BRIEF SUMMARY OF PROPOSED PROJECT

RESIDUE UPGRADATION PROJECT AT HPCL-MUMBAI REFINERY

For Residue Upgradation Project (MREP Phase –II), the following objectives have been envisaged:

 To improve refinery profitability (GRM) by maximizing distillate yields using Hydrogen Based
Bottoms Upgradation facilities.
 To achieve nil Fuel oil and nil export Naphtha production.

The total estimated capital cost for the MREP- II is Rs. 6963 crores. The project will come up within
the existing HPCL-Mumbai Refinery.

The following Residue upgradation technologies are being considered:

 Slurry bed hydrocracking technology

 Ebullated bed hydrocracking technology

Design Capacities of new process units

A. New Processing Unit Capacity

1 Residue Upgradation Facility (RUF) KTPA 1810
B. New Auxiliary Units
1 Hydrogen Generation Unit (HGU) KTPA 65
2 Sour Water Stripper Unit (SWS) TPH 66
3 Amine Regeneration Unit (ARU) TPH 310
Sulphur Recovery Unit (SRU) with Tail Gas
4 Treating Unit(TGTU) TPD 2 X 180 (SRU)

The existing utility systems is completely saturated. Hence, to meet the new demand, t he
following new utility facilities have been envisaged:

New Utility Systems

NEW UTILITY SYSTEM DETAILS OF FACILITIES

Bearing Cooling Tower
Compressed Air system
Utility Boiler
Sea cooling tower
2 number of cells ( 1 working + 1 standby) , each having a capacity of 700
m3/hr.
LP air Compressor :2 ( 1 working + 1 standby) Capacity: 20000 Nm3/hr
each
HP air Compressor : 1 ( 1 working) Capacity: 250 Nm3/hr.
Instrument air Dryer: 2 (1 working + 1 standby) Capacity: 10000 Nm3/hr.
each.
1 of Net Capacity: 100 TPH of VHP steam with associated Steam Turbine
Generator.
Number of cells: 3 (2 working + 1 standby) Capacity: 4000 m3/hr. each.

1
DM water chain Number : 2 (1 working + 1 standby); Capacity: 220 TPH each
Raw water sump Dimension: 25m X 25m X 5M
HC flare Flare stack: Diameter: 72”, Height: 110 m
Sour flare Flare stack: Diameter: 20”, Height: 110 m

The offsite facilities shall be augmented by adding following new storage tanks and bullets under
MREP Phase-II.
List of new offsite storage facility
Sl. No. Service Gross Capacity Each (M3) Number Type
1 LPG 2080 3 Mounded Bullet
2 HGU feed 5034 1 External Floating Roof
3 VR 14605 3 Cone roof

Apart from the above table, 4 Naphtha tanks will be reassigned to cater to the space requirement
of this project.