TATIPAKA MINI REFINERY

A SUCCESS STORY

11
SUCCESSFUL
YEARS

MINI-REFINERY - CONCEPT

Development of Marginal fields as they have less life-time.

To reduce transportation cost of oil from remote or

Inaccessible locations.

To reduce transportation cost of refined products .

Pay back period is low i.e. 3 to 5 years, instead of normal

refinery average of 15 years.

No dependency on external source for refinery crude.

Transportation hazard is minimized due to proximity of

source and processing facility.

Meets the need of the small consumers locally in the

areas even without big infrastructure support

MINI-REFINERY - Facts

100 Mini-refineries (0.03 to 1.0 MMTPA) around the

world (mainly in USA, Australia, Russia)
Only 2 Mini-refineries in India
Re-locatable Skid mounted refinery with Erection
time - 6 months to 18 months.
Re-erection time can be as small as 60 days.
Cold re-start in less than one hour and can be put in
full operation.
feed mix is possible to vary.

NEED FOR THE REFINERY

To avoid transportation of crude due to strikes or
shutdown in HPCL VKSP refinery.
To ensure uninterrupted supply of gas from Tatipaka
GCS, in case of any interruption in transportation of
oil.
To minimize safety hazards involved in long distance
transportation.
To minimize pilpherages & transit loss of crude oil
involved in long distance transportation
To meet the internal HSD requirements of
Rajahmundry and Karaikal assets.

Advantages in Processing our own crude

Savings of a huge hidden charges towards oil transportation

cost up to Yanam, Pumping cost up to the cargo, cost of
product insurance, transit losses, wharf age charges at loading
& unloading points storage & handling losses at Yanam, cargo
and Mumbai.
All the refinery products are being handed over to OMCs at
Refinery gate only which will not attribute to any kind of
product loss.
Though Refinery is designed for four products Naptha , SKO,
HSD and LSHS , we are producing six products from the those
four trays, Naptha, SKO, HSD LSHS, HFHSD and
MTO(LAWS). depending on the demand and supply of the
products with in-house expertise.
Self sufficiency for the requirement of internal consumption of
HSD of all the Assets, RJY, KKL & EOA.
No additional resources required like existing manpower, Air
compressors, water source, power supply, Fire services,
security and additional land etc. Best Utilization will reduce the
operating cost of both the refineries.

TATIPAKA REFINERY
DATE OF COMMISSIONING
3rd Sep 2001

REFINING CAPACITY
NORMAL: 1500 BPD (186 TPD)
MAX : 2000 BPD (250 TPD)

TATIPAKA REFINERY IS CERTIFIED FOR ISO-14001

(ENVIRONMENT) , ISO-9001 (QUALITY) AND OHSAS-18001
(SAFETY) SINCE 2002

ISO
9001

TATIPAKA
COMPLEX

OHSAS
18001

ISO
14001

TATIPAKA REFINERY
COST :
26.5 Crores

BASICENGG:
IOGPT,
MUMBAI

TATIPAKA
MINI-REFINERY

PROJECT
EXEC: NICCO
/ VENTECH

CONSLTAN
T: PDIL,
NOIDA
PERIOD:
450 DAYS

REFINERY SCHEMATIC FLOW DIAGRAM

MAJOR EQUIPMENTS

DESALTER

HEAT EXCHANGERS SKID

PUMPS SKID

COLUMN SKID

FURNACE

CI / NH3 / DEMULSIFIER TANKS 1 NO EACH

BOILER 2 NOS

DM WATER UNIT 1 NOS

WATER TREATMENT PLANT 1 NOS

COOLIN TOWER 2 NOS

STORAGE TANKS 8 NOS

LOADING GANTRY- 4 BAY

WEIGH BRIDGE 1 NO

PROCESS DESCRIPTION

Crude oil is heated from 36C to 135C in first stage of

preheating (through exchangers E-101, E-102, E-103 A/B) and
then sent to de-salter where the water content from the crude
is totally removed.

Desalted crude at 125C is the heated up to 220C in second

stage of preheating (through E-104A/B, E-105 A/B, E-106) and
then heated in a furnace up to 330C.

The heated crude (partially vapourized) is fed into the

atmospheric distillation column at a pressure of 0.8 atm where
products NAPHTHA (140C), SKO (180C), HSD (240C) and
LSHS (300C) get separated depending on their individual
boiling points.

