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Mangalore Refinery and Petrochemicals Ltd.Mangalore Refinery and Petrochemicals Ltd.
Production Planning
Mangalore Refinery and Petrochemicals Limited
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The Evolution
Mangalore Refinery and Petrochemicals Limited
MRPL – An Introduction Founded as Joint sector refinery by HPCL and A.V. Birla group in
1987
Located at the west coast of Karnataka, Close to Middle East and Far East crude and product markets
Installed capacity 9.69 MMTPA Revised to 11.82 MMTPA• Phase 1 : 4.82(3.69) MMTPA, commissioned in 1996.• Phase II: 7.00(6.00) MMTPA, commissioned in 1999.• Phase III: 3.00 MMTPA, commissioned in 2012.
Total project cost Phase I and Phase II refineries about Rs 7000Crore
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Mangalore Refinery and Petrochemicals Limited
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MRPL – An Introduction
• Refinery Setup under APM regime.
• APM for Refineries dismantled w.e.f. 01.04.1998.
• MRPL suffered heavy losses, on the verge of
referring to BIFR as sick company in March 2003
with accumulated losses of approx. Rs.1200 crore and
Debt Equity of 9.77:1
Mangalore Refinery and Petrochemicals Limited
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MRPL – An Introduction
• ONGC entered MRPL in March, 2003 with purchase of
full 37.39% equity held by A.V. Birla Group.
• DFR completed in just 3 weeks with 15 MRPL Lenders.
• ONGC subscribed Rs.600 crore in additional Equity
making MRPL a subsidiary of ONGC Company in March
2003.
• MRPL turned around in less than 2 years.
• Declared as Schedule B PSU on 6th Jan 2005
Mangalore Refinery and Petrochemicals Limited
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Turn around…. how?
Cost Efficiencies
Financial Restructuring
• Higher capacity utilization• Improved Crude Mix• Crude cost and freight reduced• Energy consumption minimized.
• Debt restructured • High cost debt pre-paid• Interest rates minimized with ONGC’s creditworthiness• Tax Incentives for Phase II also helped
Mangalore Refinery and Petrochemicals Limited 7
MRPL – Current Equity Structure
• Listing : Listed on BSE(08/10/1992) / NSE (07/01/2005)• Number of Shares : 1752.60 Million Shares• Dividend : FY 12 Proposed Dividend/ Share : ` 1.00• Share price (H/L) : ` 85 (H), Rs.50 (L) for 2011-12• Market Cap : ` 11,952 Cr (31-03-2012)
Mangalore Refinery and Petrochemicals Limited
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Technological Capabilities
Mangalore Refinery and Petrochemicals Limited
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Technological Capabilities
•State of the Art Technology
•Refinery designed to maximize Middle distillates
•MRPL was first in producing lead free high octane
Petrol in India from 1996
• A refinery with two Hydrocrackers and two
Continuous Catalytic Reformers
•First refinery to launch Euro III grade MS & HSD
Mangalore Refinery and Petrochemicals Limited
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- Iran - Egypt - India
- Saudi Arabia - Yemen - Malaysia
- Iraq - Sudan - Indonesia
- Qatar - Nigeria - Brunei
- Dubai - Congo - Vietnam
- Abu Dhabi - Kazhakstan - China
-Rajasthan -Libya - Russia -Gabon -Azerbajjan -Australia -Khazakhistan
• Refinery has complexity/capability to process most difficult crudes
• It has processed in the past more than 52 crudes, light to heavy / sour to sweet with 24 to 46 API gravity.
Crude Processing capabilities
With commissioning of Phase-3 Crude distillation Unit ,gained capability to process High TAN Crudes.
Mangalore Refinery and Petrochemicals Limited
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Technological Capabilities
Major Process UnitsUnit Technology Phase1 Phase2
CDU/VDU EIL
HCU UOP CCR UOP
VBU Lummus
GOHDS JEC
ISOM UOP
Hydrogen Technip KTI
SRU Technip KTI
Bitumen Porner
Mangalore Refinery and Petrochemicals Limited
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Current Process Configuration
Mangalore Refinery and Petrochemicals Limited
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• Utilities and Infrastructure
• Captive Power Plant with capacity of 112.5
MW
• All weather Mangalore port provides two
dedicated Berth with automatic loading
arms.
