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Mangalore Refinery & Petrochemicals Ltd

Mangalore Refinery & Petrochemicals Ltd. 4 th ONGC Strategy Meet 27 th – 29 th February 2004. Corporate Objectives. GROWTH Capacity enhancement PRODUCT MIX IMPROVEMENT Integration of Value Chain IMPROVING REFINERY MARGIN. Strategies. Optimized Refinery Performance

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Mangalore Refinery & Petrochemicals Ltd

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  1. Mangalore Refinery & Petrochemicals Ltd 4th ONGC Strategy Meet 27th – 29th February 2004

  2. Corporate Objectives • GROWTH • Capacity enhancement • PRODUCT MIX IMPROVEMENT • Integration of Value Chain • IMPROVING REFINERY MARGIN

  3. Strategies • Optimized Refinery Performance • Capacity Expansion with New Technologies • Improved Product Mix • Energy Conservation • Cost Reduction • ERP implementation • Environment Control

  4. Refinery Performance Operations (All figures in million tonnes per annum) Additional 75,000 tonnes Mumbai High crude sought for achieving 10 MTPA in 2003-04

  5. Refinery Performance 2004-05 Outlook: Target 10.7 million tonnes LPG make will go up to 3% on crude with ISOM project implementation

  6. Refinery Performance Product Export (MTPA) FY 2004-05 In thousand tonnes Products over 9.69 million tonnes per annum capacity may call for export. Domestic Dispatch is estimated at 8 million tonnes.

  7. Infrastructure • Offsite facilities for 12 million tonnes per annum operation • Four Tanks for the additional quantity/grade with auxiliary circulation facilities. • Ten small capacity tanks for direct marketing requirements with pumping facilities. • - Anticipated completion by June 2005.

  8. Infrastructure • Offsite facilities for New project and products • ISOM Block feed tanks. • Mixed Xylene product tank, coastal line and export pump • Three3 mounded bullets of 3,000 cubic metres for LPG storage. • Anticipated completion by June 2005

  9. Energy Conservation • VSD project: • CAPEX: Rs 200 million • Project: 7 MV and 119 LV drives • Expected completion by Jan ’05 • Expected saving: 7 MW • Other Heat Integration Schemes • Investment: Rs 30 million • Expected savings: 1000 tonnes FO/year • Energy Optimization Study by KBC - Completion by Dec ‘04

  10. Cost Reduction • Inventory Control • Current Level – Rs 1204 million • Target by Dec. ’04 – Rs 1050 million • Surplus Inventory Disposal – Rs 102 million • Acquiring Nitrogen Plant • Savings in chemicals consumption about Rs 50 million per year.

  11. ERP Implementation • SAP R/3 Implementation • Scoping study in progress • Part of the ONGC ‘ICE’ project • Operation Optimization • Add on packages for: - Advanced planning and scheduling - Production management - Operations management - Quality Management with LIMS - Preliminary discussion with Tata Honeywell initiated

  12. Product Development • US Military Grade Aviation Fuel – JP-5 • First batch for certification by Dec. ’04 • Branded High Performance Diesel • Branded Clean Fuel – Auto LPG • Polymer and Crumb Rubber Modified Bitumen - Project completion by Dec. ‘04

  13. Product Mix Improvement • Improved LPG yield (+ 1.5%) from HCU1 with catalyst change – additional revenue Rs 300 million. - Target by Dec. ’04 • Minor revamps to achieve 12 MTPA by Dec. ’04. • ISOM Complex with 12 MTPA level capacity - Completion in FY 2005-06 • Mix Xylene project for value addition - Completion in FY 2005-06 • Euro IV diesel with new catalyst in GOHDS units - Completion in FY 2005-06

  14. Expansion • 15 MTPA capacity • Conceptual study in progress • Units include FCC, Coker, Indalin (Naphtha to LPG) • Foray into Petrochemicals like propylene, butylenes etc. • Preliminary estimate of investment – Rs 20 billion • Significant improvement in product mix – LPG yield increase from current 2.5% on crude to 7%. • Distillate yield increase from 72% to 88%. • Detailed feasibility study by Dec. ‘04

  15. Safety & Environment • Study for 100% recycle of Treated Effluent from current level of 65% • Reduction in SO2, emission by more than 50% with sweet fuel gas firing possible with FCC, Coker unit as part of expansion. • Risk analysis of entire complex by Dec. ‘04

  16. ONGC Upgradation of Tatipaka Refinery

  17. Tatipaka Refinery • Presently running at 0.11 MTPA • Expansion to 0.3 MTPA • Processing entire Rajamundhry asset crude • Configuration with INDMAX process at 0.3 MTPA • INDMAX unit capacity – 100,000 TPA • Capital Investment – Rs 1400 million • Revenue from INDMAX – Rs 400 million/year • Simple pay back – 3.5

  18. Tatipaka Refinery RCO upgradation Product Sale comparison Units in tonnes/year Capacity of INDMAX unit can handle 0.4 MTPA crude processing

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