FEEDS AND PRODUCTS

KSP(W)

TPK

GMAA

LINGALA
32% @140 C

15% @170210
C

CRUDE : CONDENSATE
75:25
CRUDE OIL @330 C (44th)

27% @240-280 C

NAPHTHA
(11th)

SKO (22nd)

HSD (35th)

26% @300 C

LSHS (49th)

New Product Additions

HF-HSD

in 2005

By TEAM REFINERY

HFHSD Production

Normal HSD produced up to 2005-2006

Huge demand foreseen for HFHSD due to increased

activity in EOA- Kakinada

Already normal HSD demand met for RJY and

CAUVERY onshore rigs and production installations

Feasibility of HFHSD studied

HF HSD with Flash point above 66C need to be

produced.

HFHSD - MODIFICATIONS

HFHSD (HSD with flash point > 66 C) is planned to

produce for meeting the requirement of EOA-KKD.
To cope with increased load of HFHSD production,
Additional heat exchanger E-103B is provided in
parellel.

New operating parameters

Column Operating Parameters
Location

Before

After

Units

Top Temp

102.1

105.1

HN Draw

143.1

146.5

SKO Draw

206.7

185

HSD Draw

283.7

293.9

Feed Temp

291.6

300.5

Top Reflux

5626

5799

Kg/Hr

Kero Pump Around

8727

9196

Kg/Hr

HSD Pump Around

8432

6686

Kg/Hr

HFHSD Specifications
Sl.No.

Characterisrics

Density @ 150C

Flash Point(PM), 0C
0

Pour Point, C
Max.

Specifications

Method

Result

0.820 - 0.860

IP-160/87

0.8415

660C Min.

P-21

66

P-10

(+) 18

Visual

Light Yellow
colour

120C Winter

210C Summer

Appearance

Kinematic Viscosity,
cst

2.5 - 15.7

P-25

3.75

Sulphur, Total %by

wt. max

0.25

ASTM D
5453

0.01765

Requirement HFHSD for internal use

Name of Asset

Present
HSD Actual
supply during requirement
2010 (203Days)
of HSD

Remarks

Rajahmundry

30 KL/D

30 KL/D

100 % requirement met

Karaikal

21 KL/D

21 KL/D

100 % requirement met

Kakinada-EOA

20 KL/D

215 KL/D

195
KL/day
requirement not met.

(Based on 6500
KL/month)

Total

71 KL/D

266 KL/D

Shortage of HSD/HFHSD (195 KL/D ) is being proposed to meet through

Refinery expansion Project & Existing (95KL/D + 24 KL/D = 119 KL/D).

New Product Additions

MTO

in 2011

By TEAM REFINERY

Properties of MTO
Low odour solvent
Fast setting power
Good solvency power

Launching of New product

Mineral Turpentine Oil (MTO)

No additives required
No additional processing equipments required
No additional manpower or processing shut down required
during the change over of the product.
No modification of the existing refinery or column internals
required.
No additional financial implications but it is a source of
additional revenue.
By replacing SKO with MTO product i.e. 37 TPD or 12210
Tons/annum
SKO net realization Price = 22374 Rs/MT
MTO net realization Price = 34936 Rs/MT
Difference is 12562 Rs/MT X 12210 = 15.33 Cr
(During previous quarter rates, it was worked out as 17.9 Cr)
To reduce the demand of Naptha & increasing the yield of product
MTO will increase the profitability of the refinery.

MTO - MINERAL TURPENTINE OIL

Change in Market Dynamics after supply of Reliance Gas

motivated to diversify product line.

Present SKO production 15% of feed and it can be

replaced with MTO to improve the refinery profit margins.
MTO is an intermediate product between SKO & Naphtha.
MTO produced on Experimental basis in July, 2010 and 1st
tanker flagged off on 12.04.11
If Need arises, the product MTO can be interchanged with
SKO as per market demand without any changes in the
plant.

Applications of MTO

Adhesive industries
Paint and resin industries
Thinner industries
Agro-chemicals,households' insecticides, fungicides
industries.
Paint catalysts, driers, coating and industries
Textiles, cloth, paper, printing-processing industries
Degreasing and cleaning purpose in machineries,
machine spares manufacturing industries

FEEDS AND PRODUCTS

Fuel&loss (1.5%)
KSP(W) /
GOPAVARAM
OIL

LINGALA/
MALLESWARAM

NAPHTHA

CONDENSATE

NAPHTHA
TPK

ADVP/PON
CONDENSATE

CONDENSATE

32%
@80T(110KL)

SKO

MTO

15% @38T(49KL)

SKO
CRUDE : CONDENSATE
75:25
CRUDE OIL @250T(304KL)

HSD
27% @68T(82KL)

LSHS
25% @63T(72KL)

HSD

YEILD PATTERN OF THE REFINERY

PRODUCT

Refinery Yield

Refinery Yield
(Revised)

Production@
250 TPD

Remarks

TPD (KL/D)

NAPTHA

34%

29%

72 (98)

Low
marketable
product

15%

15%

37 (47)

Low
Profitable
product-SKO

22%

31%

78 (95)

Highly
product

28%

24%

60 (68)

Low
marketable
product

99%

99%

247(308)

(0.733)

SKO/MTO
(0.7828)

HSD / HFHSD
(0.825)

LSHS
(0.88)

TOTAL

Profitable

1 1.5% Fuel loss

Although Tatipaka Refinery is designed and constructed for producing four products
Naptha , SKO, HSD and LSHS , Through our in-house expertise we are producing six
products from the those four trays only Naptha, SKO, MTO (LAWS), HSD, HFHSD and
LSHS depending on the demand and supply of the products.

Performance at a Glance
VAP
Production
(MT)

%Capacity
Utilization

Revenue
Earned
(Cr.)

Profit Earned
(Cr.)

2002 03

91464

139 %

97.48

42.36

2003 04

90368

137%

95.15

36.20

2004 05

91577

139%

130.15

55.22

2005 06

92080

140%

164.80

77.61

2006 07

92947

141%

156.13

55.94

2007 08

61707

94%

121.83

32.28

2008 - 09

82340

125%

186.90

55.28

2009 10

54442

82.5%

95.41

20.62

2010-11

68789

103%

148.18

62.78

2011-12
(Apr-Sep)

50959

103%

90

36

Year

SPECIFICATIONS FOR NAPHTHA

Sl.No.

Characterisrics

Specific Gravity@60/600F

Specifications

Method of
Test ref.
IS:1448

To be reported

Distillation

a. IBP, 0C

25 (Min.)

b. FBP, 0C

204(Max.)

Reid Vapour Pressure ,Kg/cm2

0.7(Max.)

Non Volatile Matter, mg/100ml

5.0(Max.)

RCR, % by Mass

0.2(Max.)

C/H Ratio(Calculation)

To be reported

Net Calorific Value,Kcal/Kg

To be reported

P-18

P-39

P-8

P-7

SPECFICATIONS OF KEROSENE IS:1459-1974

Characteristics
i)

Acidity, Inorganic

ii) BURNING QUALITY:

a) Char Value, mg/kg of oil consumed, Max
b) Bloom on Glass Chimney

Specifications

Method Of Test, ref to

(P:) of IS:1448

NIL

P:2

20
Not Darker
Than Grey

P:5

iii) Color
10
a) Saybolt,Min (in case of Undyed Kerosene ) 10
b) Visual (in case of Dyed Kerosene)
Blue

P:14
P:14
-

iv) Copper Strip Corrosion for 3 hrs. at 500C

P:15

v)

Distillation:
a) Percent Recovered Below 200 0C, Min
b) Final Boiling Point, degC, Max

Not Worse than

No. 1

P:18
20
300

vi) Flash Point (Abel), degC, Min

35

P:20

vii) Smoke Point, mm, Min

18

P:31

viii) Total Sulfur, Percent by Mass, Max

0.25

P:34

SPECIFICATIONS FOR HSD IS : 1460-2005

Sl. No

CHARACTERISTICS

Acidity, Inorganic

Acidity total, mg KOH/g

Ash,% by mass

Carbon Residue(Ramsbottom) on 10% residue, % by

mass

SPECIFICATIONS

Method of Test ref.

IS:1448

Nil

P-2

To be reported, Not limited

P-2

0.01 Max

P-4

0.3 Max

P-8

Cetane Number

51 Min

P-9

Calculated Cetane Index

46 Min

ASTM D 4737

7
8
9

Pour Point, C

Winter

3 Max

Summer

15 Max

Copper strip corrosion, for 3 hrs @ 100 C

Not worse than No.1

Distillation, % v/v Recovered

P-10
P-15
P-18

Recovery at 360 C

95 Min

10

Flash Point-Abel, C

35 Min

P-20

11

Kinematic Viscocity @ 40 C , cSt

2.0 to 4.5

P-25

12

Total Contamination, mg/kg

24 Max

EN 12662

13

Density at 15 C, kg/m

820-845

P-16

14

Total Sulphur, mg/kg

350 Max

ASTM D 4294

15

Water Content, mg/kg

200 Max

ISO 12937

16

Cold Filter Plugging Point (CPFF), C

Winter

6 Max

Summer

18 Max

P-110

SPECIFICATIONS FOR LSHS IS:1593-1982

REQUIREMENTS FOR
Grade
LV

Grade
MV1

Grade
MV2

Grade
HV

Method Of
Test, ref to
(P: ) of
IS:1448

Nil

Nil

Nil

Nil

P:2

ii) Ash, Percent by mass, Max

0.1

0.1

0.1

0.1

P:4

iii) Gross, Calorific Value

Not limited, but to be reported

P:6 & P:7

iv) Relative Density at 15/15 degC

Not limited, but to be reported

P:16 or P:32

v) Flash Point,
[Pensky Martin,(closed)] degC, Min

66degC

66degC

66degC

66degC

P:21

vi) Kinematic Viscosity, cSt, at 50degC,

Max
Above
Upto

80, max

80
125

125
180

180
370

P:25

vii) Sediment, Percent by mass, Max

0.25

0.25

0.25

0.25

P:30

viii) Sulfur,Total, Percent by Mass,Max

3.5

4.0

4.0

4.5

P:33

ix) Water Content, Percent by volume,

Max

1.0

1.0

1.0

1.0

P:40

CHARACTERISTICS

i)

Acidity, Inorganic

SPECIFICATIONS FOR MTO IS:1745-1978

SL.No.

CHARACTERISTICS

1.

COLOUR SAYBOLT, Min.

2.

COLOR(ASTM), Max.

3.

Density at 150C, g/ml

4.

FLASH POINT(ABEL), 0C Min.

5.

DISTILLATION RANGE
a) IBP, 0C Min.

6.
7.
8.

9.

SOLVENT
(125/240)

SOLVENT
(140/205)

METHOD OF
TEST REF 1S:1448

+21

+20

P:14

P:12

To be reported (not limited)

30

35

125

145

b) 50% by vol. recovered at, 0C

To be reported (not limited)

c) 95% by vol. recovered at, 0C

To be reported (not limited)

P:16
P:20

P:18

d) FBP, 0C Max.

240

205

AROMATIC CONTENT, %VOL

Max.
TOTAL SULPHUR, % Wt. Max.

40

40

P:23 OR P:48

P:34 OR P:83

Cu STRIP CORROSION
for 3 Hrs. at 500C

RESIDUE ON EVAPORATION
mg / 100 ml Max.

NOT WORSE THAN No.1

P:15

P:29(AIR JET)

Naphtha Test Report at Refinery

Sl.No.
1

Characteristics
Specific Gravity@60/600F

Specifications

Method ref
to IS:1448

Results
0.7268

To be reported

Distillation
2

a. IBP, 0C

25 (Min.)

b. FBP, 0C

204(Max.)

Reid Vapour Pressure ,

Kg/cm2

0.7(Max.)

Non Volatile Matter,

mg/100ml

5.0(Max.)

RCR, % by Mass

0.2(Max.)

C/H Ratio (Calculation)

Net Calorific Value, Kcal/Kg To be reported

P-18

42
152

P-39

0.50
2.30

P-8

0.070
5.62

To be reported

P-7

10529

SKO Test Report at Refinery

Sl.No
1
2

Characterisrics
Density @ 150C
0

Manufacturer
spec

Method

Result

To be reported To be reported

IP-160/87

0.7974

IS 1448, P-20

38

Specification
0

Flash Point(Abel), C

35 C Min.

38 C Min.

Distillation
a. Recovery below
2000C
b. IBP, 0C

20 Min.

20 Min.

IS 1448, P-18

73

155
236

IS 1448, P-2

IS 1448, P-31

22

IS 1448, P-15

Better than 1a

c. FBP, C
300 Max.
290 Max.
Acidity Inorganic,mg
Nil
Nil
KOH/g
Smoke Point, mm
18 Min.
19 Min.
Copper Strip Corrosion@ Not worse than Not worse than
500C/3Hrs
1
1
Colour saybolt
+10
+10

IS 1448, P-14

+10

Sulphur , total, % by Wt

ASTM D 5453

0.0072

BURNING QUALITY

5
6

A) Char value, mg/Kg

B) Bloom on Chimney,
Predominating colour

0.25

0.25

Max 20

Max 20

14.80
IS 1448, P-5

Not darker
than grey

Not darker than

grey

Not darker than

grey

MTO Test Report at Refinery

Sl.No.

