be an attractive
option for slurry pitch utilisation.
Blast Furnace (BF) Coke Production:

Addition of coal tars as an additive to the coking coal is normal practice for years.
pitch can be such an additive as well with some positive impacts on coke quality.
This addition of pitch to the coking coal blend is proven practice on industrial scale
.Hydrogenation Residue (pitch) is added to coal in solid shape
Foundry Coke Production:

To produce larger pieces of coke with a high carbon content, necessary for cast
iron production in the foundry, a binder component is indispensable for German
coal grades. Pitch is a very suitable replacement for expensive binder
components used for that purpose. Pitch is added to the coking coal blend in a
solid shape
Circulating Fluid Bed (CFB) Boilers:

There is another option for utilization of slurry pitch as a fuel in CFB boilers. CFB
technology has been widely accepted over the last 20 years for high sulphur fuels.
CFB boilers have proven ability to handle high sulphur residues and both solid and
liquid feeds at wide variations of throughput. CFB ash contains a mixture of
calcium sulphate and oxides and is categorized as a weak cement material and
can be used as soil stabilizer and for civil engineering purposes.
Conventional Combustion in Power Plant:

Like fuel grade petroleum coke solid pitch is fed in a certain percentage to the
steam coal for combustion.
Slurry Pitch Gasification:

Slurry pitch similar to other heavy residues may be gasified in partial oxidation
(POX) systems with water gas shift of the synthesis gas with the objective of
producing hydrogen in a refinery complex. Gasification of pitch has a relatively
high installed cost, but has the advantage of a continuous non‐ interrupted
feedstock at neat zero cost.
Delayed Coking
Discontinuous Coking Process with VR as feedstock with liquids and petrol coke
as product streams. PITCH can be admixed to the feedstock in a certain
percentage. 2 operation modes are applied: anode grade coke, fuel grade coke
7.2.4.4 EBULLATED BED RESIDUE HYDROCRACKING
Key Features
 In the ebullated bed process , hydrocarbon feed and H2 are fed up-flow
through a catalyst bed, expanding and back mixing the catalyst bed. It is a
three phase system with back mixing of reactor liquid and the catalyst
particles. In this process, oil and catalyst is separated at the top of the reactor
and catalyst is re-circulated to the bottom of the bed to mix with fresh feed.
On the other hand, fresh catalyst is added on the top of the reactor and spent
catalyst is withdrawn from the bottom of the reactor.
 There are two most important ebullated bed process (I) LC fining licensed by
M/s Chevron ( LC-fining) and (II) H-OIL licensed by M/s Axens (H-OIL) . Both
the processes are similar in concept except the difference in the reactors’
mechanical details. There are more than 12 such operating units around the
world and 4 units under construction.
 As specified by the licensors, the feed to these units requires FCC slurry oil
(minimum 3% of feed) as aromatic donor solvent to solubilize the asphaltene
to achieve the desire conversion and to reduce the catalyst replacement rate .
 The unit has been configured as per information (such as feed quality
requirement, product yields, utility requirement, catalyst costs etc.) given by
technology licensor.
 The yields as considered in LP model are given below:

Table 7.2.7: Yields of ebullated bed residue hydrocracking

Yields Wt%
C1/C2 2.8-3.3
C3/C4 3.5
Naphtha (C5-150) 5.0-7.0
Diesel (150-375) 33-36
VGO (375-550) 25-28
Unconverted
20-22
Bottom (550+)
 The products from this unit is routed as follows: Naphtha to naphtha pools, Diesel
to DHDT, VGO to FCC and unconverted bottom product to produce fuel oil.
 Fuel Oil Specification:

Unconverted bottom product from Ebullated bed unit is blended with the cutter
stock (LCO & SR Kerosene) to achieve the fuel oil specification for viscosity and
sulphur. As suggested by the Licensor, due to the ambiguous nature of the
blending correlation for calculation of pour point, the pour point spec for fuel oil
was not considered in the LP model. The licensor also guaranteed that pour point
specification will be met as long as viscosity spec for fuel oil is achieved.
7.2.5 REFINERY ECONOMICS
 Material balances and operating capacities are developed for each study
configuration using LP model.
 The refinery gross margin which is equal to product revenues minus feedstock
costs, is calculated for base case and 10 MMTPA expansion cases . Delta GRM
i.e. Expansion GRM minus base case GRM is used for economic analysis
 The refinery variable operating costs are estimated by LP model. Variable

operating cost includes the cost of providing catalyst and chemicals in support of
ongoing refinery operations These operating costs for catalysts & chemicals are
furnished in each process sub-model. These costs are based on in-house data
and licensor data.
 The cost of purchasing utilities is normally included in variable operating costs.

However, all the utilities required for this project are generated internally. Raw
water and power are the only purchased utilities and the cost is based on pricing
data supplied by HPCL.

 These variable costs are subtracted from the gross margin to yield, in turn, the
net refinery operating margins.
7.2.6 REFINERY CONFIGURATION STUDY CONSIDERING VARIOUS RESIDUE
UPGRADATION OPTIONS
The refinery configuration study was carried out over a year (owing to the
modifications in crude/product prices, key considerations, crude thru’put), in order
to arrive at the most optimum and feasible configuration. The journey of the
configuration study is detailed in the following section.
7.2.6.1 PRELIMINARY STUDY OF REFINERY CONFIGURATION (STAGE 1)

Review held on 3rd may 2013 at HPCL Mumbai)
 Crude Mix:
In the original scope of study, crude thru’put of 10 MMTPA was envisaged with the
following crude mix:
Design Case - 1:
Kuwait Crude: 10 MMTPA
Design Case - 2:
Bombay High: 2 MMTPA
Arab Light: 4 MMTPA
Kuwait Crude: 4 MMTPA
However, based on the adequacy check of the FRE APS/VPS columns, they were
found capable of processing of 3.5MMTPA of PG crude and 3.75MMTPA of light
crudes (Bombay High/Arab Light) , Hence, the crude thru’put for the expansion
study was finalized as follows:
Design Case 1: Kuwait (100%)(FR=6MMTPA+FRE=3.5 MMTPA)

(FR=4MMTPA Kuwait + 2 MMTPA AL; FRE=2MMTPA BH+1.75 MMTPA AL)
 Feed/ product prices::

 Three years average price taken from 2010-2013
 Five years average price taken from 2008-2013
 Key considerations:
1. No new secondary processing unit shall be considered. However VGO HDS
option shall be worked out.

2. Solvent Deasphalting Unit would be considered for residue upgradation in the

expansion refinery due to space constraints in the existing refinery plot area.
3. Hydro treating of SRVGO to be considered in DHDTin blocked out mode of
operation and subsequent routing of hydrotreated VGO to Old FCCU.
4. Maximization of diesel considering a new kero hydrotreater unit of capacity =

100m3/hr
5. SOX limit for the refinery shall be a maximum of 12.6 TPD.
6. FR APS, Stabilizer and New VPS shall be based on inputs from HPCL (PCS
process package).
7. Hydrogen recovery from Hydrogen rich gases from DHDS, DHDT etc shall be
considered.
 Options Studied:
For 9.5 MMTPA expansion refinery, the following options are studied:
Option 1: Impact of VGO Hydrotreating
Option 2: New SDA of lift = 52% (high lift) / 25% (low lift)
Option 3: Variation in production of Euro V MS
 Analysis of Results :
Option 1: : Impact of VGO Hydrotreating in the refinery expansion scenario.

This was studied for the refinery expansion case withSDA (low lift),
considering new FCCU saturated.
Table7.2.8 :With/without VGO Hydrotreating in expansion refinery

Key Parameters With VGO HDS Without VGO HDS
Unit Capacities(KTPA) Design Case-1/ Design Case-2
813/806
Prime-G 443/421
DHDT 1960/2200 354/525
NHT/ISOM unit -/201 -/302
Hydrogen unit 25/28 21/19
Products (KTPA)
Export naphtha 250/812 778/616
Euro IV gasoline 1332/1440 700/1194
It is evident from the above data that VGO hydrotreating in new DHDT gives the
advantages of Full utilization of DHDT, More MS production and avoiding revamp
of Prime-G
However hydrogen consumption is high, new HGU would be required.

Without VGO Hydrotreating, the revamp of Prime-G goes as high as 70% in both
the Design cases.
Option 2 : New SDA of lift = 52% (high lift) / 25% (low lift) in the refinery
expansion scenario.
Table7.2.9: SDA in expansion refinery
Key Parameters HIGH LIFT (52%) SDA LOW LIFT (25%) SDA
Unit capacity (KTPA) Design Case-1/ Design Case-2
SDA capacity 1303/809 1857/383
Products(KTPA)
Fuel oil 288/360 2455/1081
Bitumen 1675/1136 718 /935
Asphalt 299/145 0/0
In the case of high lift SDA ,the entire SDA asphalt could not be converted to
bitumen due to high demand of extracts as bitumen blenders . Disposal of this
excess SDA asphalt is a concern.
In case of low lift SDA option, production of fuel oil is quite high.
To finalize the SDA capacity and its lift, bitumen demand would be required to be
finalized.
Option 3: Variation in production of Euro V MS
This was studied for the refinery expansion case with SDA (low lift), considering
new FCCU saturated.
The specs for Euro V MS are considered same as MS Euro IV, except sulphur =
10 ppmw max, RON = 95 min and MON = 85 min.
Table7.2.10 : Euro V MS production in expansion refinery

Design Case-1/ Design Case-2(KTPA)
Key Parameters With Alkylate
Without With Alkylate (50:50
(75:25 EURO
ALKYLATE EURO IV:EURO V)
IV:EURO V)
Alkylate purchase 0/0 41/68 226/228
480/488
Prime-G 443/421 480 /480
(% revamp=4)
157/260
NHT/ISOM 156/201 253/195
(% revamp=4)
EURO IV MS 1332/1440 786/1080 710/695
EURO V MS 0/0 262/360 710/695
Export Naphtha 250 /312 574/407 297 /603.6

It is evident from the above data that for production of Euro V MS, Alkylate has to
made available. Alkylate requirement depends upon the demand of Euro V MS.
ISOM unit capacity also depends upon overall MS demand and alkylate quantity.
Outcome of the study
It emerged out that the following would be followed in the future course of study.
 Prices of crude, products, RLNG and alkylate would be revised based on

current rates of duties, taxes, octroi, etc.
 Production of 100% Euro V Diesel and MS would be the intent in the expansion
refinery configuration.
 A check case shall be done considering the ratio of Euro IV and Euro V MS and
HSD in expansion case, maintained same as the.current ratio of Euro III and
Euro IV production in base case.
 Natural gas requirement should be considered in two cases. One as use in

boilers and process heaters and other as use in CPP, HGU, boilers and process
heaters.
 VBU+SDA option to be studied as another option of residue upgradation.
 A high lift SDA and saturation of FCCU capacity would be preferred in

expansion cases.
7.2.6.2 REFINERY CONFIGURATION STUDY (STAGE 2)
(Review meeting held on 19th July, 2013 at HPCL Mumbai)
 Based on the outcome of the preliminary study, the following cases were
shortlisted:
 No residue upgradation unit

 Visbreaker
 Solvent deasphalting unit
The basis of study, for this stage of study, is elaborated as follows:
 Feed/ product prices:

Three years average price taken from 2010-2013, based on current taxes/duties.

 Key considerations :
1. In addition to SDA, Visbreaker was also studied as a possible residue

upgradation option. The yields of VBU with vacuum flasher were considered in
the LP Model .
2. In order to accommodate the entire Prime-G product naphtha into Euro IV MS

pool, its sulphur was reduced to 50 ppmw (vis a vis design of 100 ppmw). The
possibility of achieving this improvement in quality in the existing installed unit
shall be subsequently pursued with the unit Licensor (M/S Axens)..
3. The revamp of MS block units was kept as 20% as well as open in some cases
(in order to target zero naphtha sales).
4. 100% Euro V diesel Production
5. Hydrogen availability limit in the refinery = 25KTPA max (revamped HGU of

capacity 18.1 KTPA +new PSA).
6. Natural Gas purchase was fixed at 40.8 KTPA (same as base case).
7. Bitumen demand in the expansion case was fixed at 1050 KTPA.
8. Maximum quantity of DAO routed to new FCCU as feed is limited to 37%.
 Options Studied
(A)Variations in Residue Upgradation Units for both Design Case 1 & 2

considering revamp of MS block units (NHT/ISOM, NHT/CCR and Prime-G) as
20% ; and no limits on their revamp.
(B)Variation in Euro V/ Euro IV MS Production
(C)Variation in Euro V/ Euro IV Diesel Production
(D)Variation in natural gas utilization

Option A: Variations in Residue Upgradation Units for both Design Case 1 & 2
Case 1: No residue upgradation

This case considers the expansion refinery with no new residue upgradation unit.
Figure 7.2.3: Product profile
Table 7.2.11 : Unit capacities (KTPA)

DESIGN MS BLOCK REVAMP
MS BLOCK 20% REVAMP
UNITS CAPACITY OPEN
DESIGN DESIGN DESIGN DESIGN
CASE 1 CASE 2 CASE 1 CASE 2
NHT/CCR 545 614 (13) 654 (20) 618 (13) 770 (41)
NHT/ISM 250 290 (16) 300 (20) 296 (18) 414 (66)
FCC (OLD+NEW) 2227 1504 1931 1501 1931
PRIME G 475 228 442 225 736 (55)
DHDS 2270 1067 2060 1072 705
DHDT 2200 2200 2200 2200 2200
VGO in DHDT 0 934 615 941 0
H2 Capacity 25
16 25 16 16
(H2 Revamp+New PSA) (18.1+7)
GRM (crores/annum) - -65 537 -64 545
() indicates % revamp.
Key findings:
In Design Case 1, the refinery processes 100% high sulphur crude – Kuwait. The yield
of Vacuum residue is quite high in this case. If the refinery does not opt for a new
residue upgradation option, the Fuel oil sales go as high as 2875 KTPA.A huge quantity
of middle distillates go to Fuel oil blend as cutter stock. As a result, the Gross refinery
margin suffers (-65 crore Rs./annum). In Design Case 2, Fuel oil production is ~ 1100
KTPA. This shows that as the refinery aims to process heavy sour crudes in future, a
new residue upgradation unit is indispensable to achive high distillate yield.

Case 2: VBU with vacuum flasher

This case consists of the expansion refinery with a new Visbreaker Unit (in order to
thermally crack the excess vacuum residue).
Figure7.2.4: Product profile
Table 7.2.12 :Unit

DESIGN MS BLOCK 20%
capacities (KTPA) CAPACITY REVAMP MS BLOCK REVAMP
UNITS OPEN
NHT/CCR 545 654 (20) 654 (20) 681 (25) 778
NHT/ISM 250 279 (12) 300 (20) 330 (32) 389 (56)
FCC (OLD+NEW) 2227 1839 2046 1857 2099
PRIME G 475 530 (12) 495 (4.2) 709 (49) 762 (60)
DHDS 2270 2270 2270 2270 2270
DHDT 2200 1486 1979 1258 1579
VBU 1476 664 1476 688
VGO in DHDT 0 546 491 380 314
H2 Capacity 25
20 25 18 20
(H2 Revamp + New PSA) (18.1+7)
GRM (crores/annum) - 1547 873 1531 921
Key findings:
As compared to No residue upgradation case, the fuel oil production is lower when a
new VBU is configured in the refinery expansion model. The purpose of a VBU is to
reduce the viscosity of the Vacuum residue feed by thermally cracking it; yielding the
product Visbreaker Tar. As a result, there is less amount of cutter stock required in
order to meet the Fuel oil specification. These help in overall improvement of yield of
distillates from the refinery. The same is evident in high GRM, as indicated above.
The capacity of VBU is higher in Design Case 1, owing to the larger yield of Vacuum
residue.

Case 3: Solvent Deasphalting Unit

This case consists of the expansion refinery with a new Solvent Deasphalting Unit (of
high lift = 52%).The Vacuum residue is fed to the existing PDA, new SDA and balance
goes to fuel oil pool.
MS BLOCK 20% REVAMP
Figure 7.2.5 : Product profile
Table 7.2.13 : Unit capacities(KTPA)

DESIGN MS BLOCK 20% MS BLOCK REVAMP
UNITS CAPACITY REVAMP OPEN
NHT/CCR 545 654 (20) 654 (20) 648 (19) 775 (42)
NHT/ISM 250 218 300 (20) 334 (34) 385 (54)
FCC (OLD+NEW) 2227 2227 2227 2227 2227
PRIME G 475 487 (2.5) 576 (20) 791 (66) 791 (66)
DHDS 2270 1773 1915 1524 1362
DHDT 2200 2200 2200 2200 2200
SDA 744 514 744 646
VGO in DHDT 0 982 584 840 272
H2 Capacity 25
22 25 22 20
GRM (crores/annum)) - 492 444 -449 482
Key findings:
A new SDA unit in the expansion refinery produces deasphalted oil (DAO – FCCU
feed)and asphalt (for blending into bitumen). Attempt is made to saturate both the
FCCUsin this option. The entire quantity of asphalt could not be used for bitumen
blending because of:
 High demand of bitumen blending streams (extracts) for conversion of SDA aphalt to
bitumen.

 As the bitumen demand is fixed, it necessitates selling the balance pitch in the
refinery as pellets.
The high lift SDA option gives low refinery margin and has thus, not been considered for
further evaluation.
Case 4 : SDA +VBU with Vacuum Flasher

This case consists of the expansion refinery with a new SDA (High lift = 52%) and a
new VBU, both taking vacuum residue as feed.
Fig 7.2.6: Product profile
Table 7.2.14 :Unit capacities(KTPA)

DESIGN MS BLOCK 20% MS BLOCK REVAMP
UNITS CAPACITY REVAMP OPEN
NHT/CCR 545 654 (20) 654 (20) 719 (32) 785 (44)
NHT/ISM 250 300 (20) 300 (20) 315 (26) 392 (57)
FCC (OLD+NEW) 2227 2227 2227 2227 2227
PRIME G 475 541 (14) 533 (12) 848 (78) 775 (63)
DHDS 2270 2270 2025 2270 1575
DHDT 2200 1912 2200 1112 2200
VBU 1417 616 1427 634
SDA 440 428 430 428
VGO in DHDT 0 955 584 413 346
H2 Capacity 25
23 25 15 21
GRM (crores/annum) - 1445 673 1483 772

Key findings:
Since a new SDA is configured in this case, attempt is made to saturate both the
FCCUs. The SDA capacity gets limited due to DAO limit of 37% in new FCC and low
price of Asphalt pellets. The balance Vacuum residue goes to VBU as feed. Bitumen is
produced by blending SDA asphalt, PDA asphalt with extracts. Fuel oil contains
Visbreaker Tar with cutter stock.
This case gives a fairly high GRM, however it would call for a high Capital investment ,
owing to the installation of two new units.
Case 5: Slurry Hydrocracker

This case consists of the expansion refinery with a new Slurry hydrocracker, with the
excess Vacuum residue as feed. The findings of Slurry HCU in Design Case 2
configuration are tabulated as follows:
Table 7.2.15: Product profile
MS Block 20% MS Block Revamp
PRODUCT
REVAMP Open
LPG 604 593
MS EURO IV 1705 1852
HSD EURO V 4227 4112
BITUMEN 1050 1050
PITCH 64 75
Table 7.2.16: Unit capacities

DESIGN MS Block 20% MS Block Revamp
UNITS CAPACITY Revamp Open
NHT/CCR 545 753 (38)

654 (20)
NHT/ISM 250 300 (20) 359 (44)
FCC (OLD+NEW) 2227 2134 2107
PRIME G 475 576 (20) 804 (69)
DHDS 2270 2270 2270
DHDT 2200 2057 1245
VGO in DHDT 0 449 0
SLURRY HYDROCRACKER 800 933
HYDROGEN UNIT 18.125 18.125 18.125
NEW HYDROGEN UNIT 33 31

Key findings :
The slurry hydrocrackerunit gives a very high distillate yield. As a result, the
production of LPG, MS, Diesel improves in this case. There is zero fuel oil sales.
However, space is required to be checked for new Slurry HCU, HGU and SRU. One
of the products of SHCU is slurry pitch. Its disposal is a cause of concern, if the unit
is selected as the preferred residue upgradation option.
The Gross differential margin was compared for all the above five residue
upgradation options of Design Case 2 (with MS block revamp = 20%). The same is
indicated in the following figure (Figure 7.2.7. )
Gross Differential Margin = Expansion case GRM – Base Case GRM (166 crore
Rs./annum)
Gross Differential Margin(crore Rs./A)

1200
983
1000
800 707
600 507
371
400 278
200
0
No Resid VBU SDA VBU+SDA SLURRY HCU
Figure 7.2.7: Gross differential margin for various residue upgradation options
The above plot indicates that the differential GRM for Slurry HCU is highest. The
option of Visbreaker unit also gives a fairly high GRM.
OPTION B: Variation in Euro V/ Euro IV Diesel Production
The analysis for Euro V diesel production was done for one of the optimized cases of
refinery expansion i.e.VBU + MS Block Revamp (20%) for Design Case 2 crude mix.
Euro V diesel product specs are maintained same as Euro IV, except for sulphur as
10ppmw max. Euro V diesel price is considered by adding the differential between
Euro III and Euro IV diesel prices to Euro IV diesel price.
The following options were studied:
Option A: 100% Euro V diesel production

Option B: Euro V & Euro IV diesel sales kept open
Option C: 100% Euro IV diesel production.

Option D: Euro IV vs Euro V diesel ratio same as base case ratio of Euro III and
Euro IV diesel production.
The key findings for the above options are listed in Table7.2.17.
Table 7.2.17 : Variation in Euro IV/V diesel production
Options
Key parameters (KTPA)
A B C D
Total Diesel produced 3580 3670 3583 3671
2270/1923 2270/1834 2270/1616 2270/1803
DHDS/DHDT capacity
VGO Processed in DHDT 449 518 449 530

KHT capacity 98 360 379 421
H2 consumption 24 23 21 23
Analyzing the above options, the variation in KHT capacity and quantity of SR Kero to
DHDS feed are plotted against the production of Euro V diesel. The plot is indicated
in the Figure 7.2.8 below.
Figure 7.2.8: Variation in Kero to DHDS/ KHT capacity with Euro V HSD
The plot indicates that as EURO V diesel production increasesKHT capacity

decreases due to limitation in KHT diesel sulphur (20ppm) and KERO processed in
DHDS increases as the sulphur specification is met.
OPTION C: Variation in Natural Gas Utilization
The analysis was performed for one of the optimized cases of the refinery expansion
model i.e. VBU + MS Block Revamp (20%) for Design Case 2 crude mix.
The following variations in the consumption of natural gas were studied:

Option 1: Purchase of natural gas fixed at 40.8 KTPA (Same as Base Case), routed
to furnace and boilers.
Option 2: Natural Gas routed to furnace and boilers, with no limit on the quantity
purchased.
Option 3: Natural Gas routed to furnace ,boilers, HGU and CPP; with no limit on the
quantity purchased.
Option 4: No Internal Fuel Oil; Natural Gas routed to furnace, boilers, HGU and
CPP; with no limit on the quantity purchased.
The key findings for the above options are listed in Table 7.2.18
Table 7.2.18 : Sensitivity analysis for Natural gas purchase

Key parameters Options
(KTPA) 1 2 3 4
Natural gas 40.8 98 303 401
Internal fuel oil 189 114 114 0
Products (KTPA)
LAN 144 152 359 359
HSD Euro IV 3575 3587 3583 3589
Fuel oil 769 787 787 895
Unit Capacities (KTPA)
FCCU (Old+New) 2047 2103 2103 2106
The variation in quantity of natural gas purchased with the refinery gross margin is
plotted in Figure 7.2.9
1000
978
GRM (CRORE RS./ANNUM)
980
960 965
940
932
920
900
880
873
860
0 100 200 300 400 500
NATURAL GAS (KTPA)
Figure 7.2.9 : Variation of GRM with natural gas purchase

The above figure indicates that Option 3 is the most optimized case, it gives the highest
GRM. As Natural Gas purchase is increased, the GRM increases simultaneously
subject to a cost of Rs. 40666 per MT.Hence, it is profitable for the refinery to buy more
natural gas at this cost. The scenario will change if the cost of natural gas shoots up.
OPTION D: Variation in Euro V/ Euro IV MS Production
The analysis was performed for one of the optimized cases of the refinery expansion
model i.e. VBU + MS Block Revamp (20%) for Design Case 2 crude mix.
The following options were studied:
Option A: 100% Euro IV MS production

Option B: 100% Euro V MS production
Option C: MS Euro IV: Euro V ratio same as base case ratio of Euro III and Euro IV MS
production.
Euro V MS product specs are maintained same as Euro IV, except for sulphur as
10ppmw max, RON min=95, MON min =95. Euro V MS price is considered by adding
the differential between Euro III and Euro IV MS prices to Euro IV MS price.
The key findings for the above options are listed in Table 7.2.19
Table 7.2.19: Variation in Euro IV/Euro V MS production
Options
Products
A B C
Alkylate purchased 0 135 65
EURO IV MS sales 1680 0 1006
EURO V MS sales 0 1228 617
LAN sales 144 258 250
Open Spec Naphtha
0 403 0
production
FCCU (Old+New) 2047 1778 1927
GRM (Cr Rs./annum) 873 -1580 631
The variation in quantity of alkylate purchased with the production of Euro V MS (for
both MS block revamp = 20% and open) is plotted in Figure 7.2.10

1800
MS 20%
1600 REVAMP
1539
MS REVAMP
1400 OPEN
1200 1228
EURO V MS
1000
800
750
600 617
400
200
0 0
0 50 100 150 200
ALKYLATE
Figure 7.2.10: Variation in Euro IV/V MS production
The above plot indicates that that the Alkylate requirement depends on EURO V MS
production.
Max Alkylate Potential in the refinery = 68.6 KTPA. This is based on the following:
i) 9.8 wt% of Butylenes in LPG of New FCC (1.22MMTPA)

ii) 6.47 wt% of Butylenes in LPG of Old FCC (0.950MMTPA)
Alkylate available : 58.1 KTPA (due to lower operating thru’put of FCCUs)
Outcome of study:
 A new case (processing SDA pitch as feed to VBU) emerged out for future study.
 Production of Euro IV HSD and MS is envisaged for post expansion cases.
Hence all cases should now be run with the objective of producing Euro IV MS
and HSD.
 The efficiency of some of the existing heaters was being improved. Accordingly,
the fuel consumption could be reduced and the same had to be captured in the
LP Model also.

7.2.6.3 DESCRIPTION OF SCREEN OUT REFINERY CONFIGURATIONS

(review meeting held on 30th october 2013)
On the basis of the results and findings of the cases detailed above, the following
residue upgradation options are screened out :
 Visbreaker Unit (VBU),

 Low lift SDA unit
 VBU+Low Lift SDA
Refinery expansion capacity : 10 MMTPA
Expansion Crudes : Two cases of design crude mix were studied:
Design Case 1: Kuwait (100%)(FR:6MMTPA & FRE:4 MMTPA)

(FR:4MMTPA Kuwait+2MMTPA AL,FRE: :2MMTPABH+
2MMTPA AL)
Feed/ product prices: Revised three years average price taken from 2010-2013
Key considerations :
1. SDA with low lift considered for residue upgradation, apart from visbreaker.
2. No alkyalte purchase taken ; since the objective was production of 100% Euro
IV MS.
3. 100% Euro IV diesel Production
4. Hydrogen availability in the refinery= 25KTPA max
5. Natural Gas purchase = 40.8 KTPA (same as per base case)
6. Production of fuel oil bunker (visc<=380cst, sulphur<=3.5 wt%) was also
considered apart from fuel oil 180 cst.
7. The pitch of low lift SDA was considered as feed to the new Visbreaker.
However, it was limited to 15% max of the total VBU feed. . The limit of 15%
has been imposed in order to avoid coking in the VBU furnace.
8. Revamp of MS block units was limited to 20% (considered as feasible through
the existing design margins of the units), and open with no capacity limits (in
order to target zero naphtha sales).