• Connected to Mangalore –Hassan -
Bangalore product pipeline for product
supply to Bangalore• Fresh water sourced from Netravati river,
with 20 days storage at Refinery
Technological Capabilities…
Mangalore Refinery and Petrochemicals Limited
Fresh water from built-up weir at Nethravathi river about 43 Kms
away from the refinery.
Infrastructure
Mangalore Refinery and Petrochemicals Limited
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Product Dispatch
• Road– HPC,BPC,IOC Terminals.
– Directly by MRPL
• Rail– Through HPC only.
• Coastal– Directly by MRPL.
• Pipe Line (MHBPL)– Declared Capacity: 2.14 MMTPA.
– Design : 5.46 MMTPA
Technological Capabilities…
Mangalore Refinery and Petrochemicals Limited
Product Despatch - Modes
Pipe Line - MHBPL• Length - 362.3 KM
• Capacity – 5.46MMTPA
• Products Naphtha MS ATF SKO HSD
CH- 1O6 KM,
EL- 1127 M)
Hassan
(CH- 165 KM, EL- 900M)
Nerriya(CH- 79 KM,
EL- 100 M)
Mangalore
(CH- 0 KM, EL- 6 M)
Bangalore
(CH- 362.3 KM, EL- 800 M)
PIPELINE ROUTE
Mangalore Refinery and Petrochemicals Limited
JETTY VIEW
Mangalore Refinery and Petrochemicals Limited
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• LPG (C3-C4)• Naphtha
– Open spec– LAN– HAN
• MS– Euro-III /IV– MS 92 / MS 95– Mauritius Grade MS
• Reformate• Mixed Xylene• ATF (Domestic)• Jet Fuel
• Kerosene• HSD
– BS III / IV – 0.5% S & 66 Flash– 0.25 % S & 66 Flash
• HSFO (180 CST)• Bunker Fuel (380 CST)• Bitumen
– VG 10 – VG 30– CRMB
• Sulphur (99.99% purity)
MRPL was the First to produce & dispatch Euro-III products MRPL was also the first to launch Euro IV grade fuels . This was possible due to Technological
Complexity of the Refinery.
Product Range
Mangalore Refinery and Petrochemicals Limited
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Performance
Mangalore Refinery and Petrochemicals Limited
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MOU PERFORMACE OF MRPL FOR LAST 6 YEARS
Year Composite Score Rating Remarks
2011-12 1.336 Excellent MOU with ONGC ( DPE approved targets).
MOU score of 2011-12 to be approved by DPE
2010-11 1.098 Excellent
2009-10 1.04 Excellent
2008-09 1.23 Excellent
MOU with ONGC2007-08 1.24 Excellent
2006-07 1.00 Excellent
For the Financial year 2009-10 MRPL has achieved the best performance scoreamong Oil PSU’s.
Petro-fed honored MRPL with “Refinery of the year” award for the year 2009-10 for its leading performance in production and operational efficiency, while meeting the norms of health, safety and environment protection.
Mangalore Refinery and Petrochemicals Limited
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Physical Performance
MMTPA
Distillate % 72.75 71.67 71.94 72.80 72.67 73.3
Capacity Utilization %
129 129 130 106 # 107 108.2
# Name Plate Capacity revised from 9.69 MMTPA to 11.82 MMTPA in 2010.
Crude throughput
Mangalore Refinery and Petrochemicals Limited
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Export Performance…
Entered into an agreement with State Trading House, Mauritius on 1st July, 2010 for supply of 1.1 MMT per annum valued 2 Billion dollars for a period of 3 years
Million Tons
Best Manufacturer Export Award 2010 ’Gold’ by Federation of Karnataka Chamber of Commerce and Industry
Mangalore Refinery and Petrochemicals Limited
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Physical Performance
Lowest Energy Consumption
Lowest ever
• MRPL has won second prize in the Jawaharlal Nehru Centenary Awards (2009-2010) for Energy Performance of Refineries
• MRPL has won First prize in the Oil & Gas Conservation(OGCF)-2010 Awards in the category of Furnace/Boiler Efficiency .
Mangalore Refinery and Petrochemicals Limited
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32,37737,339
42,719 36,081 43,800
57,207
2006-07 2007-08 2008-09 2009-10 2010-11 2011-12
Crore
Financial Performance
Turnover
Mangalore Refinery and Petrochemicals Limited
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11637 1123211608 11083
14604 23418
'06-07 '07-08 '08-09 09-10 10-11 11-12
Crore
Financial Performance…
Export Revenue (Foreign Exchange)
MRPL is accredited as ‘Premier Trading House’ by DGFT based on its export performance .MRPL is the highest exporter of Petroleum products in the Public Sector.
Mangalore Refinery and Petrochemicals Limited
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Financial Performance…
GRM, $/BBL
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Mangalore Refinery and Petrochemicals Limited
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Financial Performance…Net Profit, ` Crore
Dividend 164 246 246 245 245 (8%) (12%) (12%) (12%) (12%)` Crore
10% dividend proposed
Mangalore Refinery and Petrochemicals Limited
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Financial Performance…
ICRA and CRISIL Issuer rating of “Ir AAA” and ‘Cr AAA’ to MRPL for lowest credit risk
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Mangalore Refinery and Petrochemicals Limited
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Projects
Mangalore Refinery and Petrochemicals Limited
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Major Projects completed
Revamp of Gas-oil Desulphuriser• Capacity Revamp : 4000 TPD to 5200 TPD
• Objective : Reduction in Diesel Sulphur Content from 500 to 50 ppm Expansion of Capacity to 15 MMTPA.
• Project commissioned in April-2010 instead of original target of Aug-2010 with MRPL becoming the first Refinery in the country to supply Euro-4 HSD.
Revamp of CDU-I : 30% increase in capacity• Crude Distillation Unit-1 was successfully completed in Oct-
2011.
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Major Projects completed
Revamp of HCU-1 & HCU-2• Objective: To meet the feed quality requirement of Petro
Fluid catalytic cracking unit.
• Hydrocracker units will operate on 50% conversion mode.
• The HCU-1 unit and HCU-2 units revamp was successfully completed on October-11 and May 2012
Mangalore Refinery and Petrochemicals Limited
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Phase-III Refinery Up gradation and Expansion Project
Objectives
• Expansion of Capacity to 15 MMTPA
• Up-gradation of low value products to high value products.
• To process cheaper crudes ( Sour/ Heavy & High TAN crudes)
• Production of petrochemical feed stocks Viz. Propylene.
• Maximize distillate yield.
• Upgrading entire HSD into BS III/IV grade
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Salient Features: New Units added
• High severity Petrochemical FCC (2.2 MMTPA)• Delayed Coker ( 3.0 MMTPA)• DHDT unit ( 3.7 MMTPA)• Coker gas oil Hydro Treater unit ( 0.65 MMTPA)
Major incremental products• Polypropylene – 440 KTPA• Additional LPG – 730 TMT/Yr• Additional SKO/ATF : 1220 TMT/Yr• Additional HSD: BS III – 720 TMT/Yr & BS IV – 720 TMT/Yr
Phase-III Refinery Up gradation & Expansion Project
Mangalore Refinery and Petrochemicals Limited
Phase-3 Configuration
Crude/Vacuum Distillation Unit(CDU/VDU) EIL/Jacobs 3 MMTPAPetro Fluidised Catalytic Cracking , Propylene Recovery and Naphtha Splitter (PFCC)
Shaw Stone & Webster, USA 2.2 MMTPA
Delayed Coker Unit (DCU) Lummus, USA 3 MMTPADiesel Hydrotreating Unit (DHDT) Axens, France 3.7 MMTPACoker Heavy Gas Oil Hydrotreating Unit (CHT) UOP, USA 0.65 MMTPAHydrogen Generation Unit (HGU) HTAS,Denmark /L & T 70 KTPA Sulphur Recovery Unit (SRU) Siritec Negi,Italy / EIL 3 x 185 TPDPolypropylene Unit (PP) Novelene, Germany / EIL 4,40,000 TPAHydrocracker Unit Revamp – 1 / 2 UOP,USA 1.6 / 1.7 MMTPA
Captive Power Plant (CPP) BHEL 118 MW (2 STG , 1 Frame 5 GTG + 1 Frame 6 GTG)
Tankages Offshore/Kay Bouvet
23 Nos.(3 Crude tanks+20 Intermediate
Storage Tanks)Mounded Bullets G.R. Engineering 04 No.sOther Utilities/Offsites
UnitsLicensor / Contractor
Capacity
Mangalore Refinery and Petrochemicals Limited
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Phase-III Refinery Upgradation and Expansion project M
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Mangalore Refinery and Petrochemicals Limited
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• MRPL / ONGC Board Approval for Phase III : 02.08.2008 / 01.12.2008.