Characterisrics

COLOUR (SAYBOLT) Min

DENSITY AT 15 0 C,g/ml

FLASH POINT (ABEL),0 C Min

4
5

DISTILLATION RANGE
a) IBP,Min

b) 50% by vol recovered at,0C

c) 95% by vol recovered at,0C

0

d) FBP, Max, C

TOTAL SULPHUR, Max %Wt

10

Cu S.C.FOR 3 Hrs AT 50 0C

11

ROE,mg/100 ml,Max

METHOD OF
TEST

RESULT

(+)21
TO BE
REPORTED,NOT
LIMITED

P:14

(+)21

P:16

0.7909

30

P:20

38

MTO 125/240

125
TO BE
REPORTED,NOT
LIMITED
TO BE
REPORTED,NOT
LIMITED
240

149

P:18

175

208
222

ASTM D 5453

0.0036

NOT WORSE
THAN 1

P:15

No.1

P:29 (AIR JET)

0.8

LSHS Test Report at Refinery

Sl.No
.

Characterisrics

Specifications

Method

Result

0.8864

Density @ 150C

Flash Point(PM), 0C

66 Min.

P-21

68

Pour Point, 0C

60 Max.

P-10

42

Water Content, % V/V

1.0 Max.

P-40

<0.05

Gross Calorific Value,

To be reported
Kcal/Kg

P-7

10750

To be reported IP-160/87

Dynamic Feed Mix Change

Poor upliftment of Naphtha and LSHS

forced experiment various crude mix
Originally designed to process Crude
condensate mix (Kesanapalli)
Availability of various crudes like
Gopavaram and Lingala allowed to
make changes in the feed mix therby
producting products as per usage.
FEED MIX

PRODUCT MIX

TATIPAKA REFINERY
MARKETING
TIE UPs

NAPHTHA
APCL, VIZAG

NAPHTHA

EMERALD PETROCHEM LTD

Nagpur

PRICE @ RTP per MT

LSHS
ESSAR STEEL, VIZAG

LSHS

ITC, BANGALORE

PRICE @ RTP
MoU SIGNED FOR 2 YEARS

HSD
KG ONSHORE
KKL ONSHORE

HSD
GOKAVARAM TERMINAL

HFHSD

KKD OFFSHORE

HUGE SAVINGS TO ONGC AS TOTAL HSD

REQUIREMENT FOR KG AND KKL ONSHORE
& PARTIAL KKD REQUIREMENT MET

SKO / MTO

SKO
PDS KEROSENE

MTO

Solvents / Paint industry

Naptha Upliftment of M/s. HPCl from

Tatipaka Refinery

Rejuvenation of Refinery Operations

During 2011, RJY Asset has made efforts to improve the

upliftment of Naphtha. At this juncture HPCL has agreed to lift
sufficient quantity of Naphtha and LSHS on day to day basis and
requested ONGC, to purchase of lubes from M/s HPCL. RJY
Asset had agreed and accordingly a proposal was sent to Head
quarters on win-win situation strategy. This effort has resulted
in achieving VAP production targets and efficiency of the plant
is increased from 82.5%(2010) to 102.7% (2011)

Later to improve the profitability of Refinery though the VAP

upliftment reduced by M/s HPCL MTO is being produced in place
of the SKO.

During the less off take of the Naptha crude from Gopavaram is
processed and less off take of the LSHS more KSP crude is
processed.

Awards and Accolades

GROUP AWARD FROM DIRECTOR(ONSHORE) FOR
COMMISIONING REFINERY- 2002
GREEN TECH ENVIRONMENT EXCELLENCE
SILVER 2003-04 & 2004-05
GREEN TECH SAFETY SILVER 2003-04
& 2004-05
CERTIFICATE OF APPRECIATION FROM NATIONAL
SAFETY COUNCIL, AP CHAPTER - 2005

THE HIGH TECHNICAL AUDIT RATED AWARD FROM

DIRECTOR (T&FS) 2008-09
C&MD INNOVATION GROUP AWARD FOR NEW
PRODUCT MTO 2011
GREEN TECH ENVIRONMENT EXCELLENCE
- GOLD 2006, 2011
BEST ONSHORE INSTALLATION AWARD 2011
(All over ONGC)

BEST FIRE SUB-STATION 2011-12

(All over ONGC)

THANK YOU