Options Studied:
Design Case 1:
Case 1: Base Case for 10 MMTPA crude thru’put (No Residue Upgradation Unit)
+MS block revamp upto 20%
Case 2: Case 1 +Visbreaker unit (VBU) +MS block revamp upto 20%
Case 3: Case 1+ SDA (low lift) +MS block revamp upto 20%
Case 4: Case 1+ SDA (low lift)+VBU+MS block revamp upto 20%
Case 5: Case 1+ Slurry HCU+MS block revamp upto 20%
Case 6: Case 1+MS block revamp open
Design Case 2:
Case 11: Base Case for 10 MMTPA crude thru’put (No Residue Upgradation Unit)
+MS block revamp upto 20%
Case 12: Case 1 +Visbreaker unit (VBU) +MS block revamp upto 20%
Case 13: Case 1+ SDA (low lift) +MS block revamp upto 20%
Case 14: Case 1+ SDA (low lift)+VBU+MS block revamp upto 20%
Case 15: Case 1+ Slurry HCU+MS block revamp upto 20%
Analysis of Results:
The material balance and unit capacities for all cases were evaluated by LP model. The
economic parameters like gross refinery margin (GRM), refinery net margin (NRM), and
US$/bbl of crude processed were estimated as per methodology explained above under
section 7.2.5
a) Material Balance for cases studied are presented in Table 7.2.20 & 7.2.23
b) Unit capacities for cases studied for this option are presented in Table 7.2.21 &
7.2.24.
c) Economic analysis for cases studied are presented in Table 7.2.22 &7.2.25. GRM
and NRM for all cases are compared in graphical form in Figure 7.2.11 &7.2.12
d) Product profile for cases studied are.presented in Table 7.2.26
e) The MS and HSD product sales, varying from one case to another case are
depicted in graphical form in figure 7.2.13 &7.2.14

Table 7.2.20: Material Balance for Design Case-1
DESIGN CASE-I
STREAM Case-1 Case-2 Case-3 Case-4 Case-5 Case-6 Case-7 Case-8 Case-9 Case-10
LP Case No: 801 909 912 913 917 802 908 903 906 918
FEED (‘000 TPA)
Kuwait Crude 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000
R LNG 41 41 41 41 24 41 41 41 41 41
Additive 0 0 0 0 17 0 0 0 0 19
Total 10041 10041 10041 10041 10042 10041 10041 10041 10041 10059
PRODUCT (‘000 TPA)
LPG 480 511 564 566 600 484 514 564 553 603
LAN 75 0 0 119 0 0 0 0 0 0
Treated HEX 30 30 30 30 30 30 30 30 30 30
MS Euro IV 1566 1647 1704 1722 1670 1655 1807 1882 1889 1737
ATF 600 600 600 600 600 600 600 600 600 600
SKO 52 52 52 52 52 52 52 52 52 52
Euro IV Diesel 2251 2959 2631 3094 4450 2228 2658 2363 2704 4404
FOS 1463 0 2168 1578 0 1463 0 2276 0 5
FO Bunker 1343 2016 0 0 0 1342 2186 0 1980 0
Sulphur 74 88 84 92 167 74 74 66 75 158
150 Neutral-GRI 70 70 70 70 70 70 70 70 70 70
500 Neu tral-GRI 100 100 100 100 100 100 100 100 100 100
Spindle Oil-GRI 15 15 15 15 15 15 15 15 15 15
Spindle Oil-GRII 32 32 32 32 32 32 32 32 32 32
150 Neutral-GRII 76 76 76 76 76 76 76 76 76 76
500 Neutral-GRII 92 92 92 92 92 92 92 92 92 92
Bright Stock 50 50 50 50 50 50 50 50 50 50
Indusrial Oil 100 15 15 15 15 15 15 15 15 15 15
VG-10 920 422 0 0 422 919 422 0 0 422
VG-30 130 628 1050 1050 628 131 628 1050 1050 628
Refinery Fuel 378 393 451 431 569 385 379 449 410 560
Refinery Loss 16 21 21 22 41 16 19 14 19 37
FCCU Coke 94 105 115 115 106 94 104 118 112 106
Slurry Residue 0 0 0 0 140 0 0 0 0 148
Total 10041 10041 10041 10041 10042 10041 10041 10041 10041 10059

Table 7.2.21: Unit Capacities for Design Case-1

DESIGN CASE-I
LP Case No: 801 909 912 913 917 802 908 903 906 918
UNIT CAPACITIES (‘000 TPA)
FR APS/VPS 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000
FRE APS/VPS 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000
MS BLOCK
NSU 744 912 867 822 690 808 867 880 887 760
NHT/ISOM 297 300 294 300 281 345 361 323 344 303
NHT/CCR 654 654 654 654 654 705 741 746 758 700
Prime-G 441 531 576 529 479 439 775 876 855 791
SECONDARY PROCESS UNITS
DHDS UNIT 1210 2270 2105 2270 1887 1210 2179 921 2268 900
DHDT UNIT 2200 1799 2200 2165 2200 2200 831 2200 798 2200
KERO HDT 558 632 0 111 253 554 632 414 632 481
VGO feed pool in DHDT 717 672 983 958 608 717 111 318 146 77
Diesel feed pool in DHDT 1118 678 716 662 1281 1118 599 1720 521 2083
FCC UNITS
NEW FCCU 1081 1276 1277 1277 1178 1081 1231 1368 1277 1177
EXISTING FCC 711 680 950 950 875 711 787 950 950 950
RESIDUE UPGRADATION UNITS
PDA 755 755 755 755 755 755 755 755 755 755
New PDA 0 0 1546 799 0 0 0 1681 799 0
VBU 0 1606 0 1398 0 0 1606 0 1398 0
SHCU 0 0 0 0 1747 0 0 0 0 1854
OTHER UNITS
NEW SRU (TPD) 140 140 140 140 140 140 140 140 140 140
HGU + PSA 19 24 25 25 25 18 13 16 13 25
NEW HGU 0 0 0 0 71 0 0 0 0 69

Table 7.2.22: Economic Analysis for Design Case-1
DESIGN CASE-I
Differential GRM*, Crores Rs./Annum 391 1406 1053 1865 2261 404 1377 1080 1616 2343
Differential NRM Crores Rs./Annum 208 1201 799 1611 1890 213 1226 841 1441 1980
GRM (USD/BBL of crude ) 1.39 3.74 2.92 4.8 5.72 1.42 3.67 2.98 4.22 5.91
*Differential GRM= Case GRM – Base Case GRM, Base Case GRM = 208 Crores Rs./Annum
*Differential NRM= Case NRM – Base Case NRM, Base Case NRM = -28 Crore Rs./Annum
*NRM = GRM – Power Pruchase

Table 7.2.23: Material Balance for Design Case-2

DESIGN CASE-II
CASE NO: Case-11 Case-12 Case-13 Case-14 Case-15 Case-16 Case-17 Case-18 Case-19 Case-20
LP Case No: 801 869 879 880 900 802 868 865 866 901
FEED (‘000 TPA)
KUWAIT CRUDE 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000
ARAB LIGHT 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000
BOMBAY HIGH 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
R LNG 41 41 41 41 11 41 41 41 41 41
ADDITIVE 0 0 0 0 9 0 0 0 0 10
Total 10041 10041 10041 10041 10020 10041 10041 10041 10041 10051
LPG 556 575 546 597 623 542 563 548 601 620
LAN 199 204 195 212 127 0 0 0 0 0
SCN 96 96 96 96 96 96 96 96 96 96
TREATED HEXANE 30 30 30 30 30 30 30 30 30 30
SOLVENT 1425 9 9 9 9 9 9 9 9 9 9
MS EURO IV 1671 1711 1700 1753 1728 1878 1926 1924 1989 1934
MTO 48 48 48 48 48 48 48 48 48 48
ATF 600 600 600 600 600 600 600 600 600 600
SKO 52 52 52 52 52 52 52 52 52 52
EURO IV DIESEL 3532 3695 3607 3736 4316 3432 3595 3513 3697 4274
FO BUNKER 1077 192 707 0 0 1029 0 886 0 0
SULPHUR 55 60 67 59 104 46 51 64 59 102
150 NEUTRAL-GRI 70 70 70 70 70 70 70 70 70 70
500 NEUTRAL-GRI 100 100 100 100 100 100 100 100 100 100
SPINDLE OIL-GRI 15 15 15 15 15 15 15 15 15 15
SPINDLE OIL-GRII 32 32 32 32 32 32 32 32 32 32
150 NEUTRAL-GRII 76 76 76 76 76 76 76 76 76 76
500 NEUTRAL-GRII 92 92 92 92 92 92 92 92 92 92
BRIGHT STOCK 50 50 50 50 50 50 50 50 50 50
INDUSRIAL OIL 100 15 15 15 15 15 15 15 15 15 15
VG-10 422 422 0 0 422 422 422 0 0 422
VG-30 628 628 1050 1050 628 628 628 1050 1050 628
Refinery Fuel 379 380 398 409 459 392 383 409 418 450
Refinery Loss 16 19 17 17 28 11 18 15 17 25
FCCU COKE 102 108 123 117 112 97 103 122 116 112
FOS 0 641 227 688 0 160 948 107 691 0
SLURRY PITCH 0 0 0 0 71 0 0 0 0 81
Total 10041 10041 10041 10041 10020 10041 10041 10041 10041 10051

Table 7.2.24: Unit Capacities for Design Case-2

DESIGN CASE-II
CASE NO: Case-11 Case-12 Case-13 Case-14 Case-15 Case-16 Case-17 Case-18 Case-19 Case-20
LP Case No: 801 869 879 880 900 802 868 865 866 901
CRUDE BLOCK
FR APS/VPS 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000
FRE APS/VPS 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000
MS BLOCK
NSU 744 749 742 757 778 989 998 990 1020 943
NHT/CCR 654 654 654 654 654 788 798 795 810 791
NHT/ISOM 300 299 299 299 300 415 409 393 368 375
PRIME-G 455 495 576 551 519 737 780 739 576 813
DHDS UNIT 1495 2270 1627 1765 1794 641 2270 1166 1704 871
DHDT 2200 1759 2200 2200 2200 2200 998 2200 2200 2200
KERO HDT 539 402 555 500 533 525 397 629 502 632
VGO feed pool in DHDT 481 480 526 486 477 14 15 323 467 21
Diesel feed pool in DHDT 1459 993 1401 1421 1425 2163 946 1712 1471 2168
FCC UNITS
NEW FCCU 1099 1192 1277 1334 1254 1042 1134 1277 1320 1257
EXISTING FCC 950 950 950 950 950 950 950 950 950 950
PDA 755 755 755 755 755 755 755 755 755 755
NEW PDA 0 0 519 631 0 0 0 519 632 0
VBU 0 729 0 561 0 0 732 0 565 0
SHCU 0 0 0 0 882 0 0 0 0 1018
OTHER UNITS
HGU 22 23 24 25 25 15 15 18 21 25
NEW HGU 0 0 0 0 35 0 0 0 0 33

Table 7.2.25: Economic Analysis for Design Case-2
DESIGN CASE-II
Case- Case Case Case Case Case Case Case- Case Case
11 -12 -13 -14 -15 -16 -17 18 -19 -20
Differential GRM*, Crores
734 989 829 1163 1203 715 1001 837 1234 1329
Rs./Annum
Differential NRM Crores
546 799 609 937 912 537 847 609 997 1030
Rs./Annum
GRM(USD/BBL of crude) 2.14 2.72 2.36 3.12 3.21 2.1 2.75 2.37 3.28 3.49
*Differential GRM= Case GRM – Base Case GRM, Base Case GRM = 208 Crores Rs./Annum
*Differential NRM= Case NRM – Base Case NRM, Base Case NRM = -28 Crore Rs./Annum
*NRM = GRM – Power Purchase
Table 7.2.26: Product Yield* of Design Case-I /Design Case II (MS Block 20%
Revamp)
Case - 1/11 Case -2/12 Case - 3/13 Case- 4/14 Case -5/15
Light Distillates (Wt%) 21.3/25.5 21.8/26.1 23.0/25.6 24.2/26.7 22.8/26.0
Middle Distillates (Wt%) 29.0/42.3 36.0/43.9 32.8/43.1 37.4/44.4 51.0/50.2
Heavy Distillates (Wt%) 39.2/21.6 31.2/19.2 32.6/20.3 27.1/17.2 13.4/12.2
LOBS (Wt%) 4.5/4.5 4.5/4.5 4.5/4.5 4.50/4.5 4.5/4.5
Fuel And Loss (Wt%) 6.1/6.1 6.4/6.2 7.0/6.6 6.8/6.6 8.3/7.2
*Product yield is based on crude.

The following figure indicates the differential GRM (crore Rs./annum) and differential
NRM (crore Rs./annum) of the various upgradation option for Design Case 1, with MS
block revamp upto 20%.
Figure 7.2.11: Economic Analysis for Design Case -1 (MS Block 20%
Revamp)
The following figure indicates the differential GRM (crore Rs./annum) and differential
NRM (crore Rs./annum) of the various upgradation option for Design Case 2, with MS
block revamp upto 20%.
Figure 7.2.12: Economic Analysis for Design Case -2 (MS Block 20%
Revamp)

The following figure indicates the diesel production (KTPA) for Design Case 1, with MS
block revamp upto 20% and MS block revamp open.
5000
4450 4404
4500
4000
3500 3094
2959
3000 2658 2631 2704
2228 2363
2500 2251 2494
2000
1500
1000
500
0
NO RESID VBU CASE Low Lift SDA VBU+Low Lift SDA SLURRY
UPGRADATION HYDROCRACKER
MS BLOCK 20% REVAMP CASE
MS BLOCK OPEN
Linear (BASE CASE)
Figure 7.2.13: Euro IV HSD Product Sales Design Case 1
The following figure indicates the diesel production (KTPA) for Design Case 2, with MS
block revamp upto 20% and MS block revamp open.
5000
4316 4274
4500
4000 3695 3595 3607 3736 3697
3532 3432 3513
3500
3000
2500 2494
2000
1500
1000
500
0
NO RESID VBU CASE Low Lift SDA VBU+Low Lift SDA SLURRY
UPGRADATION HYDROCRACKER
MS BLOCK 20% REVAMP CASE
MS BLOCK OPEN
Linear (BASE CASE)
Figure 7.2.14: Euro IV HSD Product Sales Design Case 2

7.2.7 ANALYSIS FOR CHECK CASE CRUDE MIX
The following check case has been done in order to study the impact of processing
a different crude mix in the expansion refinery configuration.
The findings are as following:
Crude Case 12 Check Case

KUWAIT CRUDE 4000.0 5000.0
ARAB LIGHT 4000.0 2000.0
BOMBAY HIGH 2000.0 3000.0
R LNG 40.8 40.8
Products Case 12 Check Case

LPG 574.8 554.3
LAN 204.3 292.0
MS EURO IV 1711.4 1707.3
EURO IV DIESEL 3694.5 3668.6
IF1 640.9 819.5
BUNKER FUEL OIL 192.2
The Unit capacities comparison is as follows:

Crude Case 12 Check Case
NEW FCCU 1192.1 1174.0
EXISTING FCC 950.0 934.1
PRIME-G 495.4 488.1
NHT/CCR 654.0 654.0
DHDS UNIT 2270.0 2270.0
HYDROGEN UNIT 23.4 20.5
DHT 1758.9 1414.7
NHT/ISOM 299.0 299.0
VISBREAKER 729.2 649.0
Crude Case-12 Check Case

GROSS MARGIN 1196.8 1633.2

7.2.8 KEY OBSERVATIONS OF THE CONFIGURATION STUDY
The key observations from the results of configurations study as presented in

Tables 16.1 to 16.8 are as follows:
Product Slate
 Diesel production is maximum in case of Slurry HCU and minimum in No

residue upgradation case due to use of middle distillate as cutter stock in Fuel
oil blend. This trend is valid for both the design cases.
 In Slurry HCU cases, the production of slurry pitch is quite huge and there is
big concern for the disposal of slurry pitch.
 Fuel consumption including losses are in the range of 6 ~ 8.5 wt% on total
Crude processed.
 The fuel oil production is zero in Slurry HCU case and maximum in no residue
upgradation case. This trend is valid for both the design cases.
Unit Capacities
 Quantity of Vacuum residue in Design Case 1 is 2742 KTPA, where as the

same in Design Case 2 IS 2009 KTPA. So, the capacity of the new residue
upgradation unit is higher in Design Case 1 than in Design Case 2.
 In Slurry hydrocracker case, a new Hydrogen generation unit is required in
the configuration. Its capacity is 36 KTPA in Design Case 2 and 70 KTPA in
Design Case 1.
 For 100% HS crude processing (as in Design Case 1), a new Sulphur
Recovery Unit of capacity ~ 140 TPD is required.
Economic Analysis
 Cases with SHCU configurations have maximum sales revenue as well as

would require maximum capital investment. Due to high GRM, US dollar per
barrel of crude processing is highest in these cases.
Based on the results of configuration study, standalone VBU, SDA and Slurry
HCU are compared in the following table.

Table 7.2.27: Comparison of key features of VBU, SDA and Slurry HCU
VBU SDA SHCU
Salient Features
Conversion: 30wt% Conversion 52% (High  Conversion 90-94wt%
Lift)  High conversion thermal
cracking in the presence of
Conversion 25% (Low hydrogen + catalyst/ additive
Lift)  Reactor Pressure 140/
210barg
 Slurry phase , plug flow
reactor
Pros
Lower Capex  Lower Capex  Reactor configuration specific

Less space  Less space to licensors
requirement requirement  Wide variety of feedstock like
Proven  Proven technology VR, Pitch, Tar sands, VB Tar
technology  Flexibility to handle a  Depending on technology,
Flexibility to wide range of feeds products may or may not need
handle a wide even with poorer treating
range of feeds quality
even with poorer  NIL Hydrogen
quality consumption
NIL Hydrogen
consumption
Cons
Products need  Disposal of Asphalt  Pilot plant studies extensive,
severe however Commercial
hydroprocessing operating reference not
Fuel Oil available
production  Issues related to disposal of
pitch and its transport
logistics
 Catalyst – in-situ production

7.2.9 CONCLUSIONS
In no residue upgradation case, there is high fuel oil generation. A huge quantity
of middle distillates go for fuel oil blending as cutter stock. Thus, the refinery
margin is lowest among all options.
This proves that as the refinery aims to process heavy sour crudes in future,
Residue upgradation becomes indispensable.
For low lift SDA standalone case, the capacity of this unit is governed by the
bitumen demand of the refinery. As the same is limited to 1050 KTPA, the SDA
capacity also gets fixed accordingly. There is no incentive for running this unit at
a higher thru’put and generating more DAO (as FCC feedstock) as there is no
favorable disposal of the excess SDA pitch. This leaves a large quantity of
Vacuum Residue TO BLEND into fuel oil. The yields of middle distillates go
down in the process and hence, the gross refinery margin suffers.
The analysis of the various alternatives of Residue Upgradation units in the

HPCL Mumbai configuration predicts that the most preferable options are:
 Slurry Hydrocracker
Hydroprocessing in a slurry bed results in high conversion (90-94%). The

distillate yields are significantly high and benefits the refiner owing to high
sales revenue. It meets one of the objectives of this study by diminishing
fuel oil sales. Also by going for this technology, there is flexibility for the
refiner to process heavier feedstock.
The only concerns are a high capital investment and disposal of the slurry
pitch.
 Visbreaker
This option gives a fairly high yield of middle distillates. It is a proven

technology and requires no auxilliery units (such as HGU, etc). The space
requirement is low and it needs relatively low Capital investment,
Even though VBU+ Low lift SDA option yields higher GRM than VBU case, but
the same is not shortlisted as it calls for high Capital investment (due to two new
units- VBU and SDA).

7.2.10 DESCRIPTION OF SHORTLISTED CASES
The expansion phase for the existing refinery includes the following:
 Revamp of FRAPS upto a crude thru’put of 6 MMTPA as per the

modifications suggested in PCS BEDP.Piping modifications in the crude
preheat network of FR as the FR crude preheat train would require to utilize
all the heat available from FRVPS side streams.
 Installing a new VPS unit (VDU) for processing equivalent quantity of RCO
 Dismantling the existing FRVPS and LRVPS units.
 A new Visbreaker unit, as an option of residue upgradation: This would

improve high sulfur and heavier crude processing capability and also
improve distillate yield for value addition by reduction of cutter in fuel oil
pool.
On basis of the detail economic screening of various refinery configuration, the

following is finalized for detail feasibility report:
Refinery expansion capacity : 9.5 MMTPA
Crude Mix : Two cases of design crude mix were studied:
Design Case 1: 6 MMTPA Kuwait (FR)+3.5 MMTPA BH(FRE)

Design Case 2: 6 MMTPA Arab Light(FR)+3.5 MMTPA BH(FRE)
Feed/ product prices: Three years average price taken from 2011-2014, as
furnished by HPCL on 19th August 2014
Key considerations :
1. No alkyalte purchase taken ; since the objective was production of 100% Euro
IV MS.
2. 100% Euro IV diesel Production
3. Natural Gas purchase = 24KTPA (upto a maximum of 30KTPA)
4. Production of fuel oil bunker (visc<=380cst, sulphur<=3.5 wt%) was also
considered apart from fuel oil 180 cst.However, blending of FCCU streams
(Resid, LCO, etc) is restricted.
5. The pitch of low lift SDA was considered as feed to the new Visbreaker.
However, it was limited to 15% max of the total VBU feed.

6. Revamp of MS block units was limited to 20% (considered as feasible through

the existing design margins of the units), and open with no capacity limits (in
order to target zero naphtha sales).
7. Minimum new FCCU capacity = 130 m3/hr
8. Minimum old FCCU capacity = 90m3/hr, with a CCR wt% in FCC feed =0.2 to
0.5.
Options Studied:
Option (A): Variations in Residue Upgradation Units (considering 20% MS block)

Case - 1: No Residue Upgradation Unit for Design Case 1
Case - 2:Visbreaker unit (VBU) for Design Case 1
Case - 3: No Residue Upgradation Unit for Design Case 2
Case - 4:Visbreaker unit (VBU) for Design Case 2
Option (B): MS block revamp open for Euro IV MS production

Option (C): 100% Euro V MS production
Option (A): Variations in Residue Upgradation Units (considering 20% MS

block)
The material balance and unit capacities for all cases were evaluated by LP
model. The economic parameters like gross refinery margin (GRM), refinery net
margin (NRM) and US$/bbl of crude processed were estimated as per
methodology explained above under section 11.
a) Material Balance for cases studied are presented in Table 7.2.28
b) Unit capacities for cases studied for this option are presented in Table 7.2.30
c) Economic analysis for cases studied are presented in Table 7.2.31.
The material balance for the various cases of refinery expansion is given in Table
7.2.28
Table 7.2.28: Material Balance for Expansion case

Case no. 1 2 3
Case description Kuwait Kuwait Arab Light
No Resid VBU No Resid
LP Case No: 950 953 940
FEED (‘000 TPA)
Bombay High 3500 3500 3500
Arab Light 0 0 6000
Kuwait 6000 6000
R LNG 24 24 24
Total 9524 9524 9524
LPG 478 483 557
LAN 94 125 173
Special Cut Naphtha 96 96 96

Treated Hexane 30 30 30
Solvent 1425 9 9 9
MS EURO IV 1691 1695 1739
MTO 48 48 48
ATF 600 600 600
SKO 52 52 52
Euro IV Diesel 3223 3429 3838
Fuel Oil 180 cst 547 841 250
FO Bunker 550 0.0 0
Sulphur 59 65 65
150N Group I 70 70 70
500N Group I 100 100 100
SPINDLE OIL-GRI 15 15 15
SPINDLE OIL-GRII 32 32 32
150N Group II 76 76 76
500N Group II 92 92 92
Bright Stock 50 50 50
Industrial OIL 100 15 15 15
VG-10
594 423 640
Bitumen
VG-30
456 627 410
Bitumen
Fuel & Loss 547 551 567
Total 9524 9524 9524

Key findings:
1. There is excess naphtha produced in all the cases that goes for sales. This mainly
consists of straight run light naphtha (C5-120°C). This can be minimized if the
revamp of MS block units (NHT/ISOM, NHT/CCR and Prime-G) is kept open.
2. Diesel production is higher in Arab Light cases than in Kuwait cases. Comparing
the no residue upgradation options, the diesel production is 3223 KTPA in Kuwait
case whereas 3838 KTPA (19% higher) in Arab Light case.
This is because the yield of middle distillates is higher in the case of Arab Light
crude. The same is indicated as follows :
Arab Light Kuwait

Kero (wt% yield) 16.9 14.4
Diesel (wt% yield) 25.4 22.8
3. Fuel oil production is higher in Kuwait cases as compared to Arab Light cases.
Comparing the no residue upgradation options, the fuel oil production is 1097
KTPA in Kuwait case whereas 250 KTPA in Arab Light case.
This is because the yield of Vacuum Residue is higher in Kuwait crude. The
comparison is as follows :
(wt% yield) Arab Light Kuwait

Vacuum residue 18.4 28.3
4. For Arab Light crude, Visbreaker unit is not required since there is negligible
quantity of Arab Light VR , as shown in table below, left for Fuel oil sales.
Table 7.2.29 : VR disposition in Case 3
VR streams Quantity (KTPA)

Arab Light (AL) VR from new FRVPS 1106
Bombay High (BH) VR from FREVPS 244
Total production 1350
AL VR to PDA unit 755
AL VR to Bitumen blending 344
Balance AL VR to FO 180cst blend 7
BH VR to new FCCU 80
BH VR to internal fuel oil 136
Balance BH VR to FO 180cst blend 27
Total consumption 1350

5. Fuel oil production gets reduced with the operation of the Visbreaker Unit due to
less cutter requirement. Comparing the Kuwait cases, the fuel oil production is
1097 KTPA in no residue upgradation case whereas 841 KTPA (reduced by 23%)
in VBU case.
The unit capacities for the various cases of refinery expansion are given in the following
table.
Table 7.2.30: Unit Capacities for Expansion Case

Case no. 1 2 3
Design
Capacity
LP Case No: 950 953 940
CRUDE BLOCK
4260(Bas/Kuw)
FR APS 6000 6000 6000
4400 (AL/AM
NEW VPS 3401 3401 3086
3570 (BH)
FRE APS 3500 3500 3500
3710 (AXL
1390(PG)
FRE VPS 1179 1179 1179
1210(BH)
MS BLOCK
NSU 1222 933 868 737
NHT/ISOM 250 300 (20) 300 (20) 300 (20)
NHT/CCR 545 654 (20) 654 (20) 654 (20)
Prime-G 475 484 (2) 423 (0) 480 (1)
DHDS UNIT 2270 1757 1971 2270
DHDT UNIT 2200 1100 1100 1617
VGO feed pool in DHDT 109 109 433
Diesel feed pool in DHDT 822 799 894
FCC UNITS
NEW FCCU 1456 1171 1019 1158
OLD FCCU 950 661 834 828
PDA 755 755 755 755
VBU 0 564 0
OTHER UNITS
DHDS + DHDT SRU (TPD) 130+130 177 195 196
HGU 18.25 9.5 10.8 19.3
PSA 4.6 4.5 5.2
():indicates % revamp.

Key findings:
1. The Fluidized Catalytic cracking units (FCCUs) of the refinery are not saturated
even after increase in crude thru’put post refinery expansion.
The minimum operating capacity of Old FCCU and new FCCU are given as 90
m3/hr and 140m3/hr respectively in the LP Model.
2. DHDT runs at 50% of its design capacity. This happens because there is not
enough generation of distillates (post refinery expansion) to saturate both DHDS
(2.27 MMTPA) and DHDT (2.2 MMTPA). The LP prefers processing diesel in
DHDS more than in DHDT owing to the higher consumption (per unit of feed) of
utilities in DHDT.
3. The CCR (Conradson carbon residue) wt % of new FCCU feed pool in each of the
cases is as follows:
Case CCR wt% of New Yields of new FCCU

Description
no. FCCU feed pool considered same as
Kuwait no residue upgradation Check case yields (3.4
1 2.69
case wt%)of Post Cat cooler
2 Kuwait Visbreaker case 2.31 project*
Arab Light no residue
3 2.21
upgradation case
4. There is no requirement of a new Sulphur recovery unit (SRU). The existing two
units (DHDS SRU and DHDT SRU) will suffice in the post refinery expansion
phase also. The detail sulphur balance of the refinery is given in Section 7.3 i.e
Process description of the DFR.
ECONOMIC ANALYSIS
The economic analysis for the cases described above are tabulated as follows:
Table 7.2.31: Economic Analysis for Expansion Case

Case no. 1 2 3
LP Case No: 950 953 940
Differential GRM*, Crores Rs./Annum 332 731 483
Differential NRM Crores Rs./Annum 236 635 334
GRM (USD/BBL of crude 2.6 3.56 2.93
*Differential GRM= Case GRM – Base Case GRM, Base Case GRM = 759 Crores
Rs./Annum
*Differential NRM= Case NRM – Base Case NRM, Base Case NRM = 522 Crore
Rs./Annum
*NRM=GRM–PowerPurchase

It is evident from the above that Case 4 (expansion phase with VBU and Kuwait + BH
crude mix) gives the maximum refinery margin.
Option (C): MS block revamp open for Euro IV MS production
One of the objectives of the Configuration study was to target zero naphtha sales.
However, as the revamp of MS Block units (NHT/ISOM, NHT/CCR and Prime-G) was
limited to 20%, the excess naphtha sales could not be completely eliminated.
LP Runs were done keeping the revamp of MS block units open for no residue
upgradation options(for Kuwait crude) of the expansion case. The findings are
tabulated below.
Description of cases :
Case 3 : No residue upgradation in Expansion Phase + MS Block revamp 20%

(LP Case no. 950)
Case 3M: No residue upgradation in Expansion Phase + MS Block revamp open’

(LP Case no. 956)

The material balance for the above described cases is given below:
Table 7.2.32 : Material balance for MS block revamp cases

Case no. 3 3M
LP Case No: 950 956
FEED (‘000 TPA)
Bombay High 3500 3500
Kuwait 6000 6000
R LNG 24 24
Total 9524 9524
LPG 478 485
LAN 94 0
Special Cut Naphtha 96 96
Treated Hexane 30 30
Solvent 1425 9 9
MTO 48 48
ATF 600 600
SKO 52 52
Fuel Oil 180 cst 547 557
FO Bunker 550 540
Sulphur 59 59
150N Group I 70 70
500N Group I 100 100
SPINDLE OIL-GRI 15 15
SPINDLE OIL-GRII 32 32
150N Group II 76 76
500N Group II 92 92
Bright Stock 50 50
Industrial OIL 100 15 15
Fuel & Loss 547 557
Total 9524 9524

The unit capacities for the above described cases is given below:
Table 7.2.33 : Unit capacities for MS block revamp cases

Design 3 3M
LP Case No: Capacity 950 956
CRUDE BLOCK
4260(Bas/Kuw)
FR APS 6000 6000
4400 (AL/AM
FR VPS 1086
LR VPS 1086
New VPS 3401 3401
3570 (BH)
FRE APS 3500 3500
3710 (AXL
1390(PG)
FREVPS 1179 1179
1210(BH)
MS BLOCK
NSU 1222 933 875
NHT/ISOM 250 300 (20) 397 (59)
NHT/CCR 545 654 (20) 779 (43)
Prime-G 475 484 (2) 421 (0)
DHDS UNIT 2270 1757 1655
DHDT UNIT 2200 1100 1100
Diesel feed in DHDT 822 941
VGO feed l in DHDT 109 106
FCC UNITS
New FCCU 1456 1171 1019
Old FCCU 950 661 797
PDA 755 755 755
VBU 0 0
OTHER UNITS
HGU 18.25 9.5 6.7
PSA 4.6 4.8
The comparison of Economic analysis is given below:
Table 7.2.34: Economic Analysis for MS block revamp cases

3 3M
LP Case No: 950 956
Differential GRM*, Crores 391
332
Rs./Annum
Differential NRM Crores 284
236
Rs./Annum
GRM (USD/BBL of crude 2.6 2.74
Hence, as can be inferred from above, with the revamp of MS block units
open, the naphtha sales is extinguished, leading to increase in MS
(gasoline) sales.

In order to target zero naphtha sales, the following is the requirement of revamp of
MS block units:
Maximum revamp of NHT/ISOM =59%

Maximum revamp of NHT/CCR = 43%
Maximum revamp of Prime-G = 0%
OPTION(C): 100% EURO V MS PRODUCTION
Feasibility of production of Euro V MS was carried out or the expansion refinery.
The same was checked for the following expansion case:
Case no. 4: FRAPS revamp + new VPS + Visbreaker + MS block revamp upto
20% (LP Case no. 953)
Case no. 4M5:100 % MS Euro V production in Case 4 (LP Case no. 963)
Key considerations
 The product specification for MS Euro V is considered same as MS Euro IV ,

with sulphur reduced to 10 ppmw.
 Also, the revamp of MS block units was kept open for Cases E and G.
 The price of Euro V MS has been arrived by adding the differential between
Euro III and Euro IV MS to the price of Euro IV MS.
 Prime G naphtha sulphur is considered as 15 ppmw, as per the feedback
from HPCL.
The material balance is tabulated as follows:
Table 7.2.35 : Material balance for Euro V production cases

4 4M5
LP Case No: 953 963
FEED (‘000 TPA)
Kuwait 6000 6000
R LNG 24 24
Total 9524 9524
LPG 483 500
LAN 125 0
Solvent 1425 9 9
MS EURO IV 1695 0
MS EURO V 0 1934
MTO 48 48
ATF 600 600

4 4M5
LP Case No: 953 963
SKO 52 52
FO Bunker 0 0
Sulphur 65 65
150N Group I 70 70
500N Group I 100 100
150N Group II 76 76
500N Group II 92 92
Bright Stock 50 50
VG-10 514
423
Bitumen
VG-30 536
627
Bitumen
Fuel & Loss 551 572
Total 9524 9524
The comparison of unit capacities is as follows:
Table 7.2.36: Unit Capacities for Euro V production cases

4 4M5
Design Capacity
LP Case No: 953 963
CRUDE BLOCK
4260(Bas/Kuw)
FR APS 6000 6000
4400 (AL/AM
FR VPS 1086 1026 1026
LR VPS 1086 1026 1026
3570 (BH)
FRE APS 3500 3500
3710 (AXL
1390(PG)
FREVPS 1349 1349
1210(BH)
MS BLOCK
NSU 1222 868 1009
NHT/ISOM 250 300 (20) 470 (88)
NHT/CCR 545 654 (20) 817 (50)
Prime-G 475 423 (0) 723 (52)
DHDS UNIT 2270 1971 1712
DHDT UNIT 2200 1100 1100
Diesel feed pool in DHDT 799 1014
VGO feed pool in DHDT 109 0
FCC UNITS
New FCCU 1456 1019 1088
Old FCCU 950 834 808

4 4M5
Design Capacity
LP Case No: 953 963
PDA 755 755 755
VBU 0 0
OTHER UNITS
HGU 18.25 10.8 7.94
PSA 4.5 5.41
() indicates % revamp
Table 7.2.37: Economic Analysis for Euro V production case

4 4M5
LP Case No: 953 963
Differential GRM*, Crores Rs./Annum 731 822
Differential NRM Crores Rs./Annum 635 698
GRM (USD/BBL of crude ) 3.56 3.77
Hence, as can be inferred from above, the refinery post expansion is capable of
producing 100% Euro V MS.
In order to target production of MS Euro V, huge capacity expansion is required
in all the MS block units.
7.2.11 FINE TUNING OF THE BASE CASE AND EXPANSION CASE
Post submission of Draft DFR, the base case and the selected expansion case
were further modified based on the following considerations:
1. The Crude mix for Base Case was made consistent with the Expansion case.
Design crude mix for Base Case: 4 MMTPA Kuwait (FR) + 3.5 MMTPA BH
(FRE)
Design crude mix for Expansion Case: 6MMTPA Kuwait (FR) + 3.5 MMTPA
BH (FRE)
2. The properties of reformate from NHT/CCR were revised (as per HPCL email
dated 7th November 2014), in order to match with the existing operating case.
The revised reformate properties, as considered in the revised LP runs, are

given below:
Table 7.2.38: Revised Reformate Properties
REFORMATE UNITS VALUE
PROPERTY
Specific gravity 0.8174
Research Octane no. 100
Reid Vapor Pressure psia 3.4
Sulphur Wt% 0.0001
Benzene Vol% 0.5
Aromatics Vol% 68
Olefins Vol% 1.4

3. The product yield of CCR was also revised (as per HPCL email dated 28th
October 2014) in order to match the operating yields. The table below indicates
the revised CCR yields:
Table 7.2.39: CCR unit details

Parameters units value
Feed N+2A Vol% 56.5
H2 Yield Wt% 2.39
Reformate yield Wt% 92.1
LPG yield Wt% 1.65
Off gas Wt% 5.53
4. The hydrogen consumption in MSDW/RHDT was revised to 12 TPD in order to

make it consistent with the operating data.
5. The power produced in the CPP of the refinery was reduced to 13 MW from 49
MW. The balance power was imported from grid.
6. The naphtha consumed in order to generate 1 MW of electricity in the refinery
gas turbines was reduced from 0.35 Tons to 0.3125 Tons, as per feedback
obtained from HPCL.
7. The steam produced per ton of fuel oil fired in Utility boilers was improved from
12.17 tons to 14 tons.
8. The recovery of hydrogen from refinery off gases was not considered. The
balance hydrogen requirement was met from a new hydrogen generation unit.
9. The prices were revised as per HPCL email dated 11th December 2014
Revised Cases studied:
1. New Base Case

2. Revised Expansion cases
Option A: Variations in Residue upgradation unit (considering 20% MS
block revamp and VGO hydrotreating in DHDT)
Case 1: No residue upgradation unit
Case 2: Visbreaker unit (VBU)
Option B: MS block revamp open for Euro IV MS production

Case 3: VBU for residue upgradation unit + MS block revamp open
Option C: Requirement of hydrotreating VGO in DHDT

Case 4: VBU for residue upgradation unit + MS block revamp open + No VGO
hydrotreating in DHDT.
3. Revised SHCU Case.

7.2.11.1 New Base Case
Material balance for base case (existing refinery configuration) for the revised
crude mix is tabulated below in table 7.2.40.
Table 7.2.40: Material Balance for Base case
Feeds
Bombay High 3500 46.5
Kuwait 4000 53.2
Natural gas 24 0.3
Products
Liquefied Petroleum Gas 332 4.4
LAN 272 3.6
Special cut naphtha 96 1.3
Treated Hexane 30 0.4
Solvent 1425 8.5 0.1
MS Euro III 1075 14.3
MS Euro IV 0 0.0
SKO 52 0.7
ATF 600 8
MTO 48 0.6
HSD Euro III 1810 24
HSD Euro IV 776 10.3
LDO 88 1.2
Fuel Oil 567 7.5
Bitumen 707 9.4
LOBS Production
Spindle oil Group I 15
Spindle oil Group II 19
5.8
Bright Stock 61
Industrial Oil 100 9
Rubber Processing Oil 70 0.9
Sulphur 37 0.5

Unit capacity utilization

The design capacities and its utilization in base case is given below in Table
7.2.41:
Table 7.2.41: Unit capacities Utilization in Base case
Primary Processing Units
FR APS/VPS 4400 4000
FRE APS/VPS 3000 3500
PDA 755 755
FCCU (Existing +New) 2227 1430
Middle Distillate Treating Units
DHDS 2270 940
DHDT 2200 1140
Light Distillate Treating Units
NSU 1222 903
NHT/ISOM 250 175
NHT/CCR 545 445
PRIME G 475 531
HGU 14.5 19.2
Power Plant
5 Gas Turbines 48 MW 13 MW
Economic Summary
Based on the prices of crudes and products as given in the Design Basis (Section
4) and quantities of crude and products as listed above in Table 7.2.40, economic
evaluation for the base case is summarized below in Table 7.2.42
Table 7.2.42: Economic Summary of Base case

Economic Parameters Based on 3 Yr Avg Price (2011-14)
Gross Margin ( Rs Crore / Annum) 540
Power purchase ( Rs Crore / Annum) 466
Net Refinery Margin ( Rs Crore / Annum) 74
US $/ bbl of Crude 1.62
Note : The economic summary for Base Case is based on crude prices , without
octroi recovery.

7.2.11.2 Revised Expansion Case
Option (A): Variations in Residue Upgradation Units (considering 20% MS

block)
In order to assess the impact of a new residue upgradation unit in the expansion
phase, the following cases were studied:
Case 1: No residue upgradation unit
Case 2: Visbreaker unit (VBU)
The revamp of MS block units (NHT/ISOM, NHT/CCR and Prime-G) was limited
upto 20%. DHDT was considered to be operating on dual mode- for Hydrotreating
diesel and VGO.
The material balance for the various cases of refinery expansion is given in Table
7.2.43
Table 7.2.43: Material Balance for Expansion cases
Case no. 1 2
Case description Kuwait Kuwait
No Resid VBU
LP Case No: 990 987
FEED (‘000 TPA)
Arab Light 0 0
Kuwait 6000 6000
R LNG 24 24
Total 9524 9524
LPG 464 471
LAN 191 238
Solvent 1425 9 9
MTO 48 48
ATF 600 600
SKO 52 52
Euro IV Diesel 3266. 3466
FO Bunker 557 0.0
Sulphur 78 67
150N Group I 70 70
500N Group I 100 100
150N Group II 76 76

Case no. 1 2
No Resid VBU
LP Case No: 990 987
500N Group II 92 92
Bright Stock 50 50
VG-10
593 505
Bitumen
VG-30
457 545
Bitumen
Fuel & Loss 541 551
Total 9524 9524
The unit capacities for the various cases of refinery expansion are given in the following
table.
Table 7.2.44: Unit Capacities for Expansion Case

Case no. 1 2
Design
No Resid VBU
Capacity
LP Case No: 990 987
CRUDE BLOCK
4260(Bas/Kuw)
FR APS 6000 6000
4400 (AL/AM
NEW VPS 3401 3401
3570 (BH)
FRE APS 3500 3500
3710 (AXL
1390(PG)
FRE VPS 1179 1179
1210(BH)
MS BLOCK
NSU 1222 1022 939
NHT/ISOM 250 300 (20) 300 (20)
NHT/CCR 545 654 (20) 654 (20)
Prime-G 475 424 (0) 425 (0)
DHDS UNIT 2270 1794 2034
DHDT UNIT 2200 1100 1100
FCC UNITS
NEW FCCU 1456 1019 1019
OLD FCCU 950 778 813
PDA 755 755 755
VBU 0 565
OTHER UNITS
HGU 14.5 14.5 14.5
New HGU 6.15 8.1

Mode of Operation of DHDT Unit
In Expansion Case, Annual VGO feed to DHDT is 147042 tonnes

Capacity of DHDT in VGO Mode is 4368 TPD
No. of Operating days required to process VGO is 34 days.
Annual Diesel Feed to DHT is 877967 tonnes

DHT capacity to be considered based on available operating days is 3768 TPD.
Operating days for DHT in Diesel mode is 233 days
Total no. of operating days of DHT in Diesel and VGO mode is 267 days
Shutdown days considered for the unit is 32 days
Changeover days from Diesel VGO vice versa is 66 days
ECONOMIC ANALYSIS
The economic analysis for the cases described above are tabulated as follows:
Table 7.2.45: Economic Analysis for Expansion Case

Case no. 1 2
No Resid VBU
LP Case No: 990 987
*Differential GRM= Case GRM – Base Case GRM, Base Case GRM = 540
Crores Rs./Annum
Rs./Annum
As can be referred from the Economic Analysis, the differential GRM for VBU (Case
2) is higher than No residue upgradation option (Case 1). The salient features of the
expansion cases, vis-a vis the base case, are as follows:
1. Feed Stock price per MMTPA for Base case is Rs 4568 Cr/Annum where as the
same for Expansion case is Rs 4527Cr/Annum due to increase in low cost
Kuwait Crude processing from 4MMTPA to 6 MMTPA. This results into decrease
in feed stock price which ultimately leads to Higher GRM.
2. LPG produced in the Expansion case is high due to increase in crude
processing capacity and higher FCC thru'put (in expansion case).

3. LAN in expansion case is lower than that in Base Case due to revamp in MS
block units (NHT/ISOM and NHT/CCR) by 20%.
4. Prorating the crude processing capacity, the MS produced in expansion case
should be (9.5/7.5)*1075=1361 KTPA. However, MS produced in case 2 is even
more than 1361 KTPA due to higher FCC thru'put.
5. The production of diesel improves in Case 2 over base case due to increase in
refinery crude thru’put, higher FCCU capacity and operation of a new VBU.
6. Prorating the crude processing capacity, fuel oil in expansion case should be
(9.5/7.5)*567=718KTPA.
FO produced in case 2 is even more than 718 KTPA. This is due to higher yield
of Vacuum residue (VR) in expansion Case. VR in expansion case =1944 KTPA
(20.5 wt%) whereas the same in Base Case is 1289 KTPA (17.1wt%).
Case 1 has no residue upgradation unit. Thus, FO production is high as large
quantity of VR gets dumped into FO pool.
Option (B): MS block revamp open for Euro IV MS production
One of the objectives of the DFR study was to target zero naphtha sales.
However, as the revamp of MS Block units (NHT/ISOM, NHT/CCR and Prime-G)
was limited to 20%, the excess naphtha sales could not be completely
eliminated.
LP Runs were done keeping the revamp of MS block units open for Visbreaker
option (for Kuwait crude) of the expansion case. The findings are tabulated
below.
Description of cases :
Case 2 : Visbreaker unit in Expansion Phase + MS Block revamp 20% (LP Case
no. 987)
Case 3: Visbreaker unit in Expansion Phase + MS Block revamp open’

(LP Case no. 988)


Case no. 2 3
Case description Kuwait
Kuwait
VBU+MS
VBU+MS
block
block
revamp
revamp 20%
open
LP Case No: 987 988
FEED (‘000 TPA)
Kuwait 6000 6000
R LNG 24 24
Total 9524 9524
LPG 471 480
LAN 238 0
Solvent 1425 9 9
MTO 48 48
ATF 600 600
SKO 52 52
FO Bunker 0.0
Sulphur 67 67
150N Group I 70 70
500N Group I 100 100
150N Group II 76 76
500N Group II 92 92
Bright Stock 50 50
VG-10
505 514
Bitumen
VG-30
545 536
Bitumen
Fuel & Loss 551 561
Total 9524 9524

Case no. 2 3
Kuwait
VBU+MS
VBU+MS
Design block
Capacity
block revamp
revamp
open
20%
LP Case No: 987 988
CRUDE BLOCK
4260(Bas/Kuw)
FR APS 6000 6000
4400 (AL/AM
NEW VPS 3401 3401
3570 (BH)
FRE APS 3500 3500
3710 (AXL
1390(PG)
FRE VPS 1179 1179
1210(BH)
MS BLOCK
NSU 1222 939 1073
NHT/ISOM 250 300 (20) 424 (70)
NHT/CCR 545 654 (20) 925 (70)
Prime-G 475 425 (0) 421 (0)
DHDS UNIT 2270 2034 1928
DHDT UNIT 2200 1100 1100
FCC UNITS
NEW FCCU 1456 1019 1019
OLD FCCU 950 813 802
PDA 755 755 755
VBU 565 566
OTHER UNITS
HGU 14.5 14.5 14.5
New HGU 8.1 4.2

Case no. 2 3
VBU+MS VBU+MS
block block
revamp revamp
20% open
LP Case No: 987 988
*Differential GRM= Case GRM – Base Case GRM, Base Case GRM = 540 Crores
Rs./Annum
Rs./Annum
Hence, as can be inferred from above, with the revamp of MS block units open, the
naphtha sales is extinguished, leading to increase in MS (gasoline) sales.
In order to target zero naphtha sales, the following is the requirement of revamp of
MS block units:
Maximum revamp of NHT/ISOM =70%

Maximum revamp of NHT/CCR = 70%
Maximum revamp of Prime-G = 0%
Option (C): Requirement of hydrotreating VGO in DHDT
In order to assess the requirement of Hydrotreating VGO in DHDT, one sensitivity

case was run for the selected expansion case.
The following cases were studied :
Case 2 : Visbreaker unit in Expansion Phase + MS Block revamp 20%

(LP Case no. 987)
Case 4: Visbreaker unit in Expansion Phase + MS Block revamp open+ No VGO

hydrotreating in DHDT.
(LP Case no. 989)


Case no. 2 4
Kuwait VBU+MS
VBU+MS block
block revamp
revamp 20% open+no
VGO hydt
LP Case No: 987 989
FEED (‘000 TPA)
Kuwait 6000 6000
R LNG 24 24
Total 9524 9524
LPG 471 485
LAN 238 0
Solvent 1425 9 9
MTO 48 48
ATF 600 600
SKO 52 52
FO Bunker 0.0
Sulphur 67 66
150N Group I 70 70
500N Group I 100 100
150N Group II 76 76
500N Group II 92 92
Bright Stock 50 50
VG-10
505 514
Bitumen
VG-30
545 536
Bitumen
Fuel & Loss 551 567
Total 9524 9524


Case no. 2 4
VBU+MS VBU+MS
Design block block revamp
Capacity revamp open+no VGO
20% hydt
LP Case No: 987 989
CRUDE BLOCK
4260(Bas/Kuw)
FR APS 6000 6000
4400 (AL/AM
NEW VPS 3401 3401
3570 (BH)
FRE APS 3500 3500
3710 (AXL
1390(PG)
FRE VPS 1179 1179
1210(BH)
MS BLOCK
NSU 1222 939 1136
NHT/ISOM 250 300 (20) 455 (82)
NHT/CCR 545 654 (20) 938 (72)
Prime-G 475 425 (0) 689 (45)
DHDS UNIT 2270 2034 1655
DHDT UNIT 2200 1100 1100
FCC UNITS
NEW FCCU 1456 1019 1164
OLD FCCU 950 813 712
PDA 755 755 755
VBU 565 566
OTHER UNITS
HGU 14.5 14.5 14.5
New HGU 8.1 3.6

Case no. 2 4
Kuwait
VBU+MS
VBU+MS
block
block
revamp
revamp
open+no
20%
VGO hydt
LP Case No: 987 989
Crores Rs./Annum
*Differential NRM= Case NRM – Base Case NRM, Base Case NRM = 74
Crore Rs./Annum
*NRM=GRM–Power Purchase
Hence, as can be inferred from above, a revamp of Prime-G by 45% becomes

necessary in a scenario when there is no hydrotreating of VGO in DHDT.
7.2.11.3 Revised Slurry Hydrocracker Case

This case consists of the expansion refinery with a new Slurry hydrocracker, with the
excess Vacuum residue as feed. The findings of Slurry HCU in Design Case 2
configuration are tabulated as follows:
Table 7.2.52: Product profile
PRODUCT MS Block 20% REVAMP
LPG 501
MS EURO IV 1611
HSD EURO V 4076
BITUMEN 1050
PITCH 67
Table 7.2.53: Unit capacities

DESIGN MS Block 20%
UNITS CAPACITY(KTPA) Revamp(KTPA)
NHT/CCR 545
654 (20)
NHT/ISM 250 300 (20)
FCC (OLD+NEW) 2227 1988
PRIME G 475 416(0)

DHDS 2270 2114

DHDT 2200 1100
VGO in DHDT 0 147
SLURRY HYDROCRACKER 839
HYDROGEN UNIT 14.5 14.5
NEW HYDROGEN UNIT 43.4
Key findings :
The slurry hydrocracker unit gives a very high distillate yield. As a result, the
production of LPG, MS, Diesel improves in this case. There is zero fuel oil sales.
However, space is required to be checked for new Slurry HCU, HGU and SRU. One
of the products of SHCU is slurry pitch. Its disposal is a cause of concern, if the unit
is selected as the preferred residue upgradation option.
In SHCU case, if DHDT runs in VGO Mode only, the peak requirement of New
hydrogen Unit is around 52 KTPA.
ECONOMIC ANALYSIS
The economic analysis for the case described above is tabulated below:
Table 7.2.54: Economic Analysis for SHCU Case

Case no. 1
Case description SHCU
LP Case No: 993
Differential GRM*, Crores Rs./Annum 1184
Differential NRM Crores Rs./Annum 998
GRM (USD/BBL of crude 4.11
Crores Rs./Annum
*Differential NRM= Case NRM – Base Case NRM, Base Case NRM = 74
Crore Rs./Annum

PROCESS DESCRIPTON Document No.
SECTION 7.3
PROCESS DESCRIPTION

7.3.0 PROCESS DESCRIPTION

The expansion capacity of HPCL Mumbai refinery shall be 9.5 MMTPA. The
following crude mix is considered:
Kuwait Crude: 6 MMTPA (FR)

Bombay High: 3.5 MMTPA (FRE)
The refinery expansion shall include the following:

The FRAPS is planned to be revamped up to 6 MMTPA as per the
modifications suggested in PCS BEDP.
A new VDU, for the FR unit, shall also be implemented for the revamped
FRAPS. The BEDP for the new VPS unit is also prepared by M/S PCS. The
existing two VDUs of the FR unit i.e. LRVPS and FRVPS are proposed to
be dismantled.
A new Visbreaker Unit shall be installed for residue up gradation in post

expansion phase.
This section describes the study for suitability / adequacy of existing units for
crude processing capacity of 9.5MMTPA.
7.3.1 FRAPS/FRVPS/LRVPS
The existing design capacity of FRAPS (Crude distillation unit) is 4260 KTPA
(Bas/Kuw)/ 4400 KTPA (AL/AM). In the existing configuration, the RCO
produced from FRAPS is routed to two Vacuum distillation units : FRVPS and
LRVPS. The design capacity of each of these units is 1086 KTPA.
In post expansion scenario, the FR unit shall be revamped to achieve a

maximum crude thru ‘put of 6 MMTPA, with Kuwait and Arab Light crudes as
design feed.
Process Consulting Services (PCS) has completed a revamp study for the FR
APS, Stabilizer, FR VPS and LR VPS Units at HPCL’s Mumbai Refinery. The
primary study objective was to maximize capacity while improving distillate yield
and energy efficiency.
PCS has concluded that the existing FR and LR VPS Units should be replaced
with a new single modern VPS Unit. Essentially all of the major equipments and
much of the ancillary equipments would need to be replaced in the existing
VPS Units to achieve HPCL’s fractionation and capacity objectives.
In the expansion phase, the FRAPS unit shall be first revamped upto a capacity
of 6 MMTPA, as per the column, desalter, pre-flash column (PFC) and heater
modifications suggested in PCS process package. The equivalent RCO
produced shall be processed in the new VDU i.e new VPS.

In the existing configuration, FR crude is being preheated by LRVPS RCO feed

and FRAPS/VPS streams. However, as per the proposed expansion study, the
FR crude preheat shall be integrated with FRAPS and new VPS sidestreams.
7.3.2 FRE APS/VPS

The existing design capacity of FREAPS/VPS (Crude and Vacuum distillation
unit) is 3.57/3.71 MMTPA (BH/AXL).
The preliminary adequacy of the FRE APS Column was checked for a capacity
of 4 MMTPA. For adequacy check, process data of FRE revamp project which
was done under GFEC project is considered. Adequacy check is performed for
increment of 133% (3 to 4 MMTPA increase) load on the earlier simulated data
generated during GFEC project.
Column-wise observations are as follows:
ATMOSPHERIC PIPE STILL (31-T-1)
Preliminary adequacy check of this Column was performed based on the

Process data given in FREAPS revamp package ( FRE APS capacity revamp
to 3.0MMTPA) under GFEC project The detailed analysis will be done during
BEDP stage based on As-Built GA drawings of installed column internals.
Table 7.3.1 Adequacy check of Atmospheric pipe still (31-T-1)
Section Type of Adequate/Inadequate for 133% Remarks

internal
BH MTO PG TAPIS
1-4 Valve trays Adequate Adequate Adequate
upto 125%
of loads
equivalent
to
3.0MMTPA
utpo 125%
of loads
equivalent
to
3.0MMTPA
17-20 High These trays
capacity being Vendor
trays propreitary, the
21-30 High exact
capacity adequacy for
trays revised
31-33 High conditions


internal
BH MTO PG TAPIS
capacity should be
trays provided by
the Vendor.
Bed #1 Structured Adequate Adequate Inadequate
Packing upto
125%
Bed #2 Structured Adequate Adequate Inadequate
Packing upto
125%
FBS STRIPPER (31-T-2A)
The column I.D. is 914 mm. On a preliminary basis, this column I.D. appeared
to be adequate for 133% of GFEC loads.
However, based on the as-built GA drawings of existing installed column
internals, adequacy check should be re-worked during BEDP stage.
JBO STRIPPER (31-T-2B)
The column I.D. is 1067 mm. On a preliminary basis, this column I.D. appeared
to be adequate for 133% of GFEC loads.
However, based on the as-built GA drawings of existing installed column
internals, adequacy check should be re-worked during BEDP stage
MTO/SKO/ATF STRIPPER (31-T-3A)
This Column consists of high capacity trays. These trays being Vendor
proprietary, the exact adequacy for revised conditions should be provided by
the Vendor.
LVGO STRIPPER (31-T-5)
Existing valve trays were found adequate for 133% of GFEC loads in BH, PG
and TAPIS case. However, based on the details of the as-built GA drawings,
adequacy check should be re- verified and confirmed during BEDP stage
NAPHTHA STABILIZER (31-T-4)
Adequacy check for this column was performed based on the hydraulic data
sheet and process data sheet of GFEC project.

Table 7.3.2 Adequacy check of Naphtha Stabilizer (31-T-4)

internal
BH MTO PG TAPIS
1-14 Valve trays Adequate Adequate Adequate With modifications
upto in the existing
115% trays, 133% in
TAPIS case can
be met.
15-37 High These trays being
Capacity Vendor
Trays proprietary, the
exact adequacy
for revised
conditions should
be provided by the
Vendor.
Following is the observations for vacuum pipe still column for an enhanced
throughput of RCO corresponding to 4MMTPA of crude processing in FREAPS
unit.
VACUUM PIPE STILL (32-T-1)
Based on the details of internals available, following is a summary of adequacy

check for the Column I.D.
Table 7.3.3 Adequacy check of Vacuum Pipe Still (32-T-1)

internal
BH MTO PG TAPIS
1-4 Valve trays Adequate Inadequate Adequate Pressure drop
(Adequate increases max.
upto 110%) allowable
pressure drop
in PG case.
5-8 Valve trays Adequate Adequate Adequate Pressure drop
increases max.
allowable
pressure drop
in BH and PG
case.
9-10 Valve trays Adequate Adequate Adequate Pressure drop
increases max.
allowable
pressure drop
in BH and PG
case.


internal
BH MTO PG TAPIS
Bed #1 GRID Adequate Adequate Adequate Pressure drop
increases max.
allowable
pressure drop
in BH and PG
case.
Bed #2 Structured Adequate Adequate Adequate Pressure drop
packing increases max.
allowable
pressure drop
in BH and PG
case.
Bed #3 Structured Adequate Adequate Adequate Pressure drop
packing increases max.
allowable
pressure drop
in BH and PG
case.
Bed #4 Structured Adequate Inadequate. Adequate Pressure drop
packing (Adequate increases max.
upto 110%) allowable
pressure drop
in BH and PG
case.
The above may be considered as a preliminary check. Detailed analysis shall

be done during BEDP stage based on the As-Built GA drawings of installed
column internals.
The existing unit is designed for processing Arab Extra Light, Bombay High
and Tapis crudes. The capacity of FREAPS/VPS in the expansion phase shall
be 3.5 MMTPA of Bombay High crude..
Since the unit is already designed for Bombay High crude and it is operating at
a capacity of 3.5 MMTPA; hence, no modification in FREAPS/VPS is envisaged
in the expansion phase.

7.3.3 MS Block Units
In HPCL Mumbai refinery, MS Block comprises of the following units :
Table 7.3.4 MS block units

Unit Design capacity (KTPA) Licensor
NHT-ISOM 250 Axens
NHT-CCR 545 UOP
Prime G 475 Axens
There is a Naphtha splitter unit installed in the existing refinery upstream of

NHT/ISOM and NHT/CCR. The design capacity of NSU is 1.222 MMTPA and it
is found adequate in post expansion phase. Therefore, no modifications are
required in the existing Naphtha splitter unit.
7.3.3.1 NHT/ISOM:
The NHT/ISOM has an existing design capacity of 250 KTPA. In post
expansion scenario, it is planned to revamp the unit upto 300 KTPA (i.e. 20%
revamp). To quantify the revamped modifications, scoping study for the
selected case needs to be performed by the respective Licensor.
7.3.3.2 NHT/CCR
The NHT/CCR has an existing design capacity of 545 KTPA. In post expansion
scenario, it is planned to revamp the unit upto 654 KTPA (i.e. 20% revamp).
M/S UOP has performed preliminary study (meeting RON as 103) for revamp of
CCR upto 140% and 115% of the design capacity. The key findings are listed
as follows:
 M/S UOP recommended switching from the current R-234 catalyst to a

higher density R-264 HY catalyst for both cases in order to address the
envisaged issue of reactor pinning at higher feed rates.
 Existing WAIT and catalyst volume are adequate for both the cases (with R-
264 HY catalyst).
 Potential solution for the reactor pinning issue can be developed as part of a
detailed revamp Assessment.
 The CCR section will require major revamp in both the cases.
 For the 140% capacity change, the existing compressor has been used for
recycle gas only service. Hence, the net gas system will have to be
configured for this case.
To quantify the revamped modifications, scoping study for the selected case
needs to be performed by the respective Licensor.
7.3.3.3 Prime-G

PRIME-G (FCC Naphtha hydrotreater) has an existing design capacity of 475

KTPA. In post expansion scenario, it is planned to revamp the unit upto 570
KTPA (i.e. 20% revamp). Also the sulphur of light and heavy gasoline products
are to be reduced from 100 ppmw (in existing design cases) to 50 ppmw. This
is required to accommodate the Prime-G product naphtha streams into the
Euro IV MS product pool. These requirements were informed to the Licensor of
the unit – M/S Axens.
According to them, there is margin in the reactor for more loading of fresh
catalyst (mainly in HDS reactors). Fresh catalyst loading at a later stage was
already considered in project design stage. And thus, fresh catalyst to be
loaded can be proposed to meet the requirement.
To quantify the revamped modifications, scoping study for the selected case
needs to be performed by the respective Licensor.
7.3.4 KERO HYTREATING UNIT
It is envisaged that two existing industrial oil hydro-finer reactors shall be

revamped from 12 m3/hr (each) to a capacity of 100 m3/hr for processing
straight run kero in post expansion scenario. M/s DuPont Isotherming
Technologies have done the feasibility for the same. The objective being
production of distillate with sulphur less than 20 ppmw and minimum smoke
point of 19 mm.
The kero hydrotreater was initially considered as an option in the expansion
case LP Model. However, in the subsequent stages of the study, it was found
that running the KHT did not add much to the refinery margin. Also, the
objective of the refinery expansion was made to maximize Euro IV diesel
production, with no demand for Euro V diesel. Hence, it was concluded that the
existing DHDS and DHDT would be sufficient to cater to treating the increased
distillates due to refinery expansion and investing in a new KHT was not
required.
7.3.5 DIESEL TREATING UNIT
In the existing refinery, there are two diesel hydro-treating units i.e. DHDS for
mainly sulphur removal and DHDT for sulphur removal and cetane
improvement. Post expansion, the additional middle distillates produced (due to
increase in refinery crude thru’put) are foreseen to be processed in these
existing units.
7.3.5.1 DHDS
The revamp of existing DHDS is being currently implemented by HPCL. The
Licensor for capacity enhancement upto 2.27 MMTPA is M/S Dupont
Isotherming Technology.
Post refinery expansion, there are no modifications envisaged in DHDS unit.

7.3.5.2 DHDT
HPCL has also recently implemented a DHDT unit for processing diesel of
capacity 2.2 MMTPA.
This unit shall be used for VGO Hydrotreating also in blocked out mode of
operation. The yields, product properties and VGO processing capacity (as
obtained by the Licensor – M/S UOP) are incorporated in the DHDT sub model
of the refinery LP Model. The feed rate of VGO in the existing design of DHDT
is 4368 TPD, with an yield of hydrotreated VGO of 91%. This hydrotreated
VGO is routed to Old FCCU.
Benefits of VGO Desulphurization

The main objective of the VGO Desulphurization is to produce hydrotreated
VGO having desired level of low sulphur and low nitrogen. It becomes the feed
stock of FCC reducing the sulphur of FCC Naphtha so as to blend directly in
MS Pool bypassing Prime G+.So, Revamp in Prime G is not required further.
7.3.6 OLD FCCU
The existing design capacity of Old FCCU (Fluidized Catalytic Cracking Unit) is
950 KTPA with a feed CCR limitation of 0.2-0.5wt%. The feed to the unit
consists of straight run VGO from FR and FRE units, Wax and Extracts from
the Lube processing block.
Post refinery expansion, there is no capacity expansion envisaged in this unit.

However hydrotreated VGO from DHDT shall be routed to Old FCCU as one of
the feed streams. The yields of FCCU for hydrotreated VGO have been based
on Bombay High VGO test run data (furnished by HPCL). Refer Section 4
(Design Basis) for the same.
7.3.7 NEW FCCU
The New FCCU (Fluidized Catalytic Cracking Unit) is designed for two cases –
 Design Case: capacity = 1277 KTPA, Feed CCR = 4.2 wt%
 Check Case : capacity = 1457 KTPA, Feed CCR = 3.4 wt%

For the expansion study, in LP model, both these cases have been configured
with their respective yields. Refer Section-4 (Design Basis) for the yields.
As per discussion held with HPCL, DHDS unstabilized naphtha and Lube
naphtha (from MSDW/RHDT) are considered to be routed to new FCCU.
These streams shall be directly fed to the Main Fractionator column of the unit.
No new secondary processing unit is required to process additional straight run

VGO.
The entire quantity of VGO shall be used to feed both the FCCUs, after
saturating the LOBS demand.

7.3.8 HYDROGEN GENERATION UNIT
The existing installed capacity of HGU is 14.5 KTPA. The hydrogen availability
in the refinery in expansion case is considered from the following sources:
 Existing hydrogen generation unit (14.5 KTPA)
 Hydrogen from revamped NHT/CCR
 New HGU in expansion phase of the refinery

In the selected cases of refinery expansion, the hydrogen balance is worked
out. The same is indicated as follows:
Table 7.3.5 Hydrogen balance for expansion case
UNITS Expansion Case (LP case 987)
DHT running
considering DHT DHT running in
in Diesel
operating in both Diesel VGO mode
mode
and VGO mode (4368TPD)
(3300TPD)
KTPA TPD TPD TPD
HYDROGEN PRODUCTION
EXISTING HGU 14.5 43.5 43.5 43.5
PROPOSED 20% REVAMP IN
CCR 17.275 51.8 51.8 51.8
TOTAL KTPA 31.8 31.8 31.8
PRODUCTION
TPD 95.3 95.3 95.3
HYDROGEN CONSUMERS
PRIME G+ 1.714 5.14 5.14 5.14
NHT (OF CCR) 1.014 3.04 3.04 3.04
NHT/ISOM 3.811 11.43 11.43 11.43
DHDS UNIT 16.198 48.59 47.44 54.48
DHT/VGO UNIT 11.718 35.15 37.026 60.41
SRU 0.049 0.15 0.15 0.15
SOLVENT EXTRACTION UNIT 1.169 3.51 3.51 3.51
LOUP (MSDW/RHDT) 4.008 12.02 12 12
TOTAL KTPA 39.7 - 39.9 50.1
CONSUMPTION
TPD - 119.0 119.7 150.2
Additional
Hydrogen 7.91 - 8.15 18.29
KTPA
requirement
without revamp of - 23.72 24.44 54.86
existing HGU TPD
NEW HGU CAPACITY REQUIRED WITH 10% MARGIN,
20.12
(KTPA)
Say 21 KTPA
7.3.9 LUBE REFINERY UNITS

The existing lube plant produces Group I basestocks by Vacuum Distillation,

Solvent Extraction, Hydrofinishing, and Propane Dewaxing. Raffinate
Hydrotreating/ Selective Dewaxing unit (RHT/MSDW) is also installed to
process waxy raffinates from the Solvent extraction units into high quality
Group II Lube Base Oils.
Post refinery expansion, the total demand of Lube oil base stocks (LOBS) is
given as 450 KTPA. The existing facilities are sufficient to meet this demand
and hence, no modifications in these units are envisaged.
7.3.10 TREATING UNITS
7.3.10.1 SOUR WATER STRIPPER (SWS)
Table 7.3.6 SOUR WATER CAPACITY
1 Existing DHDS SWS Unit Capacity 408 TPD

(DHDS UNIT) (17 TPH)
2 Existing GFEC SWS Unit Capacity 120 TPH
(FR UNIT,FRE UNIT,LR VPS,

NHT/CCR,NHT/ISOM,PRIME G+,ARU)
3 Existing DHDT SWS Unit Capacity 25 TPH

(DHDT,HGU,ARU,SRU)
Total SWS Capacity 162 TPH
Sour Water Production in Post Expansion case is as follows:
Table 7.3.7 Sour Water Production in Post Expansion case
Post
Existing Delta Req in
UNIT Sour Water Expansion Sour Water
Capacity post expansion
Capacity
(MMTPA) (TPH) (MMTPA) (TPH) (TPH)
FRAPS 4.2 35 6 50 15
New FCC 1.456 Note 1 1.456 18 18
NHT/CCR 0.545 5 0.654 6 1
NHT/ISOM 0.25 1.3 0.3 1.56 0.26
Prime G+ 0.475 1.7 0.576 2.06 0.36
VBU 0.564 3.03 3.03
Post expansion Sour Water Production 37.6
Notes

1. New FCC was installed after GFEC project. So,sour water production from
this unit is considered in post expansion case
2. Sour water production in revamped Units in Expansion Case are taken as
difference between revamp requirement & existing capacity requirement.
Findings
Sour water
production(TPH)
Sour water from DHDT when it runs at design capacity of 2.2
MMTPA is 18.6
But in Post expansion case DHDT runs at 1.1 MMTPA, Sour water
produced is 9.3
Margin available in SWS Unit 9.3
Sour water from DHDS when it runs at design capacity of 2.27

MMTPA is 17.0
But in Post expansion case DHDS runs at 2.034 MMTPA, Sour
water produced is 15.2
Sour water from Old FCC when it runs at design capacity of 1

MMTPA is 18.0
But in Post expansion case OFCC runs at 0.813 MMTPA, Sour
Sour water from New FCC when it runs at design capacity of 1.456
MMTPA is 18.0
But in Post expansion case NFCC runs at 1.019 MMTPA, Sour
Total margin available in existing SWS units to meet the
requirement in post expansion case is 20
Since DHDS, DHDT, Old FCC, New FCC Units are not running upto its design
capacity in post expansion case, existing SWS units will suffice to cater the post
expansion sour water production.
7.3.10.2 LPG TREATING UNIT
Expansion Case
(LP CASE NO. 987)
FR LPG (KTPA) = 65.3
FRE LPG (KTPA) = 52.9
TOTAL STRAIGHT RUN LPG (KTPA)= 118.2
TOTAL STRAIGHT RUN LPG (m3/hr)= 26.9
OLD FCCU LPG (KTPA)= 156.1

NEW FCCU LPG (KTPA)= 179.4

TOTAL CRACKED LPG (KTPA)= 335.5
TOTAL CRACKED LPG (m3/hr) 76.1
Note-Density of LPG considered = 550kg/m3
LPG treating units

installed in the refinery REMARKS POST EXPANSION
used
Straight run LPG produced post
Old cracked LPG treating currently for
expansion = 26.9m3/hr, which is less than
unit of capacity = 38 m3/hr treating virgin
the available capacity (of 38m3/hr)
LPG
New cracked LPG treating Cracked LPG produced post expansion
unit of capacity = 104.6 (76.1 m3/hr) is less than the available
m3/hr capacity (of 104.6 m3/hr)
Virgin LPG treating unit of not presently
capacity = 19m3/hr used
Hence, from the above balance, it is evident that the LPG produced post
expansion can be treated in the existing units and there is no revamp
envisaged.
7.3.10.3 FUEL GAS TREATING UNIT
Fuel gas generated (KTPA) in

Units
expansion case
FR 0.2
FRE 10.1
OLD FCCU 22.2
NEW FCCU 35.2
Prime-G 6.4
NHT/ISOM 4.5
MSDW/RHDT 6.3
HGU 0.5
VBU 9.2
TOTAL = 94.6
Fuel gas treating units installed in the refinery:
1. Attached to Old FCCU = 7.2 TPH

2. Attached to New FCCU = 12.05 TPH
Total installed capacity=19.25 TPH i.e. 154 KTPA.
Hence, from the above balance, it is evident that the fuel gas produced post
expansion can be treated in the existing units and there is no revamp
envisaged.

7.3.10.4 AMINE REGENERATION UNIT
Rich Amine Balance
Sl. No. Existing ARUs in refinery Capacity

DHDS ARU 2400 TPD
1 (DHDS UNIT) =100 TPH
GFEC ARU
130.08 TPH
2 (LPG Treating UNIT,Fuel Gas treating Unit)
DHDT ARU 107m3/hr
3 (DHDT,LOUP,FGATU) = 114 TPH
Total ARU Capacity 344.08 TPH
Since ,there is no capacity enhancement of LPG treating Unit & Fuel gas
treating Units in Post expansion Case, No New ARU Unit is required
7.3.11 SULPHUR RECOVERY UNIT
The existing refinery has two installed SRUs:

Table 7.3.8 Existing SRUs
Unit Capacity (TPD) Recovery (%)
DHDS SRU 65X2 99.9
DHDT SRU 65X2 99.8
The sulphur balance of the refinery in the expansion phase is worked out. The
same is indicated as follows

Table 7.3.9: Sulphur balance for Expansion Case
S Sulphur Sulphur
KTPA
(wt%) (KTPA) (TPD)
FEED
KUWAIT CRUDE 6000 2.74 164.4 493.2
BOMBAY HIGH 3500 0.12 4.2 12.6
TOTAL FEED SUL 168.6 505.8
PRODUCTS
LPG 470.9 0.000 0.000 0.000
LOW ARO NAPHTHA 238.4 0.007 0.017 0.051
SPECIAL CUT NAPHTHA 96.0 0.006 0.006 0.017
TREATED HEXANE 30.0 0.000 0.000 0.000
SOLVENT 1425 8.5 0.001 0.000 0.000
MS EURO IV 1590.0 0.004 0.064 0.191
MINL TERPENTINE OIL 48.0 0.011 0.005 0.015
AVIATION TURBINE FUE 600.0 0.150 0.902 2.707
SUP. KEROSENE OIL 52.2 0.100 0.052 0.157
HSD EURO IV 3466.2 0.004 0.139 0.416
FOS 815.5 4.000 32.620 97.860
FO BUNKER 0.0 3.500 0.000 0.000
150 NEUTRAL-GRI 70.0 0.950 0.665 1.995
500 NEUTRAL-GRI 100.0 1.300 1.300 3.900
SPINDLE OIL-GRI 15.0 0.720 0.108 0.324
SPINDLE OIL-GRII 32.0 0.030 0.010 0.029
150 NEUTRAL-GRII 76.0 0.030 0.023 0.068
500 NEUTRAL-GRII 92.0 0.030 0.028 0.083
BRIGHT STOCK 50.0 1.020 0.510 1.530
INDUSRIAL OIL 100 15.0 0.030 0.005 0.014
VG-10 505.1 5.655 28.563 85.689
VG-30 544.9 6.527 35.565 106.694
TOTAL PDT SUL 100.579 301.739
DIFFERENCE 68.020 204.06
S loss ex fuel gas firing 0.0326

S loss ex natural gas firing 0.0007
S loss ex fuel oil firing 2.4526
S loss ex CPP fuel firing 0.0088
Equivalent Sulphur in SOX from OLD FCCU 0.6465
Equivalent Sulphur in SOX from NEW FCCU 0.3974
BALANCE 66.84 200.52
EXISTING SRU CAPACITY 260

NEW SRU capacity 0

It is evident from the above tables that there is no requirement of any new
Sulphur Recovery Unit post refinery expansion.
7.3.12 PROPANE DEASPHALTING UNIT
In the existing refinery, vacuum residue is processed in PDA unit (design

capacity = 755KTPA) to make Deasphalted Oil and Asphalt/Pitch. The DAO is
routed to New FCCU and LOBS section for Bright Stock production. The PDA
asphalt is routed for Bitumen (VG 30 grade) blending.
Post refinery expansion, there is no revamp envisaged in PDA Unit.
7.3.13 New Residue Upgradation unit
7.3.13.1 Introduction
In the existing refinery, the excess Vacuum Residue is routed to internal fuel oil
pool, fuel oil sales and Bitumen (VG 10 grade) blending
In post expansion phase, the vacuum Residue generated would be higher due
to increase in refinery crude throughput and processing of larger proportion of
high sulphur crude (Kuwait). This excess VR is envisaged to be routed to a new
Residue Upgradation unit. Various options for residue updration such as
Solvent Deasphalting Unit, Slurry hydrocracker, Visbreaker were evaluated
during Configuration Study stage. The details of configuration study is given in
the section 7.2 Refinery Configuration Study.
After broad evaluation of the various options, Visbreaker Unit was finalised as a
the preferred residue up gradation unit for the refinery. It would improve high
sulphur and heavier crude processing capability and also enhance distillate
yield for value addition by reduction of cutter stock in fuel oil pool.
7.3.14 VISBREAKER UNIT
The process description of the unit is given in the following sub section. The
process flow scheme of VBU is given in Annexure 2B of the DFR.
Feed to VBU
The visbreaker unit is to be designed to process feedstock which is 100%
Kuwait Vacuum residue.
Visbreaker feed preheat

The feed is mixed in feed Mixer and heated against HP steam in HP
Steam/Feed Exchanger before they enter the Feed surge Drum. It is heated to
maintain the temperature in the Feed surge drum below auto-ignition
temperature.
From, the feed surge drum, the vacuum residue is pumped by Visbreaker feed
pumps via Feed/Vac flashed VB residue exchanger1 and Feed/Fractionator
quench exchanger to VBU heater.

Reaction Section
The reaction section consists of VBU Heater and the Soaker. The heater feed
is distributed over the four furnace coils by flow controllers at each inlet.
The feed is first heated in the convection section of Heater. Injection water is
injected in each coil in the shock tubes of the convection section by injection
water pump.
In the radiant section of the heater, the feed is further heated and partly
cracked. The temperature of combined heater outlet is controlled by a
temperature controller adjusting the heater firing. This temperature is the main
process variable controlling the cracking severity. To prevent excessive coking
of an individual coil, thereby shortening the run length of the heater, the
conversion in all coils should be kept equal.
The heater effluent is sent to the Soaker where residence time is provided to
crack the residue to desired conversion. The cracking severity (conversion) can
be controlled by two parameters i.e. the heater outlet temperature and the
residence time.
The soaker is provided with perforated plates, which reduce back mixing. In this
way, a broad spread in residence time is avoided, reducing the risk of partial
over cracking, which leads to a reduced conversion at given fuel oil stability
level.
The pressure in the Soaker is controlled by a pressure control in Soaker outlet
line.
Visbreaker Fractionator Bottoms Section

The Soaker effluent enters the flash zone of Visbreaker fractionator at
temperature in the range of 425-430 deg C.In the Fractionator,gas,naptha and
gasoil are separated from the residue.
The liquid part of the feed is quenched with cooled residue in the bottom of the
Fractionator (stripping section) to a high temperature in range of 380-400 Deg
C to prevent excessive after cracking. Part of the Fractionator bottoms is used
for this quench. The hot Fractionator quench is pumped by the Fractionator
quench pump to the feed preheat section, where the quench is cooled against
the VBU feed in Feed/Fractionator quench exchanger.
The net Fractionator bottom is sent directly to the Vacuum flasher to recover a
reasonable amount of vacuum distillate.
Circulating Reflux section

Heat is removed from the Fractionator by a circulating reflux system.
ThisSystem controls the cut-point between the Fractionator residue and
thegasoil product by controlling the reflux flow to the column and thuscontrolling
the amount of flash zone vapours condensed.

Gas Oil section

Gas oil is drawn from the Fractionator and routed to gas oil stripper. The
overhead vapour is sent back to the Fractionator.
Normally the gas oil is drawn totally from the draw off tray, but the valve in the
gas draw off line can be hand controlled such that an overflow of gas oil to the
circulating reflux system is obtained.
The bottom product of the Gas Oil stripper is pumped out by the pump. Part of
gas oil is sent for fuel oil blending. The remainder is sent to Gas Oil product
Cooler. The gas oil is further cooled in Gas Oil product trim cooler and sent to
DHDT Unit.
Fractionation Section
In the fractionation section, the separation of gasoil and naphtha is obtained.
The quality of separation is controlled by the top reflux flow which is reset by
the temperature controller in the appropriate tray in the column.
Fractionator Overhead and Recontacting Section

The overhead of the Fractionator is partially condensed in the Fractionator
reflux condenser. At the inlet of it, sour water is injected in each bundle, to
prevent corrosion. The Air cooler effluent is sent to Fractionator reflux drum for
separating vapour, hydrocarbon liquid and water.
The sour water is pumped by sour water pump to the Fractionator overhead
product condenser on interface level control of Fractionator reflux drum.
The vapours from Fractionator reflux drum are mixed with the circulating sour
water
from sour water pump and kick back flow from sour gas compressor at the inlet
of Fractionator overhead product condenser. The mixture is cooled here
followed by cooling further in fractionator overhead product trim condenser,
condensing the unstabilised naphtha. The remaining vapours, the naphtha and
the sour water are separated in the Fractionator Overhead product drum. The
Unstabilised naphtha is pumped out to the recontacting condenser via
unstabilised naphtha pump. The sour water is pumped out to battery limit via
sour water circulation pumps.
The vapours from Fractionator Overhead product drum are pressurized in sour
gas compressor and mixed with the liquid unstabilised naphtha stream coming
from unstabilised naphtha pump. The vapour stream is partially condensed in
recontacting condenser and recontacting trim condenser and routed to
recontacting drum. The remaining vapors, the unstabilised naphtha and the
sour water are separated in the Recontacting drum. Sour water is sent to
fractionators Overhead product drum..
Stabiliser Section
Unstabilised naphtha feed for the stabiliser comes from the recontacting drum.
The feed stream is preheated in the Stabiliser Feed/Bottoms exchanger against
the stabilised naphtha bottoms streams from the Naphtha Stabiliser. In the
Naphtha stabiliser, the light hydrocarbon fraction is separated from the naphtha
feed stream and stabilised naphtha is produced at the bottom of the column.
The Column bottom stream is pumped via stabiliser bottoms pump and
subsequently cooled with the Naphtha stabiliser feed stream in Stabiliser
Feed/Bottoms exchanger and with cooling water in the stabilised naphtha
Product cooler. The column is provided with a Stabiliser reboiler which utilises
intermediate pressure steam for heating.
The Stabiliser overhead is cooled in Stabiliser Overhead condenser. The
overhead stream is partially condensed and routed to the Stabiliser overhead
drum, where the vapour, hydrocarbon liquid and water streams are separated.
Vacuum Flasher Flash Zone
The residue from the Fractionator, which is gradually let down in pressure in the
transfer lines, enters the Vacuum Flasher in the Flash zone. In the flash zone
the two phase feed flow is separated into a liquid and a vapour fraction. In order
to achieve best possible separation between liquid and vapour, and thus to
minimise residue entrainment, the transfer line and the flash zone form an
integral part. In the transfer line the two phase flow is kept out of the mist flow
region, while the velocities in the flash zone are limited to allow separation of
liquid and vapour.
Vacuum Flasher Overhead system

The high vacuum in Vacuum flasher is maintained by vacuum Flasher ejector
package with MP steam as motive steam. The pressure of vacuum flasher is
controlled by a pressure controller in flash zone.
The ejector set comprises of three stages .The effluent of the ejectors is
condensed in three stages condensers. The condensate of the condensers is
sent to ejector effluent separator where the sour water and slop oil are
separated.Then,the sour water and slop oils are pumped by vacuum flasher
sour water pump and VB slop oil pump to sour water treatment facility and slop
oil collection system respectively.
The vapour from each condenser is sent to next stage of ejector set. The
vapour from last stage is routed to off gas Seal drum. The off gas stream from
this drum is routed to VBU heater via OFF gas flame arrestor. The liquid in the
seal drum protects the Vacuum Flasher and overhead system against backflow
from the heater firebox in case vacuum system fails.
Vacuum Flasher Bottom Compartment, Fuel Oil Blending and Cooling

The liquid from the flash zone is quenched by cooled vacuum flashed quench in
bottom compartment of the vacuum Flasher to a high temperature in range of
330 Deg C to minimise after cracking of the vacuum flashed visbreaker residue.
The flasher bottoms after passing through Vacuum Flasher bottoms filter is
pumped via Vacuum flashed VB residue pump to feed/vacuum Flashed VB
Residue exchanger 1 where it is cooled after passing through Vacuum Flashed
VB residue filter. Part of vac .Flashed VB residue from downstream of
feed/vacuum Flashed VB Residue exchanger 1 is used as vacuum flasher
quench. The remainder is sent to Vac. Flashed VB residue steam generator
where it is cooled by generating LP steam and it is mixed with part of Vac.
Flashed residue from downstream of feed/vacuum Flashed VB Residue
exchanger 1 and sent as Vacuum flashed Quench to vacuum Flasher. The
remainder of Vac. Flashed VB residue is mixed with VB gas Oil in a Mixer and
cooled in Vacuum Flashed VB Residue/BFW preheater.Then, the residue is
further cooled in a Trim cooler before being sent to final fuel oil blending outside
Battery limit.
7.3.15 HYDROGEN GENERATION UNIT
Refer schematic flow diagram no A430-02-41-00-0105-A.
The hydrogen plant can be divided into two discrete plant sections. The first is
referred to as the ‘’front-end’’ and comprises all the necessary process steps to
generate a hydrocarbon feed stream suitable in terms of chemical quality,
pressure and temperature for the downstream plant section. The downstream
plant section is commonly referred to as ‘’back-end’’. The front and back end
are divided by the hydrocarbon feed valve where the ratio of steam and
hydrocarbon feed is controlled.
Feed Desulphurization
To ensure adequate pressure drop for the control valve feeding the reformer,
the pressure in the front-end is controlled at the location where the (various)
feeds and hydrogen are blended at 33.9 barg. Naphtha from BL is sent under
level control to the Naphtha Feed Surge Drum. To avoid air ingress the
pressure is maintained above 0.5 barg by nitrogen blanketing. The feed is then
pumped by the Naphtha Feed Pumps into the process. The hydrogen required
for the desulphurization reactions is added in ratio to the feed streams. The
actual catalyst design parameter is the molar ratio, to be maintained at: • 0.15
mole H2 to mole LPG • 0.50 mole H2 to mole Heavy Naphtha
The actual controlled mass ratio is to be set by the operator based on analysis
of the feed stream (Molecular weight). The typical resulting mass ratio is 0.01
kg/kg. The hydrogen used is a slip stream from the hydrogen produced from the
PSA unit. The hydrogen is compressed by the Recycle Hydrogen Compressors.
The feed/hydrogen mixture is vaporized against saturated/superheated steam
to around 300 °C in the Feed Pre-heater / Vaporizer and the Feed Superheater
I before superheating in the Feed Superheater II. The superheated feed at
about 370 °C passes through the Hydrogenation Reactor and the
Desulphurization Reactors arranged in lead-lag configuration.
Reforming:
The desulphurized feed is mixed with process steam under ratio control. The
required steam to feed ratio is set by the catalyst in the unit and is chemically
defined by the molar ratio of steam to carbon contained in the feed stream
(“Steam to carbon ratio’’). Since this ratio cannot be measured in the plant, the
actual controlled parameter is the mass ratio of steam to total feed that is set for
all feeds to 3.5 (‘’Steam to feed ratio’’). This ratio is maintained for capacities
down to 50% of the normal feed rate to the reformer. At lower turndown ratio’s
the feed rate will be further reduced but the steam rate will be maintained
constant resulting in an increasing steam to feed ratio. Hydrogen is required for
the hydroprocessing units- hydrocracker, diesel hydrotreating unit,
isomerisation unit, naphtha hydrotreating unit. The hydrogen generation unit
design is based on catalytic reforming and pressure swing adsorption (PSA)
system is to produce 99.9 mol% pure hydrogen gas. The capacity of the
hydrogen generation unit is 40 KTPA.
Hydrogen is produced by steam reforming of naphtha from hydrocracker.
Naphtha from surge drum is pumped to vaporizer. Vaporised naphtha after
mixing with recycled hydrogen and superheated steam enters the reformer
furnace. Superheated steam is again added at the outlet of pre-reformer to
adjuct the steam-carbon ratio, and the mixture is heated. The superheated feed
steam mixture us distributed through multi tubular reactor consisting of high
alloy reformer tubes containing nickel based catalyst. To carry out the reactions
producing CO, CO2 and H2, heat is supplied by a number of burners burning
PSA purge gas and naptha.
The reformed gas after being cooled undergoes shift conversion in shift
converters. These are cylindrical fixed bed reactors containing iron/ chromium

oxide or copper/zinc oxide catalyst. Shift conversion reaction converts most of

CO into CO2 and H2 in presence of the catalyst. The heat removed from the
converted process gas is used to vaporize and further heat the feed, and
preheat boiler feed water and demineralised water (make up).
Hydrogen is purified to remove inert gas impurities like CO2, CO, CH4, N2 and
water vapor by high pressure adsorption of these impurities on molecular
sieves, active carbon and alumina gel in pressure swing adsorption (PSA)
system. All adsorbed gases are removed during desorption and regeneration of
beds and used as reformer fuel. Desorption is done at low pressure and purge
gas is used as fuel.
The prereformer utilizes excess heat from the reformer flue gases thereby
reducing the heat load on the reformer and improving the heat recovery, both
resulting in a reduced steam generation rate. In the pre-reformer all higher
hydrocarbons will be converted to a methane, carbon monoxide, carbon
dioxide, hydrogen and steam. The selected reformer catalyst can therefore be
‘’natural gas reforming catalyst’’ for all feeds. Further the pre reformed gas will
reduce the risk of carbon formation in the reformer and thereby allow operating
at increased heat flux and increased feed superheat temperature. The
chemically defined steam to feed ratio is the mass ratio that can be directly
controlled at the desired 3.0 ratio. This ratio is maintained constant throughout
the plant capacity range. This implies that at capacities below 50% more and
more steam will be bypassing the pre reformer. To maintain the bypass line
warm throughout the entire capacity range, the overall steam to feed ratio is
always selected higher than the pre reformer steam to feed ratio.
The feed / steam mixture to the Pre reformer is preheated to 450°C in the Feed
/ Steam Preheater. The process gas leaves the pre reformer at 530°C and is
mixed with additional process steam before it is further heated to 630°C in the
Feed / Steam Super heater. The superheated feed / steam mixture is evenly
distributed over the reformer tubes filled with nickel-based catalyst, in which the
reforming reactions take place. The outlet temperature is controlled in cascade
where the reformer outlet temperature controller provides the set point for the
flue gas temperature controller. This control is selected due to the superior
response time.

Reformer Heat Supply and Flue Gas Heat Recovery

The heat required for the reforming reactions in the steam reformer, is supplied
by the combustion of the PSA purge gas, supplemented by Naphtha as make-
up fuel. The maximum pressure of the PSA purge gas is 0.2 barg at the burner
tip whereas the maximum pressure of the make-up fuel is at 2.0 barg at the
burner tip. The Naphtha fuel is vaporized against saturated steam and passes
through the Fuel Gas K.O. Drum and then superheated against saturated steam
to about 200 °C to avoid liquid entering the burners. Dust contained in the fuel
naphtha gas is removed in the Fuel Gas Filter to avoid plugging of the burner
tips.
During full load operation the PSA purge gas provides the major amount of heat
to the furnace. When the PSA unit is not in operation the typical sustainable
heat load on the furnace is 50% of the normal heat load resulting in typical 40%
plant capacity. Since the maximum heat load of the make-up fuel is much larger
than the normal requirement (in combined firing) the normal make-up fuel
pressure at the burner is well below the maximum pressure.
The combustion air is boosted in pressure by the Combustion Air Fan. After
preheating to around 500°C in the dual stage air pre-heater, the air is delivered
to the burners. The draft in the reformer box is maintained by the Flue Gas Fan.
The excess air is controlled by the air to fuel ratio controller. The calculated air
rate required can be increased with a factor set by the DCS system based on
the oxygen content in the cross-over as measured by the online oxygen
analyzer. The excess air at 100% plant load is controlled at 10%.
The heat from the flue gas leaving the radiant section is recovered in the
convection section by the following sequence of coils:
• Shock Boiler
• Feed / Steam Super heater
• Feed / Steam Preheater
• Steam Super heater
• Feed Super heater II
• Combustion Air Preheater Hot Stage
• Flue Gas Boiler

• Combustion Air Preheater Cold Stage

The flue gas is discharged at a temperature of approx 150°C to the atmosphere
via the Stack.
Steam generation
The major portion of the process steam is produced by cooling of flue gas in the
Shock Boiler and the Flue Gas boiler. The boiler water is fed to the steam
generating equipment by natural circulation. The generated steam leaves the
Steam Drum at 36 barg. The process steam is superheated to 370°C by
process gas in the Steam Preheater. Pressure and capacity are controlled with
the process steam valve.
Export steam is produced by cooling the reformer effluent in the Process Gas
Boiler. The boiler water is fed to the steam generating equipment by natural
circulation. The generated steam leaves the Steam Drum at 43 barg. The
export steam is superheated to 380°C against flue gas in the Steam
Superheater. The high quality steam is generated at a higher pressure than the
process steam to avoid leakage from the process system into the clean system.
Pressure and capacity are controlled with the high quality export steam valve. A
part of the high quality steam is used as make-up process steam to meet the
required steam to carbon ratio in the process gas. The amount of high quality
steam to the process is under capacity control of the steam to feed ratio
controller.

Steam conditioning
To maintain an acceptable level of contaminants in the boiler water, part of the
boiler
Water is continuously blown down (3% and 1% of the BFW flow to the process
and export steam drum respectively). The blow down is collected in the Blow
Down Drum to generate stripping steam for the de-gasifier. The non-flashed
blow down is cooled against combustion air to 40°C while preheating the
combustion air to prevent condensing flue gasses on the flue gas side of the
combustion air pre-heater. The process gas boiler is equipped with an
intermittent blow down valve to remove deposits from the bottom of the shell or
drum and the gas inlet tube sheet. The intermittent blow down is flashed, the
resulting flashing steam is sent to safe location and the non-flashed blow down
is sent to the blow down cooler. The intermittent blow down is operated with a
maximum frequency of once per shift for duration of 10 seconds.
Shift Conversion
The reformer effluent is cooled to the required High Temperature Shift Reactor
inlet temperature of 340°C in the Process Gas Boiler. This temperature is
maintained constant throughout the life of the High Temperature shift catalyst.
The temperature is controlled by means of an internal bypass in the Process
Gas Boiler, which bypasses hot reformer effluent gas from the inlet chamber to
the exchanger outlet chamber. Because of this internal bypass arrangement no
external refractory lined bypass around the exchanger is required. The HTS
outlet temperature is about 420°C. The feedstock consumption is further
reduced by implementation of a Low Temperature Shift Reactor. The inlet
temperature of the Low Temperature Shift Reactor is to be increased gradually
over the lifetime of the catalyst based on minimization of the CO at the exit of
the reactor. During Start-of-Run the catalyst is active enough at 200°C to
achieve an acceptable approach to equilibrium. Towards End-of-Run this
temperature is to be increased to 230°C as a best compromise between
thermodynamic equilibrium and kinetic rate.
The shift section configuration has been optimized with respect to operating
cost as well as plant investment cost. The CO content in the process gas will be
reduced to approximately 1.1 vol% dry basis.

Process Gas Heat Recovery:

The process gas from the High Temperature Shift Reactor is cooled against
saturated steam and boiler feed water. The boiler feed water temperature is
normally maximized, but will be limited to about 30 °C below the boiling
temperature to avoid boiling inside the heat exchanger and to avoid two phase
flow to the steam drum. The process gas passes through the Low Temperature
Shift Reactor and is cooled against Boiler Feed Water. During the cooling of the
process gas in the boiler feed water excess steam, added to the process to
drive the reforming reaction, will start to condense. Further heat recovery from
the process gas is achieved by preheating demineralised water.
Process Gas Cooling:
The formed process condensate is separated from the process gas before the
Process Gas Air Cooler in the Hot Condensate Separator. The final cooling of
process gas to the required PSA Unit inlet temperature is achieved by cooling in
the Process Gas Air Cooler and the Process Gas Trim Cooler. The process
condensate is separated from the process gas in the Cold Condensate
Separator before the gas is sent to the PSA unit.
Hydrogen Purification
Process gas from the Cold Process Condensate Separator is fed to the PSA
Unit at 40°C. In the PSA Unit the hydrogen is purified adiabatically. The
hydrogen leaves the PSA Unit with a pressure of 21.6 barg and a temperature
of about 40°C. The hydrogen product leaves the PSA unit at a slightly higher
temperature that the feed to the PSA unit due to the heat of adsorption of the
impurities to the adsorbent. Therefore, hydrogen product cooler reduces the
temperature to 40 °C. A small part of the hydrogen is routed back to the feed as
recycle hydrogen by means of the Recycle Hydrogen Compressor.
All impurities contained in process gas leave the PSA as a purge gas and serve
as primary fuel for the reformer. The PSA purge gas leaves normally the PSA
Unit at a pressure of 0.30 barg. The PSA purge gas normally leaves the PSA
unit at a temperature below the feed temperature due to the heat required to
release the impurities from the adsorbent as well as the adiabatic expansion.
BFW preparation

In the Deaerator Boiler Feed Water is generated from imported Demin Water.
The stripped water is treated with oxygen scavenger chemicals from the
Chemical Dosing Unit. The BFW pumps pump the BFW to the Steam Drum.
Deposit control chemicals are added to the pump discharge of the BFW pumps.
The level in the Deaerator is controlled by flow control on the imported Demin
water.
In the Degasifier Boiler Feed Water is generated from process condensate. The
stripped water is treated with oxygen scavenger chemicals from the Chemical
Dosing Unit. The BFW pumps pump the BFW to the Steam Drum. Deposit
control chemicals are added to the pump discharge of the BFW pumps. The
level in the Degasifier is controlled by the amount of Boiler Feed Water to the
process.
The Degasifier and Deaerator are operated at close to atmospheric pressure
(0.3 barg) to maximize the stripping efficiency. The boiler feed water leaves the
Degasifier/Deaerator at approximately 107°C. The flow rate of BFW to the
steam drum is controlled by the amount of steam leaving the steam drum and
the water level in the drum (Three element control). Before entering the steam
drum, the boiler feed water is preheated in the BFW pre-heaters.

MATERIAL BALANCE Document No.
SECTION 7.4
MATERIAL BALANCE

7.4.1 OVERALL MATERIAL BALANCE
The overall material balance is worked out using LP model taking Base Case
as the Existing Refinery operating Conditions with crude mix same as
expansion case. Further Expansion Case was studied for post-revamp scenario
of 9.5 MMTPA expansion. Base case correspond to crude mix of Bombay High
(3.5 MMTPA) and Kuwait (4 MMTPA) whereas expansion case correspond to
crude mix of Bombay High (3.5 MMTPA) and Kuwait (6 MMTPA). Refer table
7.4.1 for Overall Material Balance and Table 7.4.2 for Unit Capacities.
Table 7.4.1: Over all Material Balance of Refinery for Selected Cases
Expansion
Stream Base Case
Case
FEED (000’TPA)
BOMBAY HIGH 3500 3500
KUWAIT 4000 6000
RLNG 24 24
PRODUCT (000’TPA)
LPG 332 471
LAN 272 238
SCN 96 96
TREATED HEXANE 30 30
SOLVENT 1425 8.5 8.5
MS EURO III 1075 0
MS EURO IV 0 1590
MTO 48 48
ATF 600 600
SKO 52 52
EURO III DIESEL 1810 0
LDO 88 0
EURO IV DIESEL 776 3466
RPO 70 0
FO 180CST 567 816
SULPHUR 37 67
150 N GR I 81 70
500 N GR-I 206 100
SPINDLE OIL –GR-I 15 15
SPINDLE OIL –GR-II 19 32
150 N GR-II 38 76
500 N GR-II 7 92
BRIGHT STOCK 61 50
IO-100 9 15
VG-10 BITUMEN 229 505
VG-30 BITUMEN 478 545

Table 7.4.2: Unit Capacities for Selected Cases
Design Base Expansion

Units
Capacity Case Case
4260(Bas/Kuw)
FRAPS/VPS 4000 6000
4400 (AL/AM)
FREAPS 3570 (BH)
3500 3500
/VPS 3710 (AXL)
NAPHTHA
SPLITTER 1222 903 939
UNIT
NHT/ ISOM 250 175 300
NHT/CCR 545 445 654
PRIME G+ 475 531 425
NEW FCCU 1456 870 1019
OLD FCCU 950 560 813
DHDS UNIT 2270 940 2034
DHDT UNIT 2200 1140 1100
VGO FEED
POOL 0 147
(DHDT)
DIESEL FEED
1081 741
POOL (DHDT)
PDA 755 755 755
HGU 14.5 19.2 14.5
New HGU 36
VBU 0 565

UTILITY SYSTEM Document No.
SECTION 7.5
UTILITIES DESCRIPTION

7.5.0 UTILITIES DESCRIPTION
This chapter provides the details of increased utility requirements and description of
additional facilities required for various utility systems envisaged for the refinery post
revamp for the detailed feasibility report.
The following utility systems are reviewed for DFR:

1. Cooling water system
2. DM water system
3. Compressed air system
4. Nitrogen system
5. Steam, power and BFW system
6. Condensate system
7. Internal fuel oil and fuel gas system
8. Bearing Cooling water
The revised utility consumption and the additional facilities required post revamp of
the above facilities have been done based on estimation of utility consumption of the
process units based on the following:
 Operating data of the existing units at increased capacity of the units

 In-house data for new units like VBU& New HGU.
The details of existing utility systems installed in the refinery are given in Attachment
4E of Section 4: Design Basis.
7.5.1 REFINERY UTILITIES SUMMARY
Refinery revamp utilities requirement summary are tabulated below in Table-7.5.1
Table-7.5.1: Refinery revamp utilities requirement summary

Post Expansion
S.No System Units
Requirement
1 CW System m3/hr 1869
2 DM Water m3/hr 100
3 Raw Water m3/hr 112
4 Nitrogen Nm3/hr 138
5 Instrument Air 1004
6 Plant Air Nm3/hr 0
7 Boiler Feed water TPH 24.7
8 Steam TPH 3.1
9 Condensate
Surface TPH 3.4
Pure TPH 10.7
Suspect TPH 2.7
10. Fired duty MMKcal/hr 24.88
11. BCW m3/hr 133

7.5.2 RAW WATER SYSTEM
Source of raw water will be treated water from Bombay Municipal Corporation
(BMC).The raw water would be stored in underground sump, from where raw water
will be supplied to meet process and other requirements.
Treated water shall be used for following purpose in this project:

1. DM Plant feed
Treated water requirement

The revised estimated treated water requirement for various purposes in the
complex is given below in Table-7.5.2
Table-7.5.2: Treated Raw Water Requirement (m3/hr)

Estimated Demand
S.No Unit
m3/hr
1 DM Plant feed 112
Total raw water Demand 112
Existing Raw water Systems of 410m3/hr (350m3/hr fresh water from BMC plus
60m3/hr IETP recycle water to DM plant feed) and 135 m3/hr envisaged for DHT
Project (Subject to approval from BMC.) will be sufficient to cater the requirement in
expansion case.
7.5.3 COOLING WATER SYSTEM
The cooling water system envisaged for the post expansion case is Sea Cooling
water system.
The sea cooling water system will cater the requirement in Post expansion case.
7.5.3.1 Sea cooling Water system

The sea water shall be used for sea cooling water system as is being used in
existing refinery. Sea Cooling water system envisaged for the expansion case is
closed loop recirculation type.
7.5.3.2 Sea cooling Water Requirement
The cooling Water Requirement of various units is given below in Table 7.5.3
Table-7.5.3: Cooling water consumption (m3/hr)
Existing Capacity Post Expansion
Unit Capacity Total Capacity Total Consider CW Req in Post
(MMTPA) Demand (MMTPA) Demand ed Expansion
(M3/HR) (M3/HR) (M3/HR) (M3/HR)
FR APS 4.4/4.26 3390 6 3366 3366 0
FR VPS 1800 3316 3316 0
LR VPS 1958 0 0 0
FRE APS 3.57/3.71 2677.5 3.5 2677.5 2677.5 0
FRE VPS 2420 2420 2420 0
NHT/ISOM 0.25 712.35 0.3 854.82 854.82 142
NHT/CCR 0.545 1229.6 0.654 1475.52 1475.52 246
DHDS 2.27 1014 2.27 1014 1014 0


DHDT 2.2 863.4 2.2 863.4 863.4 0
OFCC 0.95 2630 0.95 2630 2630 0
NFCC 1.456 3988 1.456 3988 3988 0
PRIME G+ 0.475 383 0.576 464.4 464.4 81
NSU 1.222 262 1.222 262 262 0
PDA 0.755 576 0.755 576 576 0
HGU 18.125 165 18.125 165 165 0
HEXANE 0.386 1280 0.386 1280 1280 0
UNIT
PROPANE 6.25 TPH 169 6.25 TPH 169 169 0
UNIT
SRU 130 TPD 295 130 TPD 295 295 0
SRU DHDT 130TPD 502 130TPD 502 502 0
RHDT 1052 1052 1052 0
OFFISTES 898 1137.5 1137.5 239
PDU 1281.4 1281.4 1281.4 0
SEU 3171.4 3171.4 3171.4 0
DHDT 107 107 107
OFFSITE
New HGU 0.036 543 543 543
VBU 0.564 198 198 198
OLD 38 0 38 0 0 0
CRACKED M3/HR(FOR M3/HR(F
LPG UNIT VIRGIN LPG) OR
VIRGIN
LPG
NEW 104.6 M3/HR 130 104.6 130 130 0
CRACKED M3/HR
LPG UNIT
VIRGIN REDUDNDANT
LPG UNIT
TOTAL CW REQUIREMENT IN POST EXPANSION 1869(Note 1)
Notes
1. Cooling water requirement in post expansion case with 20% Margin

2. Cooling Water requirement of revamp units in expansion case are taken as
difference between revamp requirement &existing capacity requirement.
3. Cooling water requirement of New HGU Unit is as per internal data.
4. Cooling Water requirement of VBU is as per internal data.
5. Existing Sea cooling water towers is sufficient to cater the post expansion sea
cooling water requirement.
However, a comprehensive flare study of the overall refinery in post expansion scenario
needs to be carried out during detailed engineering to take care of the existing flare
design. The cost for this flare study is considered in the DFR.

7.5.4 DM WATER SYSTEM
DM water in the refinery complex is required as Boiler feed water make-up for steam
generation and as process water for dilution, reaction and washing. The demand
summary of DM water in various units and utilities is given below in Table-7.5.4
Table-7.5.4 DM WATER (m3/hr)

Net DM
Existing Continuous Expansion Continuous requirement
Unit capacity demand capacity demand post
(MMTPA) (m3/hr) (MMTPA) (m3/hr) expansion
(m3/hr)
NHT/ISM 0.25 0 0.3 0 0
NHT/CCR 0.545 26.4 0.654 31.68 5.28
PRIMEG+ 0.475 0 0.576 0 0
VBU 0.564 0 0
New HGU 0.036 70.35 70.35
BFW FOR
PROCESS 21.47(Note-3)
UNITS
Total
(Process 97.1
Units)
For CPP 3.26(Note-2)
Total 100.36
TOTAL-
Process &
100.36
Utility
Notes
1. DM requirement of revamp units in expansion case are taken as difference
between revamp requirement &existing capacity requirement.
2. Steam generated in expansion case is 3.1 TPH.Assuming 5% Blow down BFW
required for Steam generation is 3.26TPH.
3. Refer BFW requirement below.
4. DM water requirement of VBU is as per internal data.
5. DM req of New HGU Unit is as per internal data.
DM water Requirement
DM water requirement in post expansion case is 100 m3/hr. It will be met from
existing chains of DM Plant
No New chain of DM plant is envisaged.
7.5.5 COMPRESSED AIR SYSTEM
The Compressed air is required in the complex for following usages:
 As instrument air
 As plant air
 As service air for hose stations and for other requirements of the complex.

Compressed Air Specification

Quality of Plant air and service air is same and these requirements in the complex
shall be supplied through common header.
Consumption Requirement
The requirement of instrument air and plant air in the complex are given in Table
7.5.5 and Table 7.5.6 respectively.
Table-7.5.5: Instrument Air (Nm3/hr)
Existing Continuous Expansion Continuous Net IA Requirement
Unit Capacity Requirement Capacity Requirement Post expansion
(MMTPA) (Nm3/hr) (MMTPA) (Nm3/hr) (Nm3/hr)
FR
100 100
APS/VPS
NHT/ISM 0.25 150 0.3 180 30
NHT/CCR 0.545 747 0.654 896.4 149.4
PRIMEG+ 0.475 200 0.576 242.5 42.5
OFFSITES 7.5 400 9.5 506.7 106.7
VBU 0.564 200 200
New HGU 0.036 375 375
Total 1004
Notes
1. IA requirement of revamp units in expansion case are taken as difference
2. IA requirement of VBU is as per internal data.
3. IA req of New HGU unit is as per internal data.
Table-7.5.6: Plant Air (Nm3/hr)

Net PA
Unit capacity requirement capacity requirement post
(mmtpa) (nm3/hr) (mmtpa) (nm3/hr) expansion
(nm3/hr)
NHT/ISM 0.25 0 0.3 0 0
NHT/CCR 0.545 0 0.654 0 0
PRIMEG+ 0.475 0 0.576 0 0
OFFSITES 7.5 0 9.5 0 0
VBU 0.564 0 0
New HGU 0.036 0 0
Total 0
Note: No PA requirement is envisaged in post expansion case.
Total Air Requirement

The compressed air requirement of the refinery complex works out to be
Instrument Air : 1004 Nm3/hr
Plant air : 0 Nm3/hr
Total air requirement Post revamp : 1004 Nm3/hr

Existing Compressors of CA system is sufficient enough to cater the post expansion

requirement. No additional LP Air Compressors is envisaged.
Also, Existing Instrument Air driers viz. 2w+1s of 2576 Nm3/hr,1w of 3900 and
1w+1s of 1100 Nm3/hr is suffice to meet the IA requirement in post expansion
scenario.
7.5.6 NITROGEN SYSTEM
High purity Nitrogen is required in the refinery for the following purposes:
A) Continuous Requirement
 During catalyst regeneration
 Blanketing of surge drums and storage tanks
 Purging of compressor seals
B) Intermittent Requirement
 Purging of systems during start-ups and shut-downs
 Catalyst Regeneration
The nitrogen requirement post revamp against the existing consumption is tabulated
in the table 7.5.7
Table-7.5.7: Nitrogen requirements of the various units.
Net N2
Unit capacity requirement capacity requirement post
(mmtpa) (nm3/hr) (mmtpa) (nm3/hr) expansion
(nm3/hr)
NHT/ISM 0.25 20 0.3 24 4
NHT/CCR 0.545 125 0.654 150 25
PRIMEG+ 0.475 0 0.576 0 0
OFFSITES 7.5 250 9.5 317 67
VBU 0.564 0 0
New HGU .036 42 42
Total 138
Notes
1. N2 req of Revamp Units in Expansion Case are taken as difference between
revamp requirement & Design requirement.
2. N2 req of VBU is as per internal data.
3. N2 req of New HGU unit is as per internal data.
The total nitrogen demand post is ~ 138 Nm3/hr.
The requirement of 138Nm3/hr of gaseous nitrogen post revamp will be met by
existing Nitrogen Plants of 1000 Nm3/hr and 2200 Nm3/hr which will get augmented
under DHDT project.

7.5.7 STEAM, POWER AND BFW SYSTEM

The steam is produced in the utility boiler. The fuel to UB is mixture of fuel gas and
refinery fuel oil.. The steam is being generated / consumed in process units . The
steam consumption in the various units for different purposes such as:
 Process use (Chemical reaction, Stripping steam, etc.)
 Fuel oil atomisation. Internal fuel oil atomization,
 Steam tracing of lines (congealing service)
 Tankage heating
 Deaerator
 Intermittent requirement like snuffing, decoking, soot blowing, purging etc.
 Air conditioning units for the Control rooms and the administrative building.
Steam Requirement
The unit-wise net steam consumption /generation for the existing as well as post
revamp is tabulated below in table 7.5.8:
Table 7.5.8: Steam consumption/generation (TPH)

Net steam
Existing capacity Post expansion in
expansion
Continuous Continuous Continuous Continuous Delta Delta
Capacity Capacity
Unit Consumption Generation Consumption Generation Cons Gen
(MMTPA) (MMTPA)
(TPH) (TPH) (TPH) (TPH) (TPH) (TPH)
FR APS 4.4 18.2 0 6 13.5 0 0 0
FR VPS 10.9 -1.5 42.7 -8.8
18.8 0
LR VPS 13 -9
FRE APS 3.57 14.93 0 3.5 14.9 0 0 0
FRE VPS 7.6 -1.69 7.6 -1.69 0 0
NHT/ISOM 0.25 53.8 0 0.3 64.6 0 10.8
NHT/CCR 0.545 14.2 -18.8 0.654 17 -22.6 2.8 -3.76
DHDS 2.27 3 0 2.27 3 0 0 0
DHDT 2.2 7.469 0 2.2 7.469 0 0 0
OFCC 0.95 2.08 0 0.95 2.08 0 0 0
NFCC 1.456 22 -72 1.456 22 -72 0 0
PRIME G+ 0.475 13.32 0 0.576 16.2 0 2.8 0
NSU 1.222 0 0 1.222 0 0 0 0
PDA 0.755 35.7 0 0.755 35.7 0 0 0
HGU 18.125 0 -34.4 18.125 0 -34.4 0 0
HEXANE
0.386 19 0 0.386 19 0 0 0
UNIT
PROPANE
6.25 TPH 2.125 0 6.25 TPH 2.125 0 0 0
UNIT
SRU 130 TPD 0 -17.28 130 TPD 0 -17.28 0 0
SRU DHDT 130TPD 0 -2.77 130TPD 0 -2.77 0 0
RHDT 5 0 5 0 0 0
OFFISTES 97 0 114.3 0 17.3 0
PDU 37.1 0 37.1 0 0 0
SEU 0 -31.1 0 -31.1 0 0
VBU 0.564 -10.53 0 -10.53
New HGU 0.036 0 -35.0 -35.0
Total 52.5 -49.29
Net steam Requirement in post expansion case 3.1

Notes
1. Steam requirement of revamp units in expansion case are taken as difference

2. Steam Requirement/consumption for FR Revamp is taken from PCS Report.
3. Steam requirement of VBU is as per internal data.
4. (-) indicates generation and (+) indicated consumption of steam.
5. Steam requirement/consumption for New HGU is as per internal data.
Power Requirement
Table 7.5.9 gives the power requirement of the various units operating in post
expansion case against the existing consumption is tabulated in the table 7.5.8
Table 7.5.9: Estimated Power Consumption (kW) (Normal)

Unit Ca pacity Net Power Capacity Net Power consumption Power Req in
(MMTPA) consumption (MMTPA) (KW) Expansion(KW)
(KW)
FR APS 4.4 2293 6 3868 1575
FR VPS 364.5 2238
1409.5
LR VPS 464
FRE APS 3.57 2706.51 3.5 2706.51 0
FRE VPS 1005.66 1005.66 0
NHT/ISOM 0.25 2390 0.3 2868 478
NHT/CCR 0.545 7284.3 0.654 8741 1457
DHDS 2.27 4200 2.27 4200 0
DHDT 2.2 16630 2.2 16630 0
OFCC 0.95 7774 0.95 7774 0
NFCC 1.456 19571 1.456 19571 0
PRIME G+ 0.475 1071.6 0.576 1299 228
NSU 1.222 958 1.222 958 0
PDA 0.755 1443 0.755 1443 0
HGU 18.125 1030 18.125 1030 0
HEXANE
0.386 498.4 0.386 498.4 0
UNIT
PROPANE
6.25 TPH 86 6.25 TPH 86 0
UNIT
SRU 130 TPD 1557 130 TPD 1557 0
SRU DHDT 130TPD 2033 130TPD 2033 0
RHDT 3188 3188 0
OFFISTES 25000 28129 3129
PDU 7252.8 7252.8 0
SEU 2471.5 2471.5 0
VBU 0.564 410 410
New HGU 0.036 1388.5 1388.5
Total 10.07 MW
Notes
1. Power req of Revamp Units in Expansion Case are taken as difference
between revamp requirement & Design requirement.
2. Power req of VBU is as per internal data.
3. Power req of New HGU is as per internal data.

Total power requirement post revamp will be 10.07 MW.As confirmed by HPCL, It
will be imported from outside source.
Post expansion power available from CPP will be13MW.
Total steam requirement for all units post revamp: 3.1TPH which can be met from
HRSGs.No New Boilers/GTG/HRSG is envisaged in expansion case.
Hence no new facility is required for steam.
Boiler Feed Water Requirement

Boiler feed requirement of various units and Captive Power Plant (CPP)is given in
Table-7.5.10.
Table 7.5.10: BFW consumption (TPH)

Existing Capacity Post expansion
Net BFW
Continuous
Capacity Continuous Capacity Req in
Units Demand
(MMTPA) Demand(TPH) (MMTPA) Expansion
(TPH)
(TPH)
FR VPS 5.9(Note-1) 15 9.1
NHT/CCR 0.545 0 0.654 0 0
NHT/ISOM 0.25 0 0.3 0 0
PRIME G+ 0.475 6.2 0.576 7.52 1.32
VBU 0.564 11.06
FOR CPP 3.26
New HGU 0.036 0
Total 24.7
Notes
1. BFW requirement of existing FRVPS unit is as per GFEC Package and in

expansion case is taken from PCS process package..
2. BFW requirement of revamp units in expansion case are taken as difference

3. BFW requirement of VBU is as per internal data.
4. BFW req of New HGU Unit is as per internal data.
BFW requirement in post expansion case is 24.7 TPH.Existing BFW deaeration

capacities are adequate to cater the post expansion requirement. Thus, no change
in BFW system is envisaged.

7.5.8 CONDENSATE SYSTEM
Steam is being used in the refinery as process steam motive fluid for the steam
turbine drives, ejectors, heating etc. Condensate results from the condensing
steam turbine drives, steam re-boilers and ejector condensers. Within the each
individual units suspect condensate and pure condensate is segregated. During
normal operation, suspect condensate is treated in centralised condensate
polishing unit before use.
However, the pure condensate and surface condensate is directed to polished

condensate tanks.

Configuration Study & DFR For A430-00-02-41-RPT-001
Condensate generation summary for various units is given below in Table-7.5.11.
Table 7.5.11: Condensate Balance

Existing Capacity Expansion Capacity
Suspect Pure Surface Suspect Pure Surface Net Gen Net Gen Net Gen
Capacity Capacity (Suspect) (Pure) (Surface)
Units Condensate Condensate condensate Condensate Condensate condensate
MMTPA MMTPA
(TPH) (TPH) (TPH) (TPH) (TPH) (TPH)
NHT/
31.7
ISOM 0.25 11.2 5.9 0.3 13.44 38.04 7.08 2.24 6.34 1.18
NHT/
3
CCR 0.545 2.5 11 0.654 3 3.6 13.2 0.5 0.6 2.2
PRIMEG+ 0.475 0 17.81 0 0.576 0 21.6 0 0 3.8 0
VBU 0.564 0 0 0 0 0 0
New HGU 0.036 0 0 0 0 0 0
TOTAL 2.7 10.7 3.4
TOTAL
with 1.6 9.6 3.04
Recovery
Notes
1. Condensate generation of revamp units in expansion case are taken as difference between revamp generation &existing
capacity generation
2. 60% Recovery is considered for Suspect Condensate and 90% Recovery is considered for Pure Condensate and Surface
Condensate.
3. Condensate generation of New HGU unit is as per internal data.

Condensate System Capacity
Design condensate from Units (GFEC+FR BLOCK) is 247TPH.Actual Condensate

Return is 140TPH which is lower than design as steam consumption is lower than
design case.
Design condensate from Units (LR BLOCK) is 45.6TPH.Actual Condensate Return

is 36TPH which is lower than design as steam consumption is lower than design
case.
Also, DHDT Project condensate generation is 22.6 TPH.
Post expansion Total condensate generation will be 16.8 TPH .The break up of
condensates for the post revamp scenario is as follows:
Surface Condensate : 3.4 TPH
Pure Condensate : 10.7 TPH
Suspect Condensate : 2.7 TPH
Although the post revamp requirement is very less, Existing condensate systems are
adequate to cater the post expansion requirement. Thus, no new condensate
system is envisaged in post expansion case.
7.5.9 INTERNAL FUEL OIL AND FUEL GAS SYSTEM

The fuel requirement of refinery complex would be met by the internal fuel oil and
the fuel gas systems. Fuel is consumed only in Process units. Total requirement of
fuel in all the furnaces within the process units would be met mostly by fuel gas
system and partly by internal fuel oil systems. All the furnaces shall be designed for
dual firing. The existing fuel network shall be integrated with the fuel network.
Fuel Demand
The total duty (MMKcal/Hr) of respective units, considering all units running, is
indicated in the Table-7.5.12.
Table 7.5.12: Duty requirement for expansion
Existing Capacity Expansion Capacity Net

UNIT Capacity Continuous Capacity Continuous requirement
(MMTPA) requirement (MMTPA) requirement post expansion
(MM Kcal/hr) (MM Kcal/hr) (MM Kcal/hr)
NHT/ISOM 0.25 1.44 0.3 1.728 0.29
NHT/CCR 0.545 2.23 0.654 2.7 0.45
P-RIME G+ 0.475 2.1 0.576 2.5 0.45
VBU 0.564 21.60
New HGU 0.036 2.10
TOTAL 24.88
Notes
1. FG requirement of VBU is as per internal data.
2. FG requirement of New HGU unit is as per internal data.

7.5.10 BEARING COOLING WATER SYSTEM
Bearing Cooling Water shall be used in various process units .In existing refinery,
following BCW systems are present to meet the demand of Bearing Cooling water:
 GFEC BCW System-1800 m3/hr

 LEU BCW System-800 m3/hr
 DHDS BCW System-250 m3/hr
 LOUP BCW System-300 m3/hr
 DHT BCW System-1200 m3/hr.
The Bearing Cooling water requirement of various units is given below in Table-7.5.13
Table 7.5.13: Bearing Cooling Water Consumption
Existing Capacity Expansion Capacity Net BCW

UNIT Capacity Total Capacity Total Demand requirement
(MMTPA) Demand (MMTPA) (m3/hr) post expansion
(m3/hr) (m3/hr)
NHT/CCR 0.545 169.1 0.654 202.92 33.8
VBU 0.564 60 60
New HGU 0.036 39 39
TOTAL 133
Notes
1. BCW requirement of VBU is as per internal data.
2. BCW requirement of New HGU unit is as per internal data.
3. BCW requirement of Revamp units in expansion case is taken as
difference between revamp requirement and existing capacity
requirement.
7.5.11 BEARING COOLING WATER TOWER
Bearing cooling water requirement in post expansion scenario is 133 m3/hr.Keeping

10% as design margin on requirement, Bearing cooling Tower capacity works out to
be 150 m3/hr.Bearing Cooling Tower having one working cell of 150 m3/hr capacity
have been provided to meet this requirement.
Bearing cooling water pumps

To cater the bearing cooling water requirement, two bearing cooling water pumps
(1W+1S) of capacity 150 m3/hr is to be installed in Bearing Cooling Tower.

OFFSITE DESCRIPTION Document No.
Configuration Study & DFR for A430-RP-02-41-0001
SECTION 7.6
OFFSITES DESCRIPTION
Template No. 5-0000-0001-T2 Rev. 1 Copyright EIL – All rights reserved

7.6 OFFSITE SYSTEM
The Project facilities envisage adequate storage and transfer facilities for the
various feed and product streams commensurate with additional quantities to
be handled for the Expansion Project. Thus, in this project no new additional
crude and product tanks will be considered, only available storage time shall
be reported.
Intermediate tanks viz Raw Diesel Storage Tanks, HGU Feed Tanks, VBU
Feed Tanks, VGO Feed Tanks, Hydrotreated VGO tanks, Diesel back blending
stream tank, Slop/off spec tanks are coming up in Expansion Case.
The offsite facilities of existing refinery consists of
a) Crude Oil storage and transfer
b) Intermediate Feed/intermediate product storage and transfer
c) Finished product storage and transfer.
7.6.1 Crude oil storage and pumping
Crude quantity to be handled post expansion at MR to be 9.5 MMTPA. from

existing refining capacity of 7.5 MMTPA. Although, refining capacity increases,
as agreed with HPCL, no additional crude tanks is considered and only
storage time is reported below in following tables for BH Crude and Kuwait
crude respectively.
Table 7.6.1 Storage days for BH CRUDE

Tanks Net Capacity (MT)
118 10476
119 10897
115 67047
Total 88420
BH Crude processing 3500 KTPA
Crude processing 437.5 MT/HR
Total Storage 88420 MT
Coverage days 8.4 days
Table 7.6.2 Storage days for Kuwait CRUDE

Tanks Net Capacity (MT)
110 61056
111 61597
112 63328
113 65088
117 65460
Total 316529
Kuwait Crude processing 6000 KTPA
Crude processing 750 MT/HR
Total Storage 316529 MT
Coverage days 17.6 days

7.6.2 Intermediate Feed Storage and Transfer
The objective of providing intermediate product storage is to ensure:
Minimum intermediate storage commensurate with unit operating philosophy

to provide buffer between upstream/downstream units.
To take into account turnaround, interruption, catalyst regeneration /

replacement etc.
Considering the above requirements, capacities of individual intermediate

storage of VGO Feed, Raw Diesel,Hydrotreated VGO,Offspec/Slop, Diesel
Back blending, HGU feed,VBU feed are worked out and indicated below:-
Raw Diesel storage Tanks
Considering Schedule as below

Changeover from Diesel to VGO 3 days
VGO mode of operation 3 days
Changeover from VGO to Diesel 3 days
Sour Diesel Generation as DHDS/DHT feed 8735 tpd

Considering DHDS full throuput while DHT in Changeover/VGO
mode 6810 tpd
Sour Diesel Accumulation per day while DHT in Changeover/VGO
mode 1925 tpd
tonne
total Sour Diesel Accumulation while DHT in Changeover/VGO mode 17325 s
tonne
Tankage accumulation at the end of the cycle 800 s
Total 18125
tonne
Basis above sour diesel storage capacity consider as 19000 s
22352.9
4 m3
11176.4
Considering 2 storage tanks with 50% capacity 7 m3
storage tank Height 20 m
Effective volume 80%
Storage tank Dia 30 m
Two tanks with 30m Dia and 20m Height is considered
Raw VGO Storage Tanks


VGO Mode of Operation considered per cycle 3 days

Operating Capacity of DHT in VGO mode 4368 TPD
Corresponding VGO for 3 days of operation 13104 tonnes
14560 m3
Two tanks with 25m Dia and 20m Height is considered.
Hydrotreated VGO Storage Tanks

VGO Mode of Operation considered per cycle 3 days

Operating Capacity of DHT in VGO mode 3931 TPD
Corresponding VGO for 3 days of operation 11793.6 tonnes
13326.1 m3
HGU Feed Storage Tanks
Capacity of HGU Sweet Naphtha 36 KTPA

108 TPD
Corresponding Naphtha for 36 KTPA 126 KTPA
378 TPD
Considering 7 days storage at 50% ISBL capacity 1323 tonnes
1837.592 m3
Considering 2 storage tanks with 50% capacity 918.79 m3

VBU Feed Storage Tanks
VR as feed to VBU 565 KTPA

1695 TPD
Considering 7 days storage at 50% ISBL capacity 5932.5 tonnes
5759.7 m3
Considering 2 storage tanks with 50% capacity 2879.8 m3
Diesel Back blending streams storage capacity
Sour Diesel Generation as DHDS/DHT feed 8375 tpd

Diesel back blending stream per day(FBS&SKO) 1868 tpd
Diesel Generation from DHDS (maximum throughput) during VGO
mode/Changeover of DHT 6607 tpd
Back blending streams (TPD)for DHDS maximum throughput 1473.6 tpd
Back blending streams for corresponding DHT Diesel generation
storage capacity 394.3 tpd
Total storage requirement for 9 days 3549 tonne

4436.2 m3
Slop/Off spec Tanks

Two tanks with 13m dia and 20 m height to is considered for Diesel-VGO
One tank with 20 m dia and 20m height is considered for offspec HSD.

7.6.3 Finished Product Storage and Transfer
As agreed with HPCL, no additional product tanks shall be considered and

only available storage time shall be reported for all the products in post
expansion case.
Storage days for LPG

Tank No Service Net Capacity (MT)
Bullet 1A LPG 830
Bullet 1B LPG 830
Bullet 1C LPG 830
Bullet 1D LPG 830
Bullet 1E LPG 830
Bullet 1F LPG 830
Bullet 1G LPG 830
Bullet 1H LPG 830
Bullet 2A LPG 830
Bullet 2B LPG 830
TOTAL 8300
EXPANSION
CAPACITY 0.471 MMTPA
58.875 MT/HR
COVERAGE DAYS 5.9 Days
Storage days for SCN

312 FBS/SCN 2384
370 SCN/FBS 7769
TOTAL 10153
EXPANSION
12 MT/HR
COVERAGE
DAYS 35.3 DAYS
Storage days for MS

103 MS 18317
101 MS 0
302 MS 3321.5
104 MS 10466.601
107 MS 4041
108 MS 4145
261 MS 5344.5

MPPL-1 MS 0
311 MS 2354
Total 47989.601
EXPANSION
CAPACITY 1.59 MMTPA
198.75 MT/HR
COVERAGE DAYS 10.1 DAYS
Note:Tk-101 is not considered as it will be dismantled in Expansion Case.
Storage days for HSD

MPPL-2 HSD/KERO 0
306 HSD 7265.82
308 HSD 4135
264 HSD 4144
301 HSD 5027
307 HSD 7154
309 HSD 4169
313 HSD 4910
314 HSD 4953
315 HSD 6064
455 HSD 5490
102 HSD 0
760 HSD 5563
TOTAL 58874.82
EXPANSION
433.25 MT/HR
COVERAGE
DAYS 5.7 DAYS
Note: Tk-102 is not considered as it will be dismantled in Expansion Case.
Storage days for ATF

363 ATF 6022
366 ATF 5993
367 ATF 3808
368 ATF 3787
369 ATF 435
451 ATF 5540
364 ATF 5977
365 ATF 6047
TOTAL 37609

EXPANSION
CAPACITY 0.6 MMTPA
75 MT/HR
COVERAGE
DAYS 20.9 DAYS
Storage days for SKO

361 KERO 4757
372 KERO 8011
373 KERO 7764
371 KERO 7769
459 SKO 4810
557 SKO 2342
TOTAL 35453
EXPANSION
6.525 MT/HR
COVERAGE
DAYS 226.4 DAYS
Storage days for MTO

561 MTO 990
562 MTO 987
TOTAL 1977
EXPANSION
6 MT/HR
COVERAGE
DAYS 13.73 DAYS
Storage days for SOL

260 SOLVENT 1729
1425
SOLVENT
259 1425 1661
TOTAL 3390
EXPANSION
1.0625 MT/HR
COVERAGE
DAYS 132.94DAYS

Storage days for HEXANE

213 HEXANE 1668
214 HEXANE 1648
257 HEXANE 1675
TOTAL 4991
EXPANSION
CAPACITY 0.03 MMTPA
3.75 MT/HR
COVERAGE
DAYS 55.46 DAYS
Storage days for ASPHALT

750 ASPHALT 1310
751 ASPHALT 610
752 ASPHALT 1881
753 ASPHALT 1878
754 ASPHALT 1875
755 ASPHALT 1852
756 ASPHALT 1070
757 ASPHALT 1071
560 ASPHALT (IFO) 8007
558 ASPHALT(IFO) 8007
462 BITUMEN 4701
TOTAL 48276
EXPANSION
CAPACITY 1.05 MMTPA
131.25 MT/HR
Storage days for IFO

572 LSHS 8310
573 LSHS 8334
574 LSHS 6342
TOTAL 22986
EXPANSION
24.375 MT/HR
COVERAGE
DAYS 39.29 DAYS

Storage days for FOS

556 IFO 7396
404 FUEL 1596
(LFO)
404B FUEL 1209.2416
(HFO)
1341 FUEL OIL 198.352
604 LFO 327
TOTAL 10726.5936
EXPANSION
101.875 MT/HR
COVERAGE
DAYS 4.39 DAYS
Storage days for PDA feed (VR)

463 VTB 6710
TOTAL 6710
EXPANSION
94.375 MT/HR
COVERAGE
DAYS 2.96 DAYS
Storage days for Prime G feed

Tank No Service Capacity(KL)
PRIME G
1002 FEED 2640
DENSITY OF PRIME 733 KG/M3
G FEED
AVAILABLE TANK
CAPACITY 1935 MT
EXPANSION 0.576708
CAPACITY MMTPA
72.0885 MT/HR
Note
1. 80% Filling of Tank-1002 is considered.

Storage days for Isomerate

1005A ISOMERATE 2560
1005B ISOMERATE 2560
TOTAL 5120
DENSITY OF 653 KG/M3
ISOMERATE
AVAILABLE TANK
CAPACITY 3343 MT
EXPANSION
34.875 MT/HR
Note
1. 80% Filling of Tanks is considered.
Storage days for Isom feed

ISOM
1004 FEED 2640
DENSITY OF ISOM 653 KG/M3
FEED
AVAILABLE TANK
CAPACITY 1724 MT
EXPANSION
CAPACITY 0.3 MMTPA
37.5 MT/HR
COVERAGE DAYS 2 DAYS
Storage days for NHT Feed

NHT FEED
1003 (CCR ) 2056
DENSITY OF NHT 740 KG/M3
FEED
AVAILABLE TANK
CAPACITY 1521 MT
EXPANSION 0.654
CAPACITY MMTPA
81.75 MT/HR
Note
1. 80% Filling of Tanks is considered.

Storage days for CCR Feed

1001 CCR FEED 2640
DENSITY OF CCR 740 KG/M3
FEED
AVAILABLE TANK
CAPACITY 1954 MT
EXPANSION 0.654
CAPACITY MMTPA
81.75
MT/HR

LOGISTICS Document No.
SECTION 7.7
LOGISTICS

7.7 LOGISTICS
This chapter deals with movement of crude, finished products and utilities.
7.7.1 Crude & BH Gas
Various Crudes viz: Bombay High, Arab Light, Arab Mix, Basrah, Tapis, Miri, etc
are processed in HPCL Mumbai Refinery. Crudes are off loaded from Jawahar
Deep through 42” pipeline to Pirpau Manifold. Subsequently, Crudes are
transported from Manifold to Mumbai Refinery through two pipelines of 24”and 36”
size.
BH Gas is transferred to Mumbai Refinery from ONGC Uran through 24” Pipeline.
7.7.2 FINISHED PRODUCTS
The final products from refinery as listed below:
 LPG
 SCN
 Export Naphtha
 Hexane &Solvent 1425
 MS
 SKO
 Aviation Turbine fuel
 MTO
 HSD
 LDO
 IFO ( Fuel Oil of various types)
 Bitumen
 LOBS of various grades
Detailed shipment facilities of all products are described below:
 LPG: LPG is evacuated from refinery via road tankers as well as via pipeline.
LPG is evacuated via pipeline to HP BDU only at a shipping rate of max
43TMT/Month. Two Big Pumps of 85TPH capacity each and three small pumps
of 40 TPH capacity each are installed for this purpose. The discharge line size
is 6”. Currently coastal evacuation facility is not available. It is being developed
by HPCL/BPCL.
 SCN: SCN is evacuated to Reliance from offsite tanks (TKS-370&312) at a

shipping rate of max 8TMT/Month via pipeline. Pump capacity of 150TPH is
installed for this purpose. The discharge line size is 8”.

 Export Naphtha: It is evacuated from Refinery (i.e. fromTanks-252&253) to

Reliance at a shipping rate of 20TMT/Month through pipeline. Maximum
shipping capacity is 30TMT/Month. A Big Pump of 750TPH capacity and small
pump of 300 TPH capacity are installed for this purpose. Also, an alternate
shipment facility to Mahul terminal by rail rake is available.
 Hexane & Solvent 1425: They are evacuated via pipeline to Mahul terminal at
a shipping rate of 1.5TMT/Month. Maximum shipping capacity is 3TMT/Month.
Two Pumps (1W+1S) of 100TPH capacity are installed for this purpose. The
discharge line size is 3”.
 MS: MS is evacuated to four destinations through Pipeline from the Refinery.

The details of the shipping facilities of above destinations are tabulated below:
Shipment Rate Suction line Discharge line

Destination
(TMT/Month) (size) (size)
MPSPL 90(Note-1) 20” 12”
Mahul Terminal 5(Note-2) 12” 6”
Wadala Terminal 10(Note-3) 12” 14”
Coastal 15(Note-4) 12” 14”/30”(Note-5)
Shipment
Notes:
1. Maximum shipping rate is 110TMT/Month.
2. Two pumps with one operating and one standby of capacity 200TPH is
installed for evacuation.
3. One Big pump of capacity 300TPH and two small pumps of 200TPh capacity
each are installed for evacuation.
4. One Big pump of capacity 675TPH and one small pump of 300TPh capacity
5. Discharge line size is 14” upto Pirpau Manifold and beyond it is 30”.
6. Simultaneous transfer of Mahulterminal, Wadala terminal and coastal
shipment is not possible due to common suction line.
 SKO: SKO is evacuated to three destinations through Pipeline from the

Refinery. The details of the shipping facilities of above destinations are
tabulated below:


Destination
MPSPL 15(Note-7) 20”
Mahul Terminal 2-5(Note-8) 10” 6”
Sewri/Wadala 5-10(Note-9) 14”/30”(Note-10)
Terminal
Notes:
8. One pump with of capacity 250TPH is installed for evacuation.
9. One Big pump of capacity 200TPH is installed for evacuation.
 ATF: ATF is evacuated to two destinations through Pipeline from the Refinery.
The details of the shipping facilities of above destinations are tabulated below:

Destination
Sewri/Wadala 5-10(Note-11) 14”/30”(Note-13)
Terminal
Airport 50(Note-12) 12” 10”
Notes:
11. Shipping facility is same as SKO.
12. Two Big pumps of capacity 250TPH and two small pumps of 175TPh capacity
 MTO: MTO is evacuated from refinery via pipeline. It is evacuated via pipeline
to Mahul terminal only at a shipping rate of max 7TMT/Month. One Pump (1W)
of 200TPH capacity is installed for this purpose. The Suction line size
&discharge line size are 10” &6” respectively.
 HSD: HSD is evacuated to three destinations through Pipeline from the

Refinery. The details of the shipping facilities of above destinations are
tabulated below:

Destination
MPSPL 180 (Note-14) 20”
Mahul Terminal 10(Note-15) 10” 6”
Coastal Shipment 25-40(Note-16) 20” 20”/30”(Note-17)
Notes:


15. One pump of capacity 300TPH is installed for evacuation.
16. One Big pump of capacity 650TPH and one small pump of 300TPh capacity
18. Simultaneous transfer to MPSPL and coastal shipment is not possible due to
common suction line.
 LDO: LDO is evacuated from Refinery to HP Mahul only through10” S/C line at
a shipping rate of max 7TMT/Month (10TMT/Month max). A Pump of capacity
of 300TPH is installed for this purpose. Discharge line size is 8”.
 Fuel Oil: Fuel Oil is evacuated in various grades i.e. IFO 180cst, IFO Bunker &
LSHS to five destinations through Pipeline from the Refinery. The details of the
shipping facilities of above destinations are tabulated below:

Destination
Mahul Terminal 40-60(Note-1,2)
Vashi Terminal 25(Note-3)
Coastal 15-30(Note-4) 20” 20”/36”(Note-5)
Shipment(Local)
Coastal 15(Note-6) 20” 20”/36”(Note-5)
Shipment(Export)
Sewri/Wadala 10(Note-7)
Terminal
Notes:
1. Four Big pumps of capacity 500TPH and two small pumps of 400TPh capacity
2. Two Big Pumps are dedicated for IFO and other two pumps are common for
both IFO& LSHS.
3. Infrastructure (pumps/piping etc) belongs to MPSPL..
4. Two Big Pumps (1W+1S) of 900TPH capacity each are installed for
evacuation purpose.
6. Export is done between June to October. Only one parcel of FO 380 is
exported. Maximum shipping rate is 100TMT/Month with three parcels
7. Only Bunker IFO is shipped vide this route. Infrastructure is common with
Coastal Local evacuation.
 Bitumen(Bulk&Packed):

 It is dispatched as ‘Bulk Bitumen’ in tanker trucks. Capacity of each tanker

truck can be 15, 20&25MT. Shipment rate is 50TMT/Month (Max
80TMT/Month) and 10TMT/Month (Max 20TMT/Month) in normal season and
rainy season respectively.
 Bitumen is also dispatched as ‘Packed Bitumen’ in drums by trucks. Capacity
of each truck is 2000 drums. Shipment rate is 15TMT/Month (Max
20TMT/Month) both in normal season and rainy season.
 A New 60 MT Bitumen weigh bridge is envisaged and the cost of same has
been considered in Capital estimate.
Also, during normal season, frequency of Tanker Truck/Day for bulk loading (three
shifts) is 110(max150) and truck for packed loading is 10-12 days.
The utility systems are an integral part of the refinery and constructed on the
Refinery site. All utilities required for the plant shall be generated inside the
complex .The refinery is self-sufficient in all its utility requirements except raw
water and partly power.
 LOBS:
HPCL is presently producing different grades of lubricating oils, viz. Spindle Oil,
150N, 500N, IO-100 & Bright Stock. These different grades are stored either in
1300 or 1400 series tanks. There are presently nine dedicated tanks in LR offsite
area for transferring existing five grades of LOBS products to marketing terminal
LOPL.
To evacuate five different grades, two 16” pipelines are existing from these nine
tanks to LOPL shipping pumps 21-P-101A/B/C/DE. Theses pipelines are termed
as “Top” & “Bottom” suction lines. Only two tanks of 500N grade LOBS are
connected to the “Top” suction line while rest seven tanks of balance grades are
connected to the “Bottom” suction line. In existing practice, suction line content is
displaced by gravitation after each & every shipment as per requirement of the
grade of LOBS to be shipped or evacuated to LOPL. . The LOPL pumps 21-P-
101A/B/C/DE are utilized to pump different grades of lube oils to tanks in
Mazgaon.
It is planned to convert the existing 16” LOPL pump suction header (Bottom) to
piggable header and also to be routed through 1400 series tank farm (for which
evacuation facility presently does not exist) before connecting LOPL pump (21-P-
101A/B/C/D/E) suction. Also this partly existing 16” header is to be replaced by a
new 16” header before connecting the new piggable header in 1400 series tank
farm area.
This new 16” header will enable routing of lube oil from both 1300 and 1400 series
tank farm areas for evacuation of Group-I and Group-II products post LOUP. The
“Top” suction line shall be dedicated for Bright Stock evacuation.

Since different grades of oil will have to be pumped using 16” LOPL pump suction
header (Bottom), it is proposed to install pig launcher and receiver for this new 16”
LOPL pump suction header (Bottom) to enable pipeline evacuation & to avoid
mixing of two different grades of oils, especially three new grades of Gr II products
which are highly sensitive as far as product quality is concerned.
Also, , it is proposed to convert the two new 150N storage tanks to Bright Stock
storage tanks and provide external heating facility (electrical heat tracing) for these
two new storage tanks to maintain the storage temperature at 40 - 50 0 C.
Raw water: Raw water is made available at the refinery battery limit from BMC..
Raw water storage and treatment facility is provided for the refinery. Raw water is
the source for Cooling water, DM water, Drinking water and BFW that are used in
the plant.
Power: Post expansion power available from CPP will be around 13 MW. The
balance power shall be available from Grid power.

ENVIRONMENTAL CONSIDERATIONS Document No.
SECTION 8
ENVIRONMENTAL CONSIDERATIONS

8.0 INTRODUCTION
Various pollution control measures required to meet the prevailing environmental

standards are planned at the different stages of execution of the project, viz.,
design, construction and operational phases.
8.1 INDIAN ENVIRONMENTAL LEGISLATION
Government of India has made many legislations/rules for the protection and
improvement of environment in India. Various environmental legislations/rules
applicable to the proposed project facilities are as follows.
Table 8.1: Indian Environmental Legislation

Legal Instrument Relevant articles/provisions
The Environment (Protection) Section 7: Not to allow emission or discharge
Act, 1986, amended up to 1991 of environmental pollutants in excess of
Environment (Protection) fifth prescribed standards
Amendment Rules, 2009 Section 8: Handling of Hazardous substances
Section 10: Power of entry and inspection
Section 11: Power to take samples
Section 15 – 19: Penalties and procedures
The Air (Prevention and Control Section 21: Consent from State Boards
of Pollution) Act 1981, as Section 37: Penalties and Procedures
amended upto 1987.
The Water (Prevention and Section 24: Prohibition on disposal

Control of Pollution) Act, 1974, as Section 25: Restriction on New Outlet and
amended upto 1992. New Discharge
Section 26: Provision regarding existing
discharge of sewage or trade effluent
Environment (Protection) Rules, Rule 3: Standards for emissions or discharge
1986 (Amendments in 1999, of environmental pollutants
2001, 2002, 2002, 2003, 2004, Rule 5: Prohibition and restriction on the
March 2008) location of industries and the carrying on
process and operations in different areas
Rule 13: Prohibition and restriction on the
handling of hazardous substances in different
areas
Rule 14: Submission of environmental
statement
Hazardous Wastes (Management Rule 4:Responsibility of the occupier and
and Handling) Rules, 2008, operator of a facility for handling of wastes
amended up to 2009 Rule 8: Disposal sites
Rule 20: Responsibility of waste generator
Manufacture storage and import Rule 4: Responsibility of operator
of hazardous chemicals rules
1989 amended 2000
EIA Notification 2006 and Requirements and procedure for seeking
subsequent amendments environmental clearance of projects

Legal Instrument Relevant articles/provisions

Noise Pollution (Regulation and Ambient noise standards and requirements of
Control) Rules, 2000, amended DG sets
up to 2010.
Coastal Regulation Zone-Notification dated May 15, 2009

The Public Liability Insurance Act, 1991, amended 1992
The Public Liability Insurance Rules, 1991, amended 1993
The refinery project shall be designed taking into account the above-referred
legislations/rules and as per the directives of Environmental Clearance
documents. Besides this the proposed effluent and emission standards for
Petroleum Refineries will also be compiled for this Project.
A brief description of the environmental protection measures proposed to be
adopted in the project with respect to the various components of the environment
like air, water, noise, land, etc., are given in the subsequent sections.
8.2 POLLUTION CONTROL MEASURES
In order to minimize the impact of the project on the environment, due attention is
being given for implementing effective pollution control measures. The design
stage Endeavour’s to mitigate the problems related to health, safety and
environment at the process technology/source level itself. The design basis for
all process units lays special emphasis on measures to minimize the effluent
generation at source.
During the operation of the refinery, the major areas of concern will be stack
emissions and fugitive emissions of hydrocarbons from the process units and
storage tanks along with disposal of treated effluent. Handling, treatment and
disposal of hazardous wastes will also be an area of concern.
The specific control measures related to gaseous emissions, liquid effluent

treatment/discharges, noise generation, solid waste disposal, etc., along with
relevant stipulated standards are described below.
8.2.1 Air Environment
The gaseous emissions from the refinery will be controlled to meet all the
relevant standards stipulated by the regulatory authorities. Standards applicable
to this refinery project can be classified into three categories:
 Emission Standards
 Ambient Air Standards and
 VOC Control, Emission and Monitoring
The standards and compliance to the above standards are given below:
The estimated SO2 emissions releases due to combustion of different types of

fuels are given below:

8.2.1.1 Emission Standards
Table 8.2: Standards for Emissions from Furnaces and Boilers

Limiting concentration in mg/Nm3,
unless stated
Sl.
Parameter New refineries, furnaces,
No. Existing
boilers commissioned
refineries
after January 01, 2006
Sulphur Gas firing 50 50
1
Dioxide (SO2) Liquid firing 1700 850
Oxides of Gas firing 350 250
2 Nitrogen
Liquid firing 450 350
(NOx)
Particulate Gas firing 10 5
3
Matter (PM) Liquid firing 100 50
Carbon Gas firing 150 100
4 Monoxide
Liquid firing 200 150
(CO)
Nickel + Liquid firing 5 5
5 Vanadium
(Ni+V)
Hydrogen 150 150
Sulphide Liquid / gas
6
(H2S) in fuel firing
gas
Sulphur Liquid / gas 1.0 0.5
content in firing
7
liquid
fuel, weight %
Notes:
(1) In case of mixed fuel (gas and liquid) use, the limit shall be computed based
on heat supplied by gas and liquid fuels.
(2) All the furnaces/ boilers with heat input of 10 million KCal/hr or more shall
have continuous systems for monitoring of SO2 and NOx. Manual monitoring
for all the emission parameters in such furnaces/ boilers shall be carried out
once in two months.
(3) All the emission parameters in furnaces/ boilers having heat input less than
10 million KCal/hr will be monitored once in a quarter.
(4) In case of continuous monitoring, one hourly average concentration values

shall be met 98% of the time in a month. Any concentration value obtained
through manual monitoring, if exceeds the limiting concentration value, shall
be considered as noncompliance.
(5) Data on Ni + V content in the liquid fuel (in ppm) shall be reported. Ni + V
content in the liquid fuel shall be monitored once in six months, if liquid fuel
source & quality are not changed. In case of changes, measurement is
necessary after a change.

In addition to the above, the particulate matter in emissions from stacks should
not exceed the maximum permissible limit of 5 mg/Nm3.
The existing refinery complex is designed to meet all the statutory requirements.
Some of the major features of these environmental measures are as follows:
 Low sulphur fuels will be used for internal fuel purpose.
 Sulphur Recovery Unit with 99.9% efficiency will be provided.
 Heaters/furnaces will be provided with well proven Low NOx burners to reduce
the emissions of Nitrogen Oxides (NOx).
 Under normal circumstances, there will be no continuous/intermittent point

releases of volatile hydrocarbon streams. However, if during start up/shut
down or an emergency situation any hydrocarbon streams are released, they
will be directed to an elevated flare for complete combustion. This will
eliminate the possibility of forming an explosive mixture due to sudden release
of unburned hydrocarbons to the atmosphere.
 The flares elevation will be such that there will be no impact of thermal
radiation on the operating personnel in the refinery. To ensure complete
combustion of released hydrocarbons through flares, a pilot burner shall
always be burning with the aid of fuel gas. Further, to ensure smokeless and
non-luminous flaring, the steam provision at the flare tip is also envisaged.
 The heights of various stacks will be determined taking into consideration the
"Guidelines for Minimum Stack Height" as per notification by MoEF dated 19th
May 1993, which fixes the minimum stack height based on emission of
Sulphur Dioxide.
This is as given below:
H=14(Q) 0.3
Where
H = Stack Height in m,
Q = Sulphur Dioxide emission in kg/hr.
If, the Pollution Control Board specifies any minimum stack height, the higher of
the two will be selected. The refinery complex is designed in such a way that the
total emissions from the refinery complex will meet all the applicable
standards/stipulations.
SOX emission limit for the existing HPCL refinery is 12.6 TPD.

Sox emission after capacity expansion:
After capacity expansion, total Sulphur Dioxide emissions from the refinery
complex will be 8.62 tonnes/ day for Expansion case. Break-up of Sulphur
Dioxide emissions, both process and emissions due to fuel use, from the refinery
complex are given below.
Table 8.4: SOx emission in Expansion case

S.No. Sources SOx (T/D)
1 FCC New 1.828
2 FCC Old 0.083
3 CPP 0.005
4 DHDS SRU 0.260
5 DHDT SRU 0.521
6 Refinery fuel gas Firing 0.074
7 Natural Gas Firing 0.001
8 Fuel Oil 5.85
Total 8.62
However in case of 85% firing by fuel oil; the SOX emission increases
to 12.43 TPD.
8.2.1.2 Ambient Air Standards
The ambient air quality around the premises will be limited to those limits as per
National Ambient Air Quality Standards, which are given below:
Table 8.5: National Ambient Air Quality Standards (Gazette No. 217
dated 18 November 2009)
Concentration in Ambient Air
Time Industrial,
S.No. Pollutant Weighted Ecologically
Residential, Methods of
Average Sensitive
Rural & measurement
Area
other areas
Annual 50 µg/m3 20 µg/m3 -Improved West
Sulphur
Average* and Gaeke
1 Dioxide
80 µg/m3 80 µg/m3 -Ultraviolet
(SO2) 24 hours**
Fluorescence
40 µg/m3 30 µg/m3 -Modified Jacob &
Annual
Hochheiser (Na-
Oxides of Average*
Arsenite)
2 Nitrogen as
80 µg/m3 80 µg/m3 -
NO2
24 hours** Chemiluminiscenc
e
Particulate Annual 60 µg/m3 60 µg/m3 -Gravimetric
3 Matter , Average* -TOEM
Size<10 µ 24 hours** 100 µg/m3 100 µg/m3 -Beta attenuation

Concentration in Ambient Air

Time Industrial,
S.No. Pollutant Weighted Ecologically
Residential, Methods of
Average Sensitive
Rural & measurement
Area
other areas
Particulate Annual 40 µg/m3 40 µg/m3 -Gravimetric
4 Matter , Average* -TOEM
Size<2.5 µ 24 hours** 60 µg/m3 60 µg/m3 -Beta attenuation
100 µg/m3 100 µg/m3 -UV Photometric
8 hours** -
5 Ozone O3 Chemilminescence
180 µg/m3 180 µg/m3 Chemical method
1 hour
0.5 µg/m3 0.5 µg/m3 -AAS/ICP method
after sampling on
Annual
EPM 2000 or
Lead(Pb) Average*
6 equivalent filter
paper
1.0 µg/m3 1.00 µg/m3 -ED-XRF using
24 hours**
Teflon filter
Carbon 2 mg/m3 2 mg/m3 -Non Dispersive
8 hours**
7 Monoxide Infra red(NDIR)
(CO) 1 hour 4 mg/m3 4.0 mg/m3 Spectroscopy
100 µg/m3 100 µg/m3 -
Annual
Chemiluminescenc
Ammonia Average*
8 e
(NH3)
400 µg/m3 400 µg/m3 -Indophenol blue
24 hours**
method
05 µg/m3 05 µg/m3 -Gas
chromotography
based continues
Annual
analyzer
9 Benzene Average*
-Adsorption and
Desorption
followed by GC
analysis
Annual 01 ng/m3 01 ng/m3 -Solvent extraction
Benzo(a)
Average* followed by
10 Pyrene
HPLC/GC analysis
(BaP)
Annual 06 ng/m3 06 ng/m3 - AAS/ICP method
Average* after sampling on
11 Arsenic (As) EPM 2000 or
equivalent filter
paper
Annual 20 ng/m3 20 ng/m3 AAS/ICP method

Average* after sampling on
12 Nickel (Ni) EPM 2000 or
equivalent filter
paper

* Annual Arithmetic mean of minimum 104 measurements in a year taken twice

a week 24 hrs. At uniform interval.
** 4 hourly/8 hourly values should be met 98% of the time in a year. However,
2% of the time, it may exceed but not on two consecutive days.
Whenever and wherever monitoring results on two consecutive days of

monitoring exceed the limits specified above for the respective category, it shall
be considered adequate reason to initiate regular or continuous monitoring and
further investigation.
8.2.1.3 VOC Control, Emission and Monitoring
Fugitive emissions are primarily due to intermittent/continuous leakage or

evaporation of Volatile Organic carbons (VOCs) from processing/storage area of
the refinery.
The major sources of such fugitive emissions of VOCs in the refinery are the
main processing area, the storage tank farm area for crude oil & products and the
loading/unloading gantry area. These fugitive emissions originate from the static
and dynamic compressor joints and seals used in flanges, pumps, valve packings
and connection joints to the atmosphere like sampling, relief valves, etc. In order
to minimize the fugitive emissions, the following measures will be taken during
engineering:
- Minimum number of flanges, valves, etc.
- High grade gasket material for packing
- Usage of state-of-the-art low leakage valves preferably with bellow seals
- Usage of pumps with Double Mechanical seals for light hydrocarbon
services
- Provisions of floating roof storage tanks
- Provisions of double seal in some of storage tanks
- Provision of covering the oil-water separation units in ETP
- Provision of seals in the drains and manholes
Storage of General Petroleum Products:
Requirements on type of storage tanks shall be as follows:

Table 8.6: Types of Storage Tanks
Total Vapour
Tank
S.No Pressure Type of Storage Tank
Capacity, m3
(TVP), KPa
Fixed Roof Tank (FRT) with pressure valve
1 > 10 4 – 75
vent
Internal Floating Roof Tank (IFRT) or External
Floating Roof Tank (EFRT) or Fixed Roof
2 10 – 76 75 – 500
Tank with vapour control or vapour balancing
system
Internal Floating Roof Tank or External
3 10 – 76 > 500 Floating Roof Tank or Fixed Roof Tank with
vapour control system
4 > 76 > 75 Fixed Roof Tank with vapour control system

Notes:
1. Requirement for seals in Floating Roof Tanks:
I. IFRT & EFRT are to be provided with double seals with minimum vapor
recovery of 96%.
II. Primary seal shall be liquid or shoe mounted for EFRT and vapour mounted
for IFRT. Maximum seal gap width will be 4 cm and maximum gap area will
be 200 cm2/m of tank diameter.
III. Secondary seal will be rim mounted. Maximum seal gap width will be 1.3
cm and maximum gap area will be 20 cm2/m of tank diameter.
IV. Material of seal and construction should ensure high performance and
durability.
2. Fixed Roof Tanks will have vapor control efficiency of 95% and vapor
balancing efficiency of 90%.
3. Inspection and maintenance of storage tanks should be carried out under strict
control. For the inspection, API RP 575 may be adopted. In-service inspection
with regard seal gap should be carried out once in every six months and repair
to be implemented in short time. In future, possibility of on-stream repair of
both seals will be examined.

VOC EMISSION STANDARD:
(I) Standards for emissions from storage of volatile liquids are as follows
Table 8.7: Standards for emissions from storage of volatile liquids
S .No Item Standards

Gasoline, Naphtha, Benzene,
1 Applicable products
Toluene, Xylene
Type of loading: (i) Road tank truck
2
(ii) Rail tank wagon (i) Bottom loading (ii) Top submerged
3 Leak testing for Vapour collection Annual leak testing
Emission control for Road tank truck/ Rail tank wagon loading
Gasoline and Naphtha: (i) VOC
4 reduction, % or (ii) Emission,
gm/m3 (i) 99.5 or (ii) 5
Benzene: (i) VOC reduction, % or
6
(ii) Emission, mg/m3 (i) 99.99 or (ii) 20
Toluene/Xylene: (i) VOC reduction,
7 % or (ii) Emission, mg/m3 (i) 99.98 or (ii) 150
(II) Standards for VOC emissions from wastewater collection and

treatment:
a) All contaminated and odorous wastewater streams should be handled in

closed systems from the source to the primary treatment stages (oil-water
separator and equalization tanks).
b) The collection system should be covered with water seals (traps) on sewers
and drains and gas tight covers on junction boxes.
c) Oil-water separators and equalization tanks should be provided with floating/

fixed covers. The off-gas generated should be treated to remove at least 90%
of VOC and eliminate odor. The system design should ensure safety
(prevention of formation of explosive mixture, possible detonation and reduce
the impact) by dilution with air/ inert gas, installing LEL detector including
control devices, seal drums, detonation arrestors, etc. The system should be
designed and operated for safe maintenance of the collection and primary
treatment systems.
d) Wastewater from aromatics plants (benzene and xylene plants) should be

treated to remove benzene/ aromatics to a level of 10/20 ppm before
discharge to effluent treatment system without dilution.
VOC Monitoring:
The standards call for stringent monitoring programme in form of LDAR which is
described below:

a) Approach: The approach for controlling fugitive emissions from equipment

leaks is to have proper selection, installation and maintenance of non-leaking
or leak tight equipment. Following initial testing after commissioning, the
monitoring for leak detection is to be carried out as a permanent on-going
Leak Detection and Repair (LDAR) programme. Finally detected leaks are to
be repaired within an allowable time frame.
b) Components to be covered: The components that shall be covered under

LDAR programme include (i) Block valves; (ii) Control valves; (iii) Pump seals;
(iv) Compressor seals; (v) Pressure relief valves; (vi) Flanges – Heat
Exchangers; (vii) Flanges – Piping; (viii) Connectors – Piping; (ix) Open
ended lines; and (x) Sampling connections. Equipment and line sizes more
than 1.875 cm or ¾ in. are to be covered.
c) Applicability: The LDAR programme would be applicable to components

(given at 2 above) for following products/ compounds: (i) hydrocarbon gases;
(ii) Light liquid with vapour pressure @ 200C > 1.0 kPa; and (iii) Heavy liquid
with vapour pressure @ 200C between 0.3 to 1.0 KPa.
d) While LDAR will not be applicable for heavy liquids with vapour pressure <
0.3 kPa, it will be desirable to check for liquid dripping as indication of leak.
e) Leak definition: A leak is defined as the detection of VOC concentration more

than the values (in ppm) specified below at the emission source using a
hydrocarbon analyzer according to measurement protocol (US EPA – 453/R-
95-017, 1995 Protocol for equipment leak emission estimates may be
referred):
Table 8.8: Estimates of equipment leak emissions

General Hydrocarbon Benzene
(ppm) (ppm)
Sl. No Component w.e.f w.e.f
Till 31st Till 31st
January January
Dec.2008 Dec.2008
01,2009 01,2009
Pump/
1 10000 5000 3000 2000
Compressor
2 Valves/ Flanges 10000 3000 2000 1000
Other
3 10000 3000 2000 1000
components
f) In addition any component observed to be leaking by sight, sound or smell,

regardless of concentration (liquid dripping, visible vapor leak) or presence of
bubbles using soap solution should be considered as leak.
g) Monitoring requirements and repair schedule: Following frequency of

monitoring of leaks and schedule for repair of leaks shall be followed:

Table 8.9: Monitoring Schedule of VOC emission

Sl.
Component Frequency of monitoring Repair schedule
No.
1 Valves/ Flanges Quarterly (semiannual after
two consecutive periods
with < 2% leaks and annual
after 5 periods with < 2% Repair will be started
leaks) within 5 working days
and shall be
completed within 15
2 Pump seals Quarterly working days after
3 Compressor seals Quarterly detection of leak for
4 Pressure relief devices Quarterly general hydrocarbons.
Pressure relief devices In case of benzene,
5 Within 24 hours the leak shall be
(after venting)
attended immediately
6 Heat Exchangers Quarterly
for repair.
7 Process drains Annually
8 Components that are Annually
difficult to monitor
9 Pump seals with Immediately Immediately
visible liquid dripping
10 Any component with Immediately Immediately
visible leaks
11 Any component after Within five days
repair/ replacement -
h) The percentage leaking components should not be more than 2% for any
group of components monitored excluding pumps/ compressors. In
case of pumps/ compressors, it should be less than 10% of the total number
of pumps/ compressors or three pumps and compressors, whichever is
greater.
i) Emission inventory: The refinery shall prepare an inventory of equipment

components in the plant. After the instrumental measurement of leaks,
emission from the components will be calculated using stratified emission
factors (USEPA) or any other superior factors. The total fugitive emission will
be established.
j) Monitoring: Following types of monitoring methods may be judiciously

employed for detection of leaks: (i) Instrumental method of measurement of
leaks; (ii) Audio, visual and olfactory (AVO) leak detection; and (iii) Soap
bubble method.
k) Data on time of measurement & concentration value for leak detection; time
of repair of leak; and time of measurement & concentration value after repair
of leak should be documented for all the components.
l) The pressure relief and blow down systems should discharge to a vapor
collection and recovery system or to flare.

m) Open-ended lines should be closed by a blind flange or plugged.
n) Totally closed-loop should be used in all routine samples.
o) Low emission packing should be used for valves.
p) High integrity sealing materials should be used for flanges.
8.2.1.4 Odour Control
Odor from the refinery complex originates due to fugitive emissions of

hydrocarbons, the burning of Sulphur containing fuels, the presence of Sulphides
and VOCs in the effluent, the addition of mercaptans to LPG to detect its
leakage, etc. Therefore, the design measures suggested as part of controlling
stack and fugitive emissions are applicable for odour control as well.
8.2.1.5 Noise Environment
Ambient Standard for Noise, specified by CPCB is given below:
Table 8.10: Noise (Ambient Standards)

S. No. Area Code Category of Area Limit in dB (a) Leq
Day Time Night Time
1.0 A Industrial area 75 70
2.0 B Commercial area 65 55
3.0 C Residential area 55 45
4.0 D Silence zone 50 40
Notes:
(1) Daytime is reckoned in between 6 a.m and 9 p.m.

(2) Nighttime is reckoned in between 9 p.m and 6 a.m.
(3) Silence zone is defined as areas upto 100 meters around such premises as
hospitals, educational institutions and courts. The silence zones are to be
declared by the competent authority.
(4) Mixed categories of areas should be as "one of the four above mentioned
categories" by the competent authority and the corresponding standard
shall apply.
Comprehensive measures for noise control will be followed at the design stage in
terms of
- Noise level specification of various rotating equipment as per Occupational
Safety and Health Association (OSHA) standards.
- Equipment layout considering segregation of high noise generating
sources.
- Erecting suitable enclosures, if required, to minimize the impact of high
noise generating sources.
- Sizing the flare lines with low Mach number to have lower noise levels.
- Green belt of appropriate width all around the refinery towards noise
attenuation

8.2.1.6 Water Environment
The additional water required for capacity expansion of refinery is 112 m3/hr
and shall be met from existing source of Bombay Municipal Corporation (BMC).
No pre-treatment of BMC raw water is required.
The waste water management system in the refinery consists of the following:-
A. Process wastewater treatment
B. Floor wash and contaminated Rain water treatment
C. Spent caustic Treatment
D. Tertiary Treatment Plant
E. Sanitary Effluent Treatment Plant
F. DM Plant
G. Cooling Tower Blow Down
The treatment shall be different for each effluent stream such as Oily Effluent
from Process units and Tank Farm area, Floor wash & Contaminated Rain
water and Spent Caustic in the wastewater Treatment Plant.
Integrated Effluent treatment plant:

IETP was commissioned in 2010 with state of art technology. The permeate
from Reverse Osmosis system is routed to DM Plant and feed.
 The design capacity of IETP is 300 m3/hr.

 The actual operating flow to IETP is 125-130 m3/hr with all the units in
operation.
 The additional flow proposed to be generated after refinery capacity
expansion shall be 48 m3/hr.
 Therefore, post refinery capacity expansion, total flow to IETP shall be
130 m3/hr + 48 m3/hr which equal 178 m3/hr.
As the existing IETP can handle the above flow of 178m3/hr, no new ETP is
proposed for treatment.
Spent caustic
The design capacity of existing spent caustic treatment system 6 m3/hr.
The additional flow after refinery capacity expansion shall be 2 m3/hr.
Contaminated rain water:

Contaminated Rain Water (CRW) will be routed as per exiting philosophy and
will be treated in LR-API Seperator.
Cooling water Blow down:

Blow down from cooling water (sea water cooling) shall be diverted as per
existing system in the refinery.
Sanitary waste:
No additional flow is envisaged from the proposed modification.

8.3 ETP TREATED EFFLUENT CHARACTERISTICS
Treated effluent from the plant shall be of fresh water quality for being recycled
as D.M. plant feed / Floor wash water network. It should meet the following
design parameters:
Treated effluent from IETP which needs to be disposed to the sea shall meet the
quantitative and qualitative limits of parameters stipulated in proposed Minimal
National Standards (MINAS-Refineries) as given below:
Table 8.14: ETP Treated Effluent Characteristics

Limiting value for
Limiting value for
quantum
concentration Averaging
S.No Parameter (kg/1000 ton of crude
(mg/l, except for Period
processed, except
pH)
for pH)
Parameters to be monitored daily: grab samples for each shift with 8-hours’ interval
1 PH 6.0 – 8.5 - Grab
2 Oil & Grease 5 2 -do-
Parameters to be monitored daily: composite sample (with 8-hours’ interval) for
24-hours flow weighted average
3 BOD3 days, 270C 15 6 24-hours
4 COD 125 50 -do-
5 SS 20 8 -do-
6 Phenols 0.35 0.14 -do-
7 Sulphides 0.5 0.2 -do-
8 CN 0.2 0.08 -do-
Parameters to monitored once in a month: composite sample (with 8-hours’ interval) for
24-hours flow weighted average
Ammonia as
9 15 6 -do-
N
10 TKN 40 16 -do-
11 P 3 1.2 -do-
12 Cr (VI) 0.1 0.04 -do-

Limiting value for

Limiting value for
quantum
concentration Averaging
S.No Parameter (kg/1000 ton of crude
(mg/l, except for Period
processed, except
pH)
for pH)
13 Total Cr 2.0 0.8 -do-
14 Pb 0.1 0.04 -do-
15 Hg 0.01 0.004 -do-
16 Zn 5.0 2 -do-
17 Ni 1.0 0.4 -do-
18 Cu 1.0 0.4 -do-
19 V 0.2 0.8 -do-
Parameters to monitored once in a month: grab samples for each shift with 8-hours’
interval
20 Benzene 0.1 0.04 Grab
Benzo(a)
21 0.2 0.08 -do-
Pyrene
Land
During the design stage itself due care will be taken to select the process
technologies generating minimum solid wastes so that their handling, treatment
and disposal do not cause any serious impact on the existing land environment.
Also, efforts will be made to recycle some of the spent catalysts by way of
returning to the original supplier for reprocessing.
The solid wastes management plan proposed is briefly described below. The
provisions of Hazardous Waste (Management & Handling) Rules, 2008,
amended up to 2009, will be complied with.
There are primarily four types of solid wastes generated in a refinery:
1. ETP Sludge’s
2. General Solid Wastes
3. Tank Bottoms
4. Chemicals
ETP Sludges
The sludge separated in different units of ETP, viz., oily & chemical sludge shall
be collected and sent to nearby Pollution control board (PCB) authorized agency
for further disposal.
General Solid Wastes

Small quantities of non-hazardous, non-recyclable solid waste consisting of
waste refractory, spent insulation, used filter cartridges, spent charcoal, spent
clay and sand will be generated. These wastes will be sent to nearby Pollution
control board (PCB) authorized agency for further disposal.
Tank Bottom Sludge

Existing Tank bottom sludge disposal scheme will be continued for all the
existing and proposed Tankages after oil recovery.

Chemicals:
The chemicals used in various process units will be procured, stored and used as
per the rules of “Manufacture Storage and import of hazardous chemicals Rules
1989, amended 2000”.
8.4 CONSTRUCTION PHASE
The overall impact of the pollution on the environment during construction phase
is localised in nature, reversible and is for a short period.
Air
The suspended particulate pollution generated during transportation will be
mitigated by covering the vehicles so as to ensure no spillage. Hosing down the
wheels of the vehicles with water and providing washing troughs for them would
further mitigate the amount of dust generated. In addition, emission of other
pollutants from construction machinery using diesel driven prime movers, will be
controlled by proper maintenance.
Noise
Noise emissions from construction equipment will be kept to a minimum by
regular maintenance. Heavy and noisy construction work will be avoided during
night time.
Water
The existing drinking and sanitation facilities at the refinery will be extended to
the construction workforce. This is necessary to reduce pollution of any receiving
water body and also to prevent hazards due to water borne vectors. Potable
water shall be provided to the workers.
Socio Economic
Being the proposed project an expansion project coming up within existing
refinery battery limit, there will be no permanent impact on the existing socio-
economic system around the refinery.
8.5 OPERATION AND MAINTENANCE PHASE
It is envisaged that with strict adherence to the pollution prevention and control
measures during the design stage, the environmental impacts could be
moderated to the minimum possible level during the operation phase.
Air
(A) In-plant Control Measures
Some of the important operational measures, which can reduce the impact
on air environment, are as follows:
- Ensuring the operations of various process units as per specified
operating guidelines/operating manuals.
- Strict adherence to maintenance schedule for various
machinery/equipment.
- Good house keeping practices

(B) Stack and Ambient Air Monitoring
In order to keep a check on the emissions of SO2, NOx, SPM and CO from
reactor/regenerator, boiler and furnace stacks shall be monitored as per
statutory regulations. Continuous monitors for emissions shall be installed
on all major stacks. Ambient Air Monitoring Stations shall continuously
monitor quality of the air outside the vicinity of the refinery premises.
Noise
As the plant is going to be operational on a 24-hour basis, noise considerations
are very important. All equipments will be specified to meet 85 dB (A) at 1 m
distance. The exposure of employees working in the noisy area shall be monitored
regularly to ensure compliance with the OSHA requirements.
Water
Some of the measures, which can be taken up during operational phase of
the complex are:
- Reducing the actual process water consumption by way of improvement

in operation of processing units.
- Looking into more options of reusing the treated effluent besides fire
water make up or for horticulture development.
- Ensuring proper monitoring and maintenance schedule for the effluent
treatment plant.
- Providing reuse and recycle of the treated effluent and water.
(B) Water Quality Monitoring

The monitoring of raw influent, the intermediate stages of Effluent Treatment
Plant, the treated effluent, the receiving water body and the ground water
quality in the surrounding areas will be carried out regularly. For regular
monitoring of the operation of various pollution control facilities, a laboratory
with sophisticated instruments and well-trained manpower shall be
established. An already existing refinery Pollution Control Cell with qualified
Chemical Engineers/Scientists also form part of the facility, which will ensure
that all pollution control measures are effectively operating and to carry out
day-to-day checks, trouble shooting and further improvements wherever
necessary.
Land
To improve the environmental quality following measures are recommended.
- The solid waste generated in the form of packaging material etc. shall be
sold off for making it suitable for reuse by reprocessing.
- The solids wastes identified to be sent to nearby authorized landfill agency
for further disposal.
- In order to improve the aesthetics in the plant surrounding, further
plantation shall be carried out the around the plant boundary.

Socio-Economic
Since the project is for green fuels it will have no major impact on the local
socio-economic status of the region particularly on infrastructure such as road,
railways communication, education and other common facilities. HPCL shall
take part actively in the overall development of the area.
8.6 ENVIRONMENT CELL
Existing Plant Safety & Environment Department under its technical services
department, which consists of well-qualified and experienced technical
personnel from the relevant fields, will look after Environment cell.

Project Implementation and Schedule Document No.
a Configuration Study & DFR For A430-RP-02-41-001
SECTION 9
PROJECT IMPLEMENTATION AND SCHEDULE

9.0 INTRODUCTION
The main purpose for realization of implementation strategy for Configuration study
& DFR for Mumbai Refinery Expansion Project is to define a natural approach to a
sequence of planned events to allow the progress of the work to be achieved in the
set time frame and within the planned budget.
There are various modes of project implementation namely:

 Conventional Mode of Execution (EPCM : Engineering, Procurement
Contract Management)
 Lump Sum Turnkey / Open Book Estimates (LSTK/OBE)
Based on the merits and de-merits of the above mentioned mode of execution of
the project HPCL shall review and finalise the mode of execution.
9.0.1 Engineering, Procurement Contract Management (EPCM) mode of

Implementation
In this mode of execution, Owner line up a CONSULTANT to perform the following

activities and Owner has responsibility for placement of orders and contracts.
 Residual Process Design

 Detailed Engineering
 Contracts and Purchase
 Inspection
 Shipping
 Construction Supervision
 Commissioning Assistance
 Overall Project Management and control
Advantages:
 Minimal Investment Risk
 Paralleling of activities with Front End Design for upstream Schedule advantages
Disadvantages:
 Diffused responsibilities leading to high Schedule risk
 Uninhibited Tendency to affect mid course changes
 Extensive Owners Management set up

9.0.2 Engineering, Procurement and Construction (EPC) mode of Implementation
In this mode of execution, there are two type of contract implementation philosophy:
 Lump sum Turn Key (LSTK)
 Open Book Estimate (OBE)
Lump Sum Turn Key (LSTK) / Open Book Estimate (OBE) mode of
Implementation
In this mode of execution, OWNER engages a CONTRACTOR to implement the job

on EPCM basis with fixed commitment on Project Schedule at an agreed fee /Cost.
In case of LSTK contract, contractor has to complete work within agreed schedule
and Cost. In case of OBE mode, the Contractual arrangement provides for the
commitments to be made by contractor & shared with the owner transparently till an
agreed commitment level of 65-70% of the target cost is achieved (at the point of
time when majority of orders and contracts are awarded, while services cost quoted
in lump sum and service fees as percentage at the time of bidding), however single
Point responsibility lies with the Contractor to deliver the project as per agreed
schedule. There may be option for conversion of the contract to LSTK mode after
typically 65-70% of the commitment of the Target cost has been achieved.
Advantages:
 Minimizes Contractor/client risks - Optimizes the Project Investment.
 Enables start of Implementation from Process Package resulting in
significant Schedule gains. No need of formal FEED.
 Transparent working arrangement between Owner and Contractor.
 Owner gets the combined benefits of EPC and EPCM under the ambit of
PSU procedures for optimal cost and Fixed time frame advantage.
 Option of Converting the OBE Contract to LSTK available with Owner based
on a pre agreed arrangement.
 Significant Cost advantage accrual out of minimisation of Financial risks of
the Contractor.

9.0.3 Comparison between Different modes of Implementation
The qualitative comparison between different modes of execution is tabulated

below:
Table 9.1: Comparison between different modes of implementation
EPC
PARAMETER EPCM
(OBE/LSTK)
Overall Cost Low High
Schedule Commitment Low High
Owner’s Risk High Low
Contractor Risk Low High
Flexibility to Change High Low
Contractual Issues & Change Orders Low High
Owners Management team Resources High Low
Quality of Produce Flexible Not Flexible
9.1 ASSUMPTION AND STIPULATIONS FOR STUDY SCHEDULE
Following assumption and stipulations have been considered in preparation of

implementation schedule:
1. Project Zero date has been considered as date of availability of MoE&F

Clearance. However Process Package and Detailed Engineering activities are
planned to commence before MoE&F Clearance.
2. Process Package for FRAPS Revamp and new VPS in FR Unit are considered to
be available from licensor M/s Process Consulting Services on the Project Start
date.
3. New VBU and new HGU are considered as licensed unit for which licensor
selection shall be done by HPCL.
4. For NHT/CCR, NHT/ISOM, PRIME-G and DHDT Unit modification, it is assumed
that HPCL has completed the award related formalities with respective former
Licensors on the project start date.
5. Revamp of FRAPS, MS Block, modification in DHDT Unit for Hydrotreating VGO
and U/O considered to be executed in EPCM mode.
6. Execution of new VPS, HGU Unit and Visbreaker Unit are considered on LSTK
basis.

7. Scope of work for unit modifications, new units and utility systems / offsite has
been considered as per the DFR scope.
8. Duration of Max. 2 weeks is considered for documents requiring Client's
comments / approval. Efforts to be made to get the documents approved within a
week or across the table.
9. Provision for air freighting of imported items shall be made depending on
schedule requirement.
10. Graded site free from all encumbrances considered to be available before start of
any construction activity.
11. Since expected Zero date is not known, the impact of monsoon is not able to
depict in the schedule. However, the construction activities shall have the
monsoon period impact (~4 Months/year). Adequate monsoon protection shall be
in scope of respective contractors.
12. Procurement of materials required for tankage works like plate, piping materials,
electrical/ instruments bulk are under scope of contractors.
13. Construction power & Construction water is considered to be made available
from existing sources of power and waters of refinery.
14. Utilities required shall be hooked-up from existing system and shutdown for new
facilities will be provided for hook ups as per schedule requirement.
15. For revamp of existing units and hook ups with existing facilities, unit shutdown
as per construction requirement considered to be available. Shutdown schedule
of each unit to be finalized in consultation with HPCL / site operations group at
later stage during Detailed Engineering.
16. Since the entire job shall be done within running refinery, barricading shall be
made for units and fabrication shop and round the clock work permit for offsite
works shall be available during construction phase.
17. Existing utilities facilities to be made available by HPCL for pre-commissioning
activities, as per schedule requirement.
9.2 IMPLEMENTATION SCHEDULE
To achieve existing refinery thru’put of 9.5 MMTPA, the implementation of the

expansion project shall include the following:
Expansion Case (Case II):
 Revamp of FRAPS upto a crude thru’put of 6 MMTPA as per the BEDP

prepared by M/S Process Consulting Services (PCS).

 Installing a new VPS Unit (VDU) for processing equivalent quantity of RCO
 Dismantling the existing FRVPS and LRVPS Units.
 Modifications in DHDT Unit to ensure hydrotreating of Vacuum Gas Oil

(VGO). The hydrotreated VGO shall be routed to Old FCCU as Feed.
 Installing a new Hydrogen Generation Unit of capacity 36 KTPA in order to

meet the peak requirement of hydrogen during operation of DHDT in VGO
mode.
 A new Visbreaker Unit, as an option of residue upgradation: This would

improve high sulphur and heavier crude processing capability and also
improve distillate yield for value addition by reduction of cutter in fuel oil pool.
 Necessary Utilities and Offsite tankages.

SCHEDULE CASE II - Configuration Study and DFR For HPCL Mumbai Refinery Expansion
S. N. DESCRIPTION REMARKS
-9 -8 -7 -6 -5 -4 -3 -2 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
I MoE&F CLEARANCE
PROJECT START PROJECT ZERO
II PROCESS ACTIVITIES DATE DATE
A FRAPS Revamp (up to 6 MMTPA)
i Process Package from M/s Process Consulting Services Available
ii Residual Process for FRAPS
B New VPS in FR Unit (New VDU)

i Process Package from M/s Process Consulting Services Available
ii Residual Process for New VPS
C New HGU (36 KTPA)

i Licenser selection (By HPCL)
ii Process Package
NHT/CCR , NHT/ISOM and PRIME-G Revamp by 20% (Licensed

D
units)
i Process Package from respective Licensors
E DHDT unit modification (Licensed units)
i Process Package from DHDT Licensor
F New Visbreaker Unit (Licensed units)
i Licenser selection (By HPCL)
ii Process Package
G UTILITIES OFFSITES
i Process Package
H Health Check
i Health Check of existing Equipment / Facilities
III EPCM ACTIVITIES MECH. COMPLN.
(NEW UNITS)
1 RESIDUAL BASIC ENGINEERING
2 DETAILED ENGINEERING
3 PROCUREMENT ACTIVITIES
a FRAPS
i CDU Column - New internals 10 M
Other columns (FBS stripper, ATF Stripper, LVGO stripper,

ii 10 M
Naphtha stabilizer) - New trays
Preflash tower - Addition of Trayed section to an existing
iii 12 M
vessel to convert it into a column
iv Preflash tower overhead receiver - 1 no. new vessel 8M

Shut Down schedule of each unit
Exchangers - (New 5 nos., New bundles & channel head for 3 to be finalized in consultation
v existing exchangers and New helical baffle bundle in 16 with HPCL / site operations 10-12 M
existing exchangers) group at later stage during
detailed engineering.
vi Pumps (New 12 nos. and New casing for one existing pump) 8-12 M
Air Cooler (One new air cooler with motor & fans and New
vii bundles for an air cooler) DEL. 12 M
b MS BLOCK (NHT/CCR, NHT/ISOM and Prime G)

New CCR net gas centrifugal compressor (140% of the
i DEL. 12 M
existing capacity)
ii Air Cooler Modifications (2 fans with structure) DEL. 12 M
iii Vessels - New 2 nos. in PSA of CCR 8M
Page 1 of 1
SCHEDULE CASE II - Configuration Study and DFR For HPCL Mumbai Refinery Expansion
S. N. DESCRIPTION REMARKS
-9 -8 -7 -6 -5 -4 -3 -2 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
c Modification in DHDT unit for Hydrotreating VGO

i Vessels (5 Nos.) 10-12 M
ii Air Cooler (2 no.) DEL. 12 M
iii Exchangers (2 Nos.) 10-12 M
iv Pumps (3 nos.) 8-12 M
d UTILITIES OFFSITES
i New Bearing Cooling water (BCW) system (150m3/ hr) 10-12 M
ii Offsite tanks (8 Nos.), Pumps (15 Nos.) and Lines 10-12 M
iii Weigh-bridge (60MT) 8M
e Bulk Procurement
i Pipes/ Fittings/ Flanges etc.
4 CONSTRUCTION
18 Months
Heater modifications - Installation of new convection section
i
with more tubes on each furnace. (FRAPS)
16 Months
ii Civil/Structural & UG Piping Work
16 Months
Composite works (Mech/Piping,Elect, Inst., insulation, painting,
iii
fire proofing etc.)
IV LSTK Packages
1 New VPS
i FEED
ii Tender & Award

30 Months
iii Execution
2 New HGU (36 KTPA)
i FEED
ii Tender & Award

26 Months
iii Execution
3 New Visbreaker Unit
i FEED
ii Tender & Award

26 Months
iii Execution
Proposed Shut down for Preheat Stream modification in FRAPS

4
(integration with New VPS)
5 Commissioning - FRAPS with New VPS Plant Commissioning with

New units
6 Dismantling of LRVPS, FRVPS unit, existing tanks and spheres

DELIVERY (FULL)
MILESTONE ISSUE LOI / FOA DELIVERY (PART) DELIVERY AT SITE COMPLETE F - FOB DELIVERY
R MATERIAL REQUISITION T TENDER READY AWARD OF WORK ACTIVITY
Configuration Study & DFR For A430-000-2744-Z003-1
PROJECT : ISSUED WITH DFR
HPCL Mumbai Refinery Expansion 1 10-Dec-14 JS SG/SSM Dr. SA STUDY SCHEDULE WITH DFR - IMPLEMENTATION (CASE II )
Document No.
CLIENT : M/s HPCL REV DATE PURPOSE PREP CHKD APVD
5-2744-0101 F1 Rev 0 dated 21.03.12
Page 1 of 1
PROJECT COST ESTIMATE Document No.
SECTION 10
PROJECT COST ESTIMATE

10.0 CAPITAL COST ESTIMATE
10.1 INTRODUCTION
HPCL Mumbai Refinery has an installed capacity of 7.5 MMTPA and 450 TMTA of
LOBS.
Due to rapid growth in demand for refined products and widening price differential
between low sulfur and high sulfur/heavy crudes, HPCL has planned for the
expansion of Mumbai Refinery from current installed capacity of 7.5 MMTPA to 9.5
MMTPA along-with Residue Up-gradation facilities to enhance high sulfur and
heavier crude processing capability and also to improve distillate yield for value
addition.
The overall refinery configuration at Mumbai refinery consists of Two Atmospheric

Pipe Still(FR/FRE), Three Vacuum Pipe Stills (FR/LR/FRE), Naphtha stabilization
Unit, Naphtha Splitter Unit, Two Fluid Catalytic Cracking (FCC) unit, Three Solvent
Extraction Unit, Propane De-waxing Unit, Distillate Diesel treating units (DHDS /
DHDT), Propane De-asphalting Unit treating facilities for LPG and ATF, and other
facilities Hydrogen Generation Unit (HGU), Two Sulfur Recovery Unit, Sour Water
Stripper (SWS), etc.
HPCL intends to implement the expansion of existing refinery and residue up-
gradation unit of latest technology to maximize the middle distillates.
HPCL has entrusted Engineers India Limited (EIL) to carry out the refinery
configuration study and preparation of preliminary Project cost estimate. Various
configuration studies were carried out and Case-II has been selected for
implementation.
10.2 SCOPE
The scope under Expansion Case (Case-II) comprises the following:
 Revamp of FR APS, NHT/ ISOM, NHT/ CCR, CCR-PSA & Prime G units.
 New VBU, New VPS, New VGO-HDT and New HGU Unit will be considered.
 Dismantling of old FRVPS AND LRVPS Unit and Relocation of Existing Equipments
 Associated Utilities and Off sites facilities have been identified for implementation.
10.3 PROJECT COST
Capital cost estimate for the identified scope works out to Rs 3223.43 Crores.
This being a revamp job and no detailed engineering has been carried out at this
stage, the above cost estimate is directional only.
Validity of Cost estimate is as of 4th Quarter 2014 price level. Details of Project cost is
enclosed as Annexure.

This Capital cost estimate shall be read along with key assumptions and exclusions
listed at Para 10.4 & 10.5.
10.4 KEY ASSUMPTIONS
The basic assumptions made for working out the capital cost estimate are as under:
 Cost estimate is valid as of 4th Quarter 2014 price level.

 No provision has been made for any future escalation.
 No provision has been made for any exchange rate variation.
 It has been assumed that all Process units and utilities & off-site facilities
would be implemented on conventional mode except for VBU, VPS and HGU
which will be implemented on LSTK Mode.
 Existing land is adequate for the upgradation project and no cost provision
has been made for the same. Existing land is flat and does not require any
site development and no cost provision has been made for the same.
 Existing infrastructure facilities are adequate and no cost provision has been
made for the same.
 Following Exchange rates has been considered (wherever applicable) for
cost estimation purpose: 1US$ = INR 60.0, 1EURO = INR 80.0.
10.5 EXCLUSIONS
Following costs have been excluded from the Project cost estimate:
 Forward escalation
 Exchange rate variation
 Cost towards statutory clearances, if any
10.6 COST ESTIMATION METHODOLOGY

Cost estimate is based on cost information available from EIL’s current in-house
cost data and Engineering inputs for cost estimation purpose. In-house cost data
has been analyzed and adopted for estimation after incorporating specific project
conditions. Cost data has been updated to prevailing price level using relevant
economic indices.
These Cost estimates are subject to identified scope of work and engineering inputs
/ technical information, the qualifications, assumptions and exclusions stated
herein.
Plant & Machinery

Cost estimate for Revamp of FR APS, New VPS and VGO-HDT Unit has been
prepared based on equipment lists and specifications available and supplemented
with in-house engineering inputs for cost estimation.
The cost estimate for revamp of other Process units (NHT/ISOM, NHT/CCR, Prime
G & CCR-PSA) has been prepared based on similar type of revamp required for
other plant and cost has been adjusted for capacity and updated to the present day
price level.

Catalyst & Chemicals

Provision for first fill of catalyst is based on in-house information on quantities and
in-house data base. Cost provision for chemicals has been made on lump-sum
basis.
Utilities & Off-sites
The cost estimate made under utilities & off-site facilities are for following systems:
 Bearing Cooling water system
 Storage Tanks
 Offsite Pumps
The cost estimate has been prepared based on system capacities, in-house
engineering information and recent in-house cost data available for similar facilities
implemented in other projects.
At this stage, MTOs have not been generated for Bulk materials and it is difficult to
assess the quantum of work for revamp job. However, cost provision for bulk
materials such as Piping, Electrical and Instrumentation have been made on factor
basis and are very preliminary. Spares and Construction costs has been made on
factor basis. These costs may vary depending upon the quantum of work assessed
during detailed engineering.
Captive Power Plant

No cost provision has been made under this head. There is an existing CPP of 49
MW to cater the power requirement of refinery. Further additional power required
will be imported.
Piling
Piling is not required as per information available.
Indirect Costs, Exchange Rates and Statutory taxes / duties
Indirect Costs and Exchange Rates
The cost estimate is based on following Exchange Rates & Indirect costs:
Exchange Rate 1 US$ = Rs. 60.0, 1 EURO = Rs. 80.0
Ocean Freight 5.0% of FOB cost of imported equipment
Port Handling 2.0% of FOB cost of imported equipment
5.0% of FOB cost of imported equipment and ex-
Inland freight
works cost of indigenously sourced equipment
Insurance 1% of total cost
Provision for ocean freight is for supplies by marine transportation / ships only. No
provision has been kept for any special transportation means such as Air freighting
or usages of barges.

Statutory Taxes & Duties

Provision for statutory taxes & duties has been made as under:
25.85% of CIF cost of imported equipment (7.5%
Custom Duty Basic Customs Duty + 12% CVD+ 3% Education
Cess and 4% SAD).
12.36% of ex-works cost of indigenously sourced
Excise Duty
equipment.
Applicable rate for CST is 2% of ex-works
including excise duty for cost of indigenously
sourced equipment. VAT has been considered
Central Sales Tax/ VAT
@12.5%. Considering 80% equipment and
material shall be sourced from outside state,
average tax considered is 4.10%.
Octroi 5.50%
Service Tax on
12.36% (12% Service Tax + 3% Education Cess)
Engineering
Service Tax on Works
4.94% on Contract value
Contract
VAT on Works 12.5% on 60% of Contract value
Contracts
Land
As per information available existing land is adequate for expansion project and no
cost provision has been made under this head.
Site Development
Existing land is flat and does not require any site development and no cost
provision has been made for the same.
Royalty, Know-How & Basic Engineering

Provision for Royalty, Process Know-How & Basic Engineering has been made
based on in-house information.
Project Management, Detailed Engineering, Procurement Services & Construction

Supervision (EPCM Services)
A provision in the cost estimate has been kept towards the services of project
management, detailed engineering, procurement services, construction supervision
and commissioning as per information. This fee is indicative in nature. Service tax
on EPCM fees has also been considered.
Roads & Buildings

Cost provision has been made for SRR and Substation buildings. Cost provision
has been made for roads based on MTO developed for the project.
Effluent Treatment Plant

It has been assumed that existing ETP shall meet the requirement of the project
and no cost provision has been made under this head.

Infrastructure Facilities
It has been assumed that existing infrastructure facilities shall meet the requirement
of the project and no cost provision has been made under this head.
Construction Site Facilities

A cost provision has been made for construction power, construction water, site
office and fabrication yard on factor basis as per in-house norms.
Township
It has been assumed that existing township is adequate.
Owner's Construction Period Expenses

Cost provision for Owner's Construction Period Expenses has been made @ 2% of
Plant & machinery for items such as project management, salaries & wages,
feasibility reports, training, legal expenses, office & vehicles hire / rentals /
maintenance, stationary, postage, travel etc. during project construction period.
Start-up & Commissioning

A cost provision for start-up & commissioning has been made @ 6.0% of plant &
machinery cost based on client’s information.
Contingency
Provision for contingency has been made @ 10% of capital cost excluding interest
during construction (I.D.C) and working capital margin. The provision has been kept
to take care of inadequacies in estimate basis definitions (including design &
execution) and inadequacies in estimating methods and data elements.
Working Capital Margin

25% of working capital has been capitalized as margin money.
Interest during construction

Interest during construction period required for the project has been worked out
based on following:
Debt - Equity ratio : 2:1
Rate of interest : 9.04%
Construction period : 3 years
Based on the above assumptions and exclusions, Project cost summary for Case-II
for the HPCL –Mumbai Refinery Expansion Project is enclosed as Annexure.

ANNEXURE 10A
Case II:
- Project Cost Summary : Case II
- FRAPS Unit Cost Summary
- New VPS Unit Cost Summary
- VGO-HDT Cost Summary
- Utilities & Offsites Cost Summary

FINANCIAL ANALYSIS Document No.
SECTION 11
FINANCIAL ANALYSIS

11.0 FINANCIAL ANALYSIS
Based on capital cost, operating cost and sales revenue, financial analysis have
been carried out for calculating internal rate of return (IRR) and other financial
results with a view to establish profitability of the project.
In-house developed Financial Model with following inputs has been used for
carrying out the financial analysis of the project.
Table 11.1 Financial Parameters

SNO FINANCIAL PARAMETERS
1 Construction Period 36 months
2 Project Life 25 years
3 Debt/ Equity Ratio 2:1
4 Expenditure Pattern Equity concurrent to Debt
5 Loan Repayment period After moratorium period in 1 year
6 Moratorium Period 10 Years
7 Interest on Long Term Debt 9.04%
Interest on Short Term / Working
8 Capital Loan 9.04%
9 Capital Phasing (Total Capital)
1st Year (03 Months) 3.0%
2nd Year 20.0%
3rd Year 42.0%
4th Year (09 Months) 35.0%
10 Capacity Build – up
1st year 90%
2nd year onwards 100%
30% + Surcharge @10% + 3%
10 Corporate Tax Rate E.Cess
18.5% + Surcharge @10% + 3%
11 MAT E.Cess
Financing charges (IDC) has been worked out as per above details.
Operating Cost
Annual operating cost has been computed based on annual quantities on
differential basis considering three years average prices towards crude, raw water &
Power. Fixed operating cost has been worked out for Repair & Maintenance @
1.0% of Plant & Machinery cost, Administrative expenses@ 0.5% of plant &
machinery and Insurance & taxes @ 0.5% of the capital cost. It is assumed that
existing manpower will cater the requirement of this project. The Operating Cost for
Case-II based on 3 years Average price with Octroi Recovery has been worked out
& is presented under Annexure.
Sales Revenue
Annual sales realization has been worked out based on annual quantities on
differential basis considering three years average prices towards products. Sales
Revenue for Case-II based on 3 years Average price has been worked out & is
presented under Annexure.
Financial Results
Based on Capital Cost estimate, Operating Cost, Sales revenue, Working Capital
and above parameters, financial results are worked out & tabulated below:
Table 11.2 Financial evaluations

SNO Description Total Cost
(Rs. Crs)
1 Capex 3223.43
2 Opex 8695.95
3 Sales 9547.13
IRR on Total Capital
Pre-tax, % 24.03%
Post-tax, % 20.60%
IRR on Equity
Pre-tax, % 50.85%
Post-tax, % 43.46%
Sensitivity Analysis
Sensitivity analysis has been carried out to check the impact on Internal Rate of
Return considering change in Capex, Opex & Sales. The IRR for all these cases
has been tabulated below based on following two scenarios:
1. Equity concurrent to Debt
Table 11.3: Sensitivity analysis for “Equity concurrent to Debt” scenario

Sr Total Capital Equity
Description
No Pre-Tax Post-Tax Pre-Tax Post-Tax
Base Case 24.03% 20.60% 50.85% 43.46%
1 Capex: +10% 21.99% 18.92% 44.83% 38.17%

Capex: -10% 26.48% 22.62% 58.24% 49.93%

Opex: +5% 12.15% 10.69% 17.27% 13.61%

Sales: -5% 10.67% 9.39% 13.00% 9.67%

2. Debt after Equity
Table11.4: Sensitivity analysis for “Debt after Equity” scenario

Sr Total Capital Equity
Description
No Pre-Tax Post-Tax Pre-Tax Post-Tax
Base Case 24.04% 20.54% 39.89% 34.47%
1 Capex: +10% 22.00% 18.86% 36.00% 30.97%

Capex: -10% 26.49% 22.55% 44.44% 38.56%

Opex: +5% 12.16% 10.65% 15.89% 12.73%

Sales: -5% 10.68% 9.35% 12.46% 9.48%
Above table indicates that Project IRR is more senstive to variation in Opex
& Product prices as compared to variation in Capex.

ANNEXURE 11A
Financial analysis

HEALTH, SAFETY AND ENVIRONMENT Document No.
Configuration
0 Study & DFR For A430-RP-02-41-0001
SECTION 12
HEALTH, SAFETY AND ENVIRONMENT
Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights

reserved
Configuration
0 Study & DFR For A430-RP-02-41-0001
12.0 HEALTH AND SAFETY
In order to ensure identification of any hazards associated with the project, which
could adversely affect the health and safety of personnel both within and outside the
complex, and the environment, a sound Health, Safety and Environment (HSE)
policy is proposed to be adopted during the course of project execution with primary
objectives as under.
a) Provide clearly defined safety system goals for the design aspects of the project.
b) Ensure a safe working environment for all plant personnel.
c) Through intrinsic safety in design, eliminate the potential for occurrence of
hazardous scenarios that can result in injuries, environmental damage, business
interruptions or loss of assets.
d) Minimize the risk and consequences of an accident which cannot be eliminated
by intrinsic safety in design.
e) Maintain satisfactory means of escape and evacuation from any conceivable
incident.
f) Minimize the potential for pollution of the environment from accidental spills,
venting or flaring of hazardous materials.
In order to ensure the above, it is proposed to carry out the following HSE related
studies during the engineering stage:
- Hazard identification (HAZID) study

- Hazard and Operability Study (HAZOP)
- Quantitative Risk Assessment (QRA) Study
- Environmental Impact Assessment (EIA)
- Hazardous Area Classification
Other health hazards that are proposed to be studied are as follows:
a) Lighting
b) Noise
c) Thermal Environment
12.1 ENVIRONMENT
Wastes are streams that are not produced for sale or internal consumption. Some of
these wastes may be toxic, poisonous, flammable and harmful to the environment.
Hence, it is of utmost importance that the wastes generated are disposed off safely.
When waste production cannot be avoided, the following design principles shall be
adopted to achieve environmental compliance:
a) Minimise the waste generation

b) Safe disposal facilities within development boundary
c) Safe disposal facilities outside the unit.

reserved
Configuration
0 Study & DFR For A430-RP-02-41-0001
Wastes generated are of three types:
a) Solid
b) Liquid
i. Aqueous
ii. Non-aqueous
c) Gaseous
i. Point source gaseous emissions
ii. Fugitive emissions
Adequate care will be taken in process design to minimize the quantity of waste
produced. In addition, solid, liquid and gaseous wastes generated from various
processes in the refinery will be handled in a manner that minimizes their impact on
the environment. Some of the measures to be taken are as follows:
 Solid Waste - It is recommended to dispose off solid waste such as spent

catalyst, tank bottom sludge and ETP sludge in secured landfills outside the
refinery complex.
 Liquid waste - A fully fledged Effluent Treatment Plant (ETP) based on the state-
of the art Reverse Osmosis (RO) technology has been considered in the
configuration to treat various liquid effluents generated in the refinery complex.
 Gaseous Effluents - Atmospheric emissions related to the proposed facilities
emanate mainly from the stacks located in various process units and in the CPP.
- SOx Control - In order to control SOx emissions according to NEMA guidelines, it

is proposed to use internal fuel oil with maximum sulphur of 0.5 wt%. This will limit
SOx emissions from individual stacks to a maximum of 12.6 TPD..
- NOx Control - Low NOx burners have been recommended to reduce NOx
emission from all furnaces.
- In addition a Plant Safety and Environment Cell consisting of qualified and

experienced technical personnel from the relevant fields will be in place to ensure
effective operation of all pollution control measures and suggest further
improvements where necessary.

reserved
RECOMMENDATIONS Document No.
SECTION 13
RECOMMENDATIONS

RECOMMENDATIONS Document No.
13.0 RECOMMENDATIONS
HPCL intends to enhance the crude processing capacity of Mumbai refinery from
present 7.5 MMTPA to 9.5 MMTPA.
The refinery capacity can be increased considering modification as enumerated in

the report. The desired capacity increase is proposed to be achieved by the
revamp of one of its CDUs (FRAPS), installing a new VPS unit, a revamp of 20% is
considered in NHT/ISOM, NHT/CCR and Prime-G respectively for necessary
enhancement of gasoline make and modifications in utilities and offsites.
The option of VBU in the expansion Case gives a fairly high yield of middle
distillates. It is a proven technology and requires no auxiliary units (such as HGU,
etc). The space requirement is low and it needs relatively low Capital investment.
The total estimated capital cost for the Expansion case is Rs. 3223.43 crores.
The cost estimates has an accuracy of ± 20% and the validity of the above cost is
as of 4th Qtr. of 2014.
IRR on total capital (post tax) for the expansion is 20.60% (based on 3 year
average price, with octroi recovery).
It is concluded that investments made can be suitably justified by increase of

product pool (MS and Diesel) and commensurate shrinkage of naphtha as well as
reduction of cutter to Fuel oil pool.

OVERALL PLOT PLAN Document No.
Configuration
0 Study & DFR For A430-RP-02-41-0001
HPCL Mumbai Refinery Expansion Page 1 of 2
ANNEXURE 1
OVERALL PLOT PLAN

reserved
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
REF. DWG. NO. REFERENCE DRAWING TITLE
N NOTES :-

DATE REVISIONS BY CHKD APPD
SCALE JOB NO. UNIT DIVN. DEPT. DWG. NO. REV.
3-1641-0500 REV.2 A0-1189 x 841

EQUIPMENT LIST Document No.
Annexure 2A
ANNEXURE 2A
EQUIPMENT LIST

reserved
Annexure 2A
1. FR APS CASE II
S.No TAG NO DESCRIPTION MODIFICATION

Vessels and Drums
New drum
Dia :2400 mm
Preflash Tower Overhead Height:6000 mm
1 11-D-2001
Receiver Type: Horizontal
Total unit equipment weight : 10500
kg
2 11-D-1021 Incorporated into 11-T-2001
Columns
New internals throughout tower
1 11-T-1 Atmospheric Pipe Still
Type:Packing +Tray
New internals :Trays 9-12
Dia :914 mm
2 11-T-2 FBS Stripper
Height:4032 mm
Type: Tray tower
Dia : 1829 mm
3 11-T-3A ATF Stripper
Height: 6248 mm
Type: Tray tower
Dia :1829 mm
4 11-T-3B LVGO Stripper
Height: 7544 mm
Type: Tray tower
New bottom 12 trays
Dia : 2500 mm
5 11-T-4 Naphtha Stabilizer
Height: 18338 mm
Type: Tray tower
Add trayed section & inlet vortex
tube cluster to 11-D-1021
Dia : 5800/2400 mm
6 11-T-2001 Preflash Tower
Height: 24200mm
Total unit equipment weight : 20300
kg
Heaters
1 11-F-1 APS Furnace Install a new convection section with
more tubes on each furnace.
2 11-F-2 APS Furnace
Air-Cooled Heat Exchangers
New service, new bundles
No of bundles:2
Area(m2)/bundle:
1 11-E-62 LVGO Air Cooler
Bare tube-197.6
Finned-3485
No of fan:2

reserved
Annexure 2A

Rating (Kw)/fan :18.6
New exchanger, motors & fans

No of bundles:4
Area(m2)/bundle:
Preflash Tower Overhead
2 11-E-2004 A/B Bare tube-698
Condenser
Finned-14991
No of fan:4
Pumps
New "D" pump
Capacity :296 m3/h
1 11-P-1A/B/C/D Crude
Head : 385 m
Motor Rating: 448 K
New pump & motor
Capacity : 81m3/h
2 11-P-4C ATF / Kerosene
Head : 120 m
Motor Rating:45 KW
New casing
Capacity : 81 m3/h
3 11-P-5C APS BPA
Head :120 m
Motor Rating:112 KW
2 new pumps
Capacity : 350 m3/h
4 11-P-5D/E APS BPA
Head : 110 m
Motor Rating: 112 KW
Purchase and install a 'D'
Capacity : 181 m3/h
5 11-P-1022D Reduced Crude
Head : 245 m
Motor Rating:166 KW
Two new pumps with motor
Capacity : 14 m3/h
6 11-P-2001A/B Preflash Overhead Water
Head : 66 m
Motor Rating: 7.5 KW
Two new pumps with motor
Capacity : 127 m3/h
7 11-P-2002A/B Preflash Overhead Product
Head : 140 m
Motor Rating:56 KW
New pump
Capacity : 73 m3/h
8 11-P-2003 Stabilizer Feed Booster
Head : 135 m
New pump & motor
Raw Crude Wash Water Capacity : 18 m3/h
9 11-P-2004A/B
Pumps Head : 345 m

reserved
Annexure 2A

Strainers
New strainer
11-STR-
1 APS BPA Wash Filters Capacity: 203 m3/hr
2001A/B
Type: Basket
New strainer
2 11-STR-2002 APS BPA PAR Strainer Capacity: 437 m3/hr
Type: Wye
New strainer
3 11-STR-2003 APS TPA PAR Strainer Capacity: 337 m3/hr
Type: Wye
New strainer
11-STR-
4 Wash Water Strainers Capacity: 6 m3/hr
2004A/B
Type: Wye

reserved
Annexure 2A
S. No TAG NO DESCRIPTION MODIFICATION

Heat Exchangers
New Exchanger
No of shells: 1
1 11-E-2001 Raw crude/VTB
Area/Shell :465.2 m2
Helixchanger design
New Exchanger
No of shells: 1
Exchanger design :Alfa laval Spiral
2 11-E-2002 Process water-desalter effluent
heat exchanger type
The duty of Exchanger is 2.4
MMKcal/hr.
New Exchanger
No of shells: 2
3 11-E-2003 A/B Desalted crude/VTB
Area/Shell:387.7 m2
Helixchanger design
New Exchanger
No of shells: 2
4 11-E-2005 A/B Flashed crude/APS TPA
Helixchanger design
New Exchanger
No of shells: 1
5 11-E-2006 Flashed crude/LVGO
Area/Shell :314 m2
Helixchanger design
New helical baffle bundle
6 11-E-1 Raw crude/ATF No of shells: 1
Area/Shell :311 m2
7 11-E-3 Raw crude/ATF No of shells: 1
Area/Shell :311 m2
8 11-E-4 Flashed crude/APS BPA No of shells: 1
9 11-E-7 Raw crude/LVGO No of shells: 1
Area/Shell :316 m2
10 11-E-9A Raw crude/APS TPA No of shells: 1
Area/Shell :297 m2
11 11-E-9C Desalted crude/APS BPA No of shells: 1
12 11-E-9D Desalted crude/II SS No of shells: 1

reserved
Annexure 2A
S. No TAG NO DESCRIPTION MODIFICATION

13 11-E-11 Flashed crude/II SS No of shells: 1
14 11-E-12 A/B Flashed crude/APS BPA No of shells: 2
15 11-E-14 Raw crude/II SS No of shells: 1
Area/Shell :316 m2
17 11-E-22 Desalted crude/APS TPA No of shells: 1
Area/Shell :192 m2
new channel head
18 11-E-52 Raw crude/II SS
No of shells: 1
Area/Shell :190 m2
20 11-E-54 Desalted crude/ATF No of shells: 1
Area/Shell :314 m2
new channel head
21 11-E-55 Desalted crude/APS TPA
No of shells: 1
Area/Shell :263 m2
Previously purchased, not installed.
Preflash Tower Overhead Trim New bundle and channel head
22 11-E-23A/B
condenser No of Shells: 2
Area/Shell: 505.1 m2
New bundles & channel heads for A, B
&C
23 11-E-48A/B/C Stabilizer Overhead Condensers
No of Shells: 4
New bundles & channel head
24 11-E-49 Reboiler No of Shells: 1

reserved
Annexure 2A
2. NEW VPS
S.
TAG NO DESCRIPTION Note 1
No
Vessels and Drums
Dia : 1250 mm
Height:3000 mm
1 24-D-1001 Fuel Gas Knock Out Drum
Type: Vertical
Total unit equipment weight :2150 kg
Dia:1500 mm
Height: 3600 mm
2 24-D-1002 Slop Wax Venting Drum
Type: Vertical
Details shall be furnished by ejector
3 24-D-1003 Ejector MP Steam Separator
vendor
Dia: 2500 mm
Height: 10500 mm
4 24-D-1004 Ejector Condensate Receiver
Type: Horizontal
Off gas Compressor Discharge Details shall be furnished by liquid ring
5 24-D-1005
Drum compressor vendor
Columns
Dia: 10300/4700/2800mm
Height:56320 mm
1 24-T-1001 Vacuum Tower
Type:6 bed structured packing +7 trays
Dia: 1500 mm
Height:9300 mm
2 24-T-1002 SPVGO Stripper
Type: structured packing
Dia: 2500 mm
Height:8800 mm
3 24-T-1003 I SS Stripper
Dia: 2500 mm
Height: 9700 mm
4 24-T-1004 II SS Stripper
Dia:1200/762 mm
Height:15900 mm
5 24-T-1005 Amine Contactor
Type: 2 beds of random packing
Heaters
Type of heater : box
1 24-F-1001 Vacuum Heater Total heater absorbed duty (M·kcal/hr)
28.33 (Normal) - 33.84 (Design)

reserved
Annexure 2A
S.
No
Air Preheaters
Type: Fixed APH of cast iron and glass
1 24-APH-1001 Vacuum Heater Air Preheater
tubes.
Air-Cooled Heat Exchangers
No of bundles:8
Area(m2)/bundle:
Bare tube-1210.8
1 24-E-1001A/B VPS TPA Cooler
Finned-26023
No of fan:8
Shell and Tube Heat Exchangers
No of shells:1
1 24-E-1002 VPS TPA Trim Cooler Duty (MM kcal/h ):2.83
2 24-E-1003A-D 1st-Stage Inter condenser
vendor
3 24-E-1004 2nd-Stage Inter condenser
vendor
4 24-E-1005 After condenser
vendor
Details shall be furnished by liquid ring
5 24-E-1006 Offgas Compressor Liquid Cooler
compressor vendor
No of shells:1
6 24-E-1007 SPVGO Cooler Duty (MM kcal/h ):1.53
No of shells:1
7 24-E-1008 I SS Cooler Duty (MM kcal/h ):1.58
No of shells:1
8 24-E-1009 II SS Cooler Duty (MM kcal/h ):3.15
No of shells:4
24-E- Flashed Crude / VPS BPA Duty (MM kcal/h ):16
9
1010A/B/C/D Exchanger Area/Shell: 345.8 m2
Helixchanger design
No of shells: 3
24-E- Duty (MM kcal/h ):11.50
10 Flashed Crude / VTB Exchanger
1011A/B/C Area/Shell: 387.7 m2
Helixchanger design
No of shells:1
11 24-E-1012 VPS BPA Steam Generator Duty (MM kcal/h ):4.93
Pumps
Capacity : 1194 m3/h
1 24-P-1001A/B VPS TPA
Head :143 m

reserved
Annexure 2A
S.
No
Capacity : 341 m3/h
2 24-P-1002A/B SPVGO Reflux Head : 57 m
Capacity : 185 m3/h
3 24-P-1003A/B I SS Reflux Head :59 m
Motor Rating:37.3 KW
4 24-P-1004A/B VPS BPA Head :125 m
Motor Rating: 447.6KW
Capacity : 46 m3/h
5 24-P-1005A/B SPVGO Product Head : 117 m
Motor Rating: 29.8KW
Capacity : 100 m3/h
6 24-P-1006A/B I SS Product Head :126 m
Motor Rating: 56 KW
Capacity : 158 m3/h
7 24-P-1007A/B II SS Product Head :207 m
Capacity : 98 m3/h
8 24-P-1008A/B Slop Wax Head :58 m
Capacity : 303 m3/h
9 24-P-1009A/B VTB Head :222 m
10 24-P-1010A/B Cooling Water Booster Head : 40 m
Capacity : 52 m3/h
11 24-P-1011A/B Vacuum Condensate Head :62 m
Capacity : 11 m3/h
12 24-P-1012A/B VGO Head : 111 m
Fans/Blowers / Compressors
MOC: 316L SS
1 24-C-1001 Vacuum Offgas Compressor
Driver Rating : 267 KW
Ejectors
1 24-J-1001A-D 1st-Stage Ejector
2 24-J-1002A/B 2nd-Stage Ejector
vendor
3 24-J-1003A/B 3rd-Stage Ejector
Strainers
Capacity: 682 m3/hr
1 24-STR-1001 VPS TPA
Type: Wye

reserved
Annexure 2A
S.
No
24-STR- Capacity: 246 m3/hr
2 TPA Reflux
1002A/B Type: Basket
3 SPVGO Reflux
4 I SS Reflux
Capacity: 741m3/hr
5 24-STR-1005 VPS BPA
Type: Wye
6 Wash Oil
24-STR-
7 Vacuum Heater Fuel Oil
1007A/B
24-STR-
8 Vacuum Heater Fuel Gas
1008A/B
Note 1-All equipments shall be new.

reserved
Annexure 2A
3. VISBREAKER UNIT
S.
TAG NO DESCRIPTION Note 2,3
No
VESSELS
1 NOTE-1 Feed Surge Drum New
2 NOTE-1 Injection Water Break Tank New
3 NOTE-1 Emergency Steam K.O. Drum New
4 NOTE-1 Decoking Drum New
5 NOTE-1 Fractionator Reflux Drum New
6 NOTE-1 Fractionator OVHD Product Drum New
7 NOTE-1 Recontacting Drum New
8 NOTE-1 Stabilizer Overhead Drum New
9 NOTE-1 HP Condensate Drum New
10 NOTE-1 LP Steam Drum New
11 NOTE-1 VB HVGO Drum New
12 NOTE-1 VB LVGO Drum New
13 NOTE-1 Ejector Effluent Separator New
14 NOTE-1 VB Off-Gas Seal Drum New
15 NOTE-1 VB Dirty Wash Oil Drum New
16 NOTE-1 Tempered Water Expansion Vessel New
Sour Gas Compressor Interstage
17 NOTE-1 New
K.O. Drum
18 NOTE-1 Flare K.O. Drum New
COLUMN
1 NOTE-1 Fractionator New
2 NOTE-1 Gas Oil Stripper New
3 NOTE-1 Stabilizer New
4 NOTE-1 Vacuum Flasher New
EXCHANGER
1 NOTE-1 Feed/Fractionator Quench Exchanger New
Circulation Reflux/ LP Stream
2 NOTE-1 New
Generator
3 NOTE-1 Gas Oil Product Cooler New
4 NOTE-1 Gas Oil Product Trim Cooler New
5 NOTE-1 Fractionator Reflux Condenser New
Fractionator Overhead Product
6 NOTE-1 New
Condenser
Fractionator Overhead Product Trim
7 NOTE-1 New
Condenser
8 NOTE-1 Recontacting Condenser New
9 NOTE-1 Recontacting Trim Condenser New
10 NOTE-1 Stabilizer Feed/Bottoms Exchanger New
11 NOTE-1 Stabilized Naphtha Product Cooler New
12 NOTE-1 Stabilizer Overhead Condenser New
13 NOTE-1 Stabilizer Reboiler New
14 NOTE-1 Vacuum Flashed VB Residue/ LP New

reserved
Annexure 2A
S.
No
Steam Generator
Vacuum Flashed VB Residue/ BFW
15 NOTE-1 New
Preheater
Vacuum Flashed VB Residue/
16 NOTE-1 New
Tempered Water Cooler
17 NOTE-1 HP Steam/Feed Exchanger New
18 NOTE-1 VB HVGO/LP Steam Generator New
19 NOTE-1 VB LVGO Air Cooler New
Feed/Vac Flashed VB Residue
20 NOTE-1 New
Exchanger No. 2
21 NOTE-1 VGO Rundown Cooler New
Feed/ Vac Flashed VB Residue
22 NOTE-1 New
Exchanger No. 1
23 NOTE-1 1st Stage Condenser New
24 NOTE-1 2nd Stage Condenser New
25 NOTE-1 3rd Stage Condenser New
26 NOTE-1 Tempered Water Air Cooler New
Sour Gas Compressor Interstage
27 NOTE-1 New
Cooler
FIRED HEATER
1 NOTE-1 Visbreaker Heater New
PUMP
1 NOTE-1 Offsite Visbreaker Feed Pump New
2 NOTE-1 Visbreaker Feed Pump New
3 NOTE-1 Injection Water Pump New
4 NOTE-1 Circulating Reflux Pump New
5 NOTE-1 Fractionator Quench Pump New
6 NOTE-1 Gas Oil Product Pump New
7 NOTE-1 Fractionator Reflux Pump New
8 NOTE-1 Sour Water Pump New
9 NOTE-1 Sour Water Circulation Pump New
10 NOTE-1 Unstabilized Naphtha Pump New
11 NOTE-1 Stabilizer Bottoms Pump New
12 NOTE-1 Stabilizer Reflux Pump New
13 NOTE-1 Vac. Flashed VB Residue Pump New
14 NOTE-1 VB HVGO Pump New
15 NOTE-1 VB LVGO Pump New
16 NOTE-1 Vacuum Flasher Sour Water Pump New
17 NOTE-1 VB Slop Oil Pump New
18 NOTE-1 VB Dirty Wash Oil Pump New
19 NOTE-1 Tempered Water Circulation Pump New
COMPRESSOR
1 NOTE-1 Sour Gas Compressor New

reserved
Annexure 2A
S.
No
FAN
1 NOTE-1 Forced Draft Fan New
2 NOTE-1 Induced Draft Fan New
FILTER
1 NOTE-1 Fractionators Bottoms Filter New
2 NOTE-1 Fractionator Quench Filter New
3 NOTE-1 Vacuum Flasher Bottoms Filter New
4 NOTE-1 VF Wash Oil Filter New
5 NOTE-1 VB HVGO Reflux Filter New
6 NOTE-1 VF Top Reflux Filter New
7 NOTE-1 VF Cold Front Reflux Filter New
8 NOTE-1 VB LVGO Under Filter New
9 NOTE-1 Vac. Flashed VB Residue Filter New
10 NOTE-1 VB Dirty Wash Oil Filter New
MISCELLANEOUS
1 NOTE-1 1st Stage Ejector New
2 NOTE-1 2nd Stage Ejector New
3 NOTE-1 3rd Stage Ejector New
4 NOTE-1 Feed Mixer New
Vac. Flashed VB Residue/ VB Gas
5 NOTE-1 New
Oil Mixer
Vac. Flashed VB Residue/VB HVGO
6 NOTE-1 New
mixer
7 NOTE-1 VB Off-Gas Flame Arrester New
8 NOTE-1 Vent Gas Flame Arrester New
NOTES:
1 Tag Numbers of new equipments will be provided during Detail Engineering.
2 All equipments of this unit shall be new
3 Equipment details shall be finalized during detail Engg.

reserved
Annexure 2A
4. HYDROGEN UNIT
S. No TAG NO DESCRIPTION Note 2,3
VESSELS
1 NOTE-1 Raw Naphtha Surge Drum New
2 NOTE-1 Naphtha Separator New
3 NOTE-1 Stripper Overhead Separator New
4 NOTE-1
Steam Condensate Pot for stripper New
reboiler
5 NOTE-1 Naphtha Surge Drum New
6 NOTE-1 Fuel Gas K.O. Drum New
Steam Condensate Pot for feed
7 NOTE-1 New
vaporizer
8 NOTE-1 Fuel Naphtha K.O. Drum New
9 NOTE-1 Steam Condensate Pot for Naphtha New

Fuel Vaporizer
10 NOTE-1 Process Condensate Separator New
11 NOTE-1 Deaerator New
12 NOTE-1 Steam Drum New
13 NOTE-1 Boiler Blow-Down Drum New
Start-up N2 K.O. Drum for HDS
14 NOTE-1 New
Section
15 NOTE-1 Start-up N2 K.O. Drum for New
Reformer/Shift Section
16 NOTE-1 Emergency Hydrogen Storage New
17 NOTE-1 Methanol Storage New
18 NOTE-1 DMDS Mixing Drum New
19 NOTE-1 DMDS Measuring Bottle New
20 NOTE-1 HP Flare K.O. Drum New
21 NOTE-1 LP Flare K.O. Drum New
COLUMN
1 NOTE-1 H2S Stripper New
EXCHANGER
1 NOTE-1 Feed/Effluent Exchanger New
2 NOTE-1 Naphtha Cooler New
3 NOTE-1 Stripper Feed Preheater New
4 NOTE-1 Stripper Reboiler New
5 NOTE-1 Sweet Naphtha Cooler New
6 NOTE-1 Stripper Overhead Condenser New
7 NOTE-1 Feed Vaporizer New
8 NOTE-1 Feed Preheater New
9 NOTE-1 Naphtha Fuel Vaporizer New
10 NOTE-1 Waste Heat Boiler New
11 NOTE-1 1st BFW Preheater New
12 NOTE-1 2nd BFW Preheater New

reserved
Annexure 2A

13 NOTE-1 3rd BFW Preheater New
14 NOTE-1 DMW Preheater New
15 NOTE-1 Water Cooler New
16 NOTE-1 Boiler Blow-Down Cooler New
17 NOTE-1 Reformer Feed Preheat Coil New
18 NOTE-1 Prereformer Feed Preheat Coil New
19 NOTE-1 HP Steam Superheat Coil New
20 NOTE-1 WHS Combustion Air Preheaters New
21 NOTE-1 WHS Boiler Coil New
22 NOTE-1 Combustion Air Preheater New
23 NOTE-1 Deaerator Reboiler New
24 NOTE-1 Start-up N2 Heater for HDS Section New
25 NOTE-1 Start-up N2 Heater for Reformer/Shift New
Section
26 NOTE-1 Start-up N2 Cooler for Reformer/Shift New
Section
27 NOTE-1 Final Water Cooler New
FIRED EQUIPMENT
1 NOTE-1 Naphtha Superheater New
2 NOTE-1 Tubular Reformer New
AIR COOLERS
1 NOTE-1 Naphtha Air Cooler New
2 NOTE-1 Air Cooler New
3 NOTE-1 Start-up N2 Cooler for HDS Section New
PUMP
1 NOTE-1 Raw Naphtha Feed Pump New
2 NOTE-1 Stripper Reflux Pump New
3 NOTE-1 Naphtha Feed Pump New
4 NOTE-1 PC Pump New
5 NOTE-1 BFWPump New
6 NOTE-1 Methanol Pump New
7 NOTE-1 DMDS Pump New
8 NOTE-1 DMDS Pump for PDS New
COMPRESSOR& BLOWERS
1 NOTE-1 1st H2 Recycle Compressor New
2 NOTE-1 Flue Gas Fan New
3 NOTE-1 Combustion Air Blower New
Start-up N2 Compressor for HDS

4 NOTE-1 Section New
Start-up N2 Compressor for

5 NOTE-1 New
Reformer/Shift Section

reserved
Annexure 2A
6 NOTE-1 2nd H2 Recycle Compressor New

7 NOTE-1 Emergency Hydrogen Compressor New
REACTORS
1 NOTE-1 1st Hydrogenator New
2 NOTE-1 2nd Hydrogenator New
3 NOTE-1 Chlorine/Sulphur Absorber New
4 NOTE-1 Prereformer New
5
MT Shift Converter New
NOTE-1
MISCELLANEOUS
1 NOTE-1 Flue Gas Stack New
2 NOTE-1 Ammonia Water Dosing Unit New
3 NOTE-1
Phosphate Dosing Unit New
4 NOTE-1 Ejector New
5 NOTE-1 PSA Unit New

6 NOTE-1 Product Filter New
NOTES:
1 Tag Numbers of new equipments will be provided during Detail Engineering.
2 All equipments of this unit shall be new
3 Equipment details shall be finalized during detail Engg.

reserved
PROCESS FLOW SCHEME Document No.
Configuration
0 Study & DFR For A430-RP-02-41-0001
ANNEXURE 2B
PROCESS FLOW SCHEME

reserved
BLOCK FLOW DIAGRAM Document No.
Configuration
0 Study & DFR For A430-RP-02-41-0001
ANNEXURE 3
BLOCK FLOW DIAGRAM

reserved

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DETAILED FEASIBILITY REPORT

HINDUSTAN PETROLEUM CORPORATION LIMITED

REPORT NO: A430‐RP-0241‐0001

The matter contained in the report is confidential.

EIL JOB NO: A430

REPORT NO: A430-RP-0241-0001

1. EXECUTIVE SUMMARY Ch 1 Page 1 to 20

1 OVERALL PLOT PLAN 1

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

1.0 EXECUTIVE SUMMARY

HPCL’s Mumbai Refinery was established in 1954. Through progressive

In order to estimate the capital investment within accuracy of ± 20% and to

1.2 SCOPE OF WORK

The scope of work under this project is performed in two parts:

Broad Scope of Work

The scope of work shall comprise the following:

 Development of Base Case LP Model (based on current refinery operation

 Expansion case developed in LP and analyze various residue upgradation

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

 Shortlist options after a broad evaluation of a number of options and

 Carry out a detailed evaluation of the shortlisted options to arrive at the

 Compilation of the Configuration Study Report.

 Detailed evaluation of the recommended option and implementation strategy

 Identify augmentation in existing process units, utilities, offsite facilities and

 Preparation of refinery layout optimizing the usage of existing land with

 Compilation of the Detailed Feasibility report (DFR).

Detailed Feasibility Report (DFR)

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

1.4 BASIC DESIGN PARAMETERS

The Basic Design Parameters are summarized below:

1.4.1 Refinery Capacity

The expansion capacity for study is considered as 9.5 MMTPA.

1.4.2 Crude Mix

Design Case (for expansion case)

1.4.3 On-Stream hours

The stream hour considered for the study is 8000hrs/Annum.

1.4.4 Objectives of the study

 Capacity Expansion of the refinery from 7.5 MMTPA to 9.5 MMTPA

1.4.5 Product Demand

At present the production of LPG, MS and Diesel are not intended to be

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

Table 1.1: Product Demand

1.4.6 Feed and Product Prices

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

1.4.7 Product Specifications

Product specifications as provided by HPCL in agreed Design basis has been

1.5 REFINERY CONFIGURATION STUDY

The configuration study involves two parts:

1. Study for Suitability / Adequacy of Existing units for 10 MMTPA crude

2. Configuration study considering various options for Residue upgradation

EIL has developed a comprehensive LP model for build-up of configurations

A total of around 200 numbers of refinery configurations are evaluated

Sl. No. Case Description

1. No residue upgradation + MS block 20% revamp

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

Sl. No. Case Description

On the basis of detail screening of various refinery configurations, the