• Project Cost – Rs. 12412 Cr (As of March 2008).
• Reduced Phase-III Project Cost – Rs 12160.26 Cr (July 2009) (Due to deletion of facilities under pressurized mode of storage & transportation of propylene).
• Schedule for Mechanical Completion : 31.10.2011
• Project Management Consultant : Engineers India Limited.
• EPCM Consultant for CDU/VDU : Jacobs Engineering India Ltd.
• OBE/LSTK Contractor for PFCC/SRU : Engineers India Limited.
• Phase-3 project progress as on 15-07-2012 :
Scheduled :100 % Actual : 95.7 % .• Financial Progress Actual up to 8847 ` Cr ( 81.8 %), based on commitment
Phase-III Refinery Up gradation and Expansion Project
Mangalore Refinery and Petrochemicals Limited
Phase-3 Units ready for commissioning
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CDU MECHANICAL COMPLETION ACHIEVED ON 27.10.2011
Commissioning on 29-03-2012
HGU MECHANICAL COMPLETION ACHIEVED ON 03.02.2012
Commissioned on 18-07-2012
DHDT MECHANICAL COMPLETION ACHIEVED ON 10.01.12
Pre-Commissioning in progress.
SRU Mechanical Completed on 29th June 2012.Precommissioning in progress.
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• MRPL /ONGC Board Approval for PP Unit : 27.05.2009 / 24.07.2009
• Approved Project Cost for PP Unit : Rs 1803.78 Crore
• Schedule for Mechanical Completion : 30.04.2012
• OBE/LSTK Contractor for PP Unit : Engineers India Limited.
• Due to non-availability of Land ( delay in evacuation of the one Project Displaced Family), PP Unit was relocated within the available space by meeting the required OISD and Petroleum & Explosive Safety Organization(PESO) Regulations. PESO approval received for the new location on 17.03.2010.
• Due to change in location MoEF choose to consider this case as a fresh case and once again asked MRPL to apply.
• MOEF clearance was obtained on 01-11-2011.• Polypropylene (PPU) progress 15-07-2012 :
Scheduled 97.7 % Actual 82.2 %.• Commitment made: ` 1297Cr. Actual amount spent: ` 595 Cr
Polypropylene Unit
Mangalore Refinery and Petrochemicals Limited
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Receive crude in VLCC tankers to minimize transportation costs. The SPM facility will also be used to pump in crude to the Indian
Petroleum Strategic Reserve (ISPRL) underground cavern for storage of Crude oil at Mangalore and Padur The proposal was approved by MRPL Board and ONGC Board on 29-07-2010.
Capex : ` 1044 Crore . Schedule of completion: May-2012 . LOA was placed with EIL on OBE-LSTK methodology of
Execution on 30-07-10. Overall progress
Scheduled(15-07-2012) : 99.9 % Actual : 95.4 %.
Single Point Mooring
Mangalore Refinery and Petrochemicals Limited
Catenary Anchor Leg Mooring Systems (CALM)
Mangalore Refinery and Petrochemicals Limited
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Thank You