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BPCL’s Kochi Refinery is implementing world class technologies in its operations for improving safety standards, bettering its refining margins as well as to meet the growing market demand of petroleum products.

Major technology absorptions at Kochi Refinery in the last few years are as follows:

  • Kochi Refinery started the consumption of R-LNG from Sep’13 in its Gas Turbine (GT). R-LNG is sourced from Petronet LNG Limited (PLL) situated at Puthuvypeen, Kochi and transported to KR limits via pipeline owned by Gas Authority of India Limited (GAIL).
  • The benefits of R-LNG are: It is a clean fuel leading to lower emissions, has higher calorific value and provides higher maintenance interval for GT’s compared to conventional Naphtha and Kerosene fuels.
  • From July 2014 Naphtha was replaced with R-LNG as Hydrogen Generation Unit (HGU) feed stock.
  • New ESP (Electro Static Precipitator) commissioned in FCCU to meet the Central Pollution Control Board norms on particulate emission.
  • 15 KW grid interactive solar photo voltaic (PV) power plant commissioned at KR.
  • Commissioned 220 KV substation on May 5th 2012 resulting in better power reliability for process units.
  • New ATF Electrostatic Coalescer was commissioned in FCCU. This would help in increasing ATF make from Merox (from 10 TPH to 40 TPH) during the processing of high naphthenic acid crudes.
  • Old Gasoline splitter in FCCU was converted to Naphtha splitter by In-house technology resulting in higher absorption of Naphtha in MS and increasing the HSD production also.
  • In December 2015, KR successfully commissioned and stabilized India’s first dividing wall column in CCR reformate splitter resulting in better upgradation of low value Naphtha to high value MS.

Major upcoming Projects

Kochi Refinery technology plans and upcoming projects include a 9.5 MMTPA Refinery located at Ambalamugal in Ernakulam District (Kerala), India. The Refinery was commissioned in 1966 with crude oil processing capacity of 2.5 Million Metric Tons per Annum (MMTPA). Through progressive revamps and addition of process units, the refining capacity has been augmented to present level of 9.5 MMTPA, incorporating advanced refining technologies.

Currently KR is marching towards the successful commissioning of Integrated Refinery Expansion Project (IREP) with the help of Engineers India Limited (EIL) as Consultant. In addition to enhancement of refining capacity to 15.5 MMTPA, quality up-gradation of auto-fuels to Euro-IV/ V norms and up-gradation of refinery residue to value added products are envisaged as part of the project. The IREP project of BPCL envisages the following:

  • Increasing the refining capacity of Kochi Refinery by 6 MMTPA from the present 9.5 MMTPA to 15.5 MMTPA.
  • Modernization of refinery to produce auto-fuels complying with Euro-IV/Euro-V specifications.
  • Up-gradation of residue stream from the refinery to value added products so that the heavy stream generation from the refinery is minimized.
  • Production of propylene as petrochemical feedstock to BPCL’s proposed petrochemical complex..

Also recently the refinery obtained environmental clearance for Propylene Derivative Petrochemical Project (PDPP) and has initiated it recently. The site related activities are in progress. The project envisages the use of propylene (from P-FCCU in IREP) as feed stock for its petrochemical complex. The products from PDPP are Acrylates, Oxo-Alcohols, and Acrylic acid. The above products are basically used in paints, adhesives, plasticizers, detergents, pulp & paper, textiles etc. Currently all these are predominantly imported to India. So the commissioning of PDPP at KR will give a boost to Govt. of India’s ‘Make in India’ campaign.

Motor Spirit Block Project (MSBP) is to be implemented for quality upgradation of auto fuels Petrol and Diesel to Bharat VI specification as stipulated by the Government of India.

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