Kochi Refineries Limited
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1.1BRIEF HISTORY OF BPCL-KOCHI REFINERY
Kochi Refineries Limited was incorporated as a public limited company in September 1963 with technical collaboration and financial participation from Phillips Petroleum Company of USA. The refