A PROJECT REPORT

ON

KRISHNA G R C (2020311020)
MAILESHWARAN P (2020311024)
SAI NIHIL S (2020311039)
SIVATHANGAVELU M (2020311043)

B.TECH PETROLEUM ENGINEERING AND TECHNOLOGY

THIRD YEAR (2020-2024)
(24th APRIL 2023– 28th APRIL 2023)

ALAGAPPA COLLEGE OF TECHNOLOGY ANNA UNIVERSITY

DEPARTMENT OF APPLIED SCIENCE AND TECHNOLOGY
 BONAFIDE CERTIFICATE

This is to certify that the submitted project report is

bonafide work Krishna G R C, Maileshwaran P, Sai nihil S,
Sivathangavelu M of B.Tech Petroleum engineering and technology
students from the Department of applied science and technology,
Anna University, Chennai-600025.

Mr. M. Kamalakannan Mr. V.Raja

Deputy General Manager(Prod engg) Senior Manager(Prod engg)
Chennai petroleum corporation Ltd., Chennai petroleum corporation
Ltd.,
Manali, Chennai -600068. Manali, Chennai -600068.
 ACKNOWLEDGEMENT

We like to deeply express our sincere thanks to our HOD Dr. J. JAYAPRIYA,
Department of applied science and technology, Anna University for
providing all the facilities required to finish our project.

We thank Ms.P.BANUMATHY Manager (Admin). Mr.P. NARAYANA BHASKAR

SM(Admin), Mr. VIJAYA KUMARR, DGM (Admin), Chennai Petroleum
Corporation Limited (CPCL), for granting me the permission to commence
this project in the first instance.

We feel to thank the company guide Mr.M. KAMALAKANNAN DGM(PROD

ENGG) for his valuable guidance, and suggestions and for supporting us
through proper direction and guidance in a flexible manner to bring out
this project a successful one.

We wish to express my deep sense of gratitude to Mr. UMASHANKAR

to arrange the project

We also acknowledged with a deep sense of reverence towards our

parents and members of our family, who have always supported us morally
as well as economically. We express our first and fervent thanks to the
almighty for allowing us the successful completion of our Project.

KRISHNA G R C
MAILESHWARAN P
SAI NIHIL S
SIVATHANGAVELU M
 DECLARATION

KRISHNA G R C (2020311020), MAILESHWARAN P (2020311024),

SAI NIHIL S (2020311039), SIVATHANGAVELU M(2020311043) pursuing
B.Tech – Petroleum Engineering and Technology , Department of Applied
science and Technology - Anna University hereby declare this project
report at Chennai Petroleum Corporation Limited (CPCL) in partial
fulfilment of requirements for the award of our degree, B.Tech – Petroleum
Engineering and Technology as our original work.

KRISHNA G R C
MAILESHWARAN P
SAI NIHIL S
SIVATHANGAVELU M
 INDEX

1. Introduction
2. About plant
 INTRODUCTION
Chennai Petroleum Corporation Limited (CPCL),
one of the leading group companies of IndianOil’s, was conceived
in 1960s as a 2.5 million metric tonnes per annum (MMTPA)
refinery designed to produce fuels and lubes base stock. At CPCL,
the past five decades have an eventful, growth-oriented phase as
the CPCL family built the organisation to reach the present stature
of 10.5 MMTPA capacity.
Today, CPCL stands tall among the public-sector refining
companies in India, with one of the most complex refineries of its
kind in the country, producing an array of value-added petroleum
products. It also pioneered key initiatives in several areas such as
process optimisation, technology absorption, energy conservation,
waste
CPCL Manali Refinery is one of the most complex refineries in
India, with Fuel, Lube, Wax and Petrochemical feedstocks
production facilities. The 5.8 MGD Sea Water Desalination Plant
set up to augment the water requirements of the refinery was the
first of its kind in the industry. CPCL has also made pioneering
efforts in Energy and Water Conservation by setting up a Wind
Farm and Sewage Reclamation plant, where 5 MGD of sewage
water from Chennai city is processed to meet the raw water
requirements of the refinery.
The Company’s main products are LPG, Motor Spirit, Superior
Kerosene, Aviation Turbine Fuel, High-Speed Diesel, Naphtha,
Bitumen, Lube Base Stocks, Paraffin Wax, Fuel Oil, Hexane, and
Petroleum Coke. CPCL is also a mother industry supplying Linear
Alkyl Benzene Feedstock (LABFS) and many other Petrochemical
feedstocks to downstream units. land reclamation and environment
management.
 ABOUT PLANT
The first refinery complex of CPCL was commissioned in 1969
with a capacity of 2.5 MMTPA (CDU-1). This refinery was
designed to produce Lube oil-based stocks (LOBS) in addition to
Fuel products like LPG, MS, HSD, SKO, ATF, Naphtha and FO.
Lube production includes process units like Aromatic extraction
unit using NMP solvent, Dewaxing unit using MEK & Toluene
solvent, Hydro-finishing unit.
The Manali refining capacity was doubled to 5.6 MMTPA in 1984
by setting up an additional Crude Distillation unit (CDU-2) with a
capacity of 2.8 MMTPA. The secondary processing unit – FCC
was also installed to increase the production of high value products
like LPG and MS.
A Wax unit was set up to produce Paraffin and Match Wax. The
capacity of CDU-2 was increased from 2.8 to 3.7 MMTPA through
de-bottlenecking, taking the total refinery capacity to 6.5 MMTPA.
In 1994, the Lube capacity was increased from 140 to 270 TMTPA
by revamping Solvent Dewaxing unit.
CPCL implemented a 3 MMTPA refinery expansion project
(Refinery-III) in 2004 with an additional crude distillation Unit
(CDU-III) and increased the refining capacity of Manali refinery to
9.5 MMTPA. Refinery III revamp taken up during 2010, has
further increased Manali Refining capacity to 10.5 MMTPA. The
total refining capacity of CPCL (Manali + CBR) has increased to
12.1 MMTPA capacity as on 2020.
In order to maximize the distillate yield of the Manali Refinery,
CPCL has implemented Residue Upgradation Project during
Nov’2017. This project involved addition of new Delayed Coker
Unit and Revamp of existing Hydro Cracker Unit along with other
associated facilities. This project enabled improvement of Distillate
yield, i.e., maximization of value-added products.

PROCESS OPERATIONS
Manali refinery is equipped with three Crude distillation units with combined capacity of 10.5 MMTPA. CDU-1
process Lube bearing crudes and other two CDUs are capable of processing opportunity crudes. Major Process
units are as follows:

OHCU
Once Through Hydro Cracker Unit (OHCU)  was licensed by M/s Chevron and it was commissioned in August
2004 along with Refinery-III Expansion project. The design capacity of the unit is 1.85 MMTPA and the unit was
revamped to a capacity of 2.25 MMTPA in March 2017 along with Resid Upgradation project. The unit produces
high quality Sulphur free Diesel and ATF. The unit is designed for 55% conversion of low value Vacuum Gas Oils
to lighter, low Sulphur  valuable products.
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FCCU
Fluid Catalytic Cracking Unit (FCCU) was licensed by M/s UOP and was commissioned in 1984 along with Ref-II.
The design capacity of the unit is 0.6 MMTPA and later revamped in October 2004 to a capacity of 0.78 MMTPA.
Post revamp, the feed to FCCU is Unconverted Oil (UCO) from the Once Through Hydrocracker Unit (OHCU).
The unit produces high quality products like LPG and MS.

CCR
CCR (Continuous Catalytic Reforming) unit was licensed by M/s Axens and was commissioned in December 2004
along with Refinery-III Expansion project. The design capacity of the unit is 0.255 MMTPA in Semi Regeneration
mode. The unit was revamped to a capacity of 0.303 MMTPA with Continuous Catalytic Reforming Unit (CCRU)
in 2010. Unit produces high octane reformate which is utilized in producing in MS product. Hydrogen produced as
a by-product in the unit is used in the Hydrocracker Unit.
ISOM
ISOM unit (Isomerisation) converts linear molecules in Naphtha stream to higher-octane branched molecules for
blending into MS product. The Isomerization unit capacity is based on producing 140,000 TPA of isomerate with
unit turndown rate of 40% of design capacity. The unit is licensed by M/s Axens India (P) Limited and
commissioned in 2011.

DCU
DCU (Delayed Coker Unit) was licensed by M/s ABB Lummus and commissioned in Nov 2017 along with Resid
Upgradation project. The design capacity of the unit is 2.2 MMTPA. The unit is designed to process vacuum
residue from the upstream vacuum distillation unit. The process thermally cracks and upgrades heavy fractions into
more valuable distillate products and Petroleum grade coke.
DHDT/DHDS
DHDS (Diesel Hydro De-Sulphurization Unit) was licensed by M/s Axens India (P) limited and was commissioned
in May 2000. The design capacity of the unit is 1.8 MMTPA and later revamped to a capacity of 2.34 MMTPA in
March 2018. The unit is designed to process straight run and cracked light and middle distillate streams. The unit is
capable of producing BS-VI grade diesel.
DHDT (Diesel Hydro Treating Unit) was licensed by M/s Axens India (P) limited and was commissioned in May
2011. The design capacity of the unit is 1.8 MMTPA and later revamped to a capacity of 2.34 MMTPA in
November 2019. The unit is designed to process straight run and cracked light and middle distillate streams. The
unit is capable of producing BS-VI grade diesel.

CDU/VDU
CPCL commissioned it’s operation in 1969 with CDU/VDU unit (with a capacity of 2.5 MMTPA) & subsequently
revamped to 2.8 MMTPA with in-house debottlenecking.
In the year 1984, 2nd CDU/VDU unit was commissioned with a capacity of 2.8 MMTPA for processing low
sulphur & high sulphur crude oil. Subsequently unit was revamped to 3.7 MMTPA in the year 1992/93. Later the
unit was revamped on 2012 for upgrading it’s diesel quality to meet Euro-IV diesel spec.
3rd unit was commissioned in the year 2004 with a capacity of 3.0 MMTPA, subsequently revamped to 4.0
MMTPA to meet Euro-IV spec for MS & HSD. Units are designed for processing Arab mix & Upper zakum crude
oil.

HGU
CPCL has three hydrogen generating units, having a combined capacity of generating 1.42 lakh to 1.54 nm3/hr
hydrogen. Two units are licensed by M/s Technip & one unit is licensed by M/s Haldor Topsoe.
Hydrogen generating unit adopts a state of art techology that generates hydrogen from naphtha. This unit produces
hydrogen of 99.9% purity to meet the demand of the secondary processing units. The main Hydrogen Generation
Unit (HGU) consists of feed Pre-desulfurisation section, followed by desulfurisation, reforming and process gas
cooling with high temperature shift conversion to increase the hydrogen content of the process gas. Purification is
done with a Pressure Swing Adsorption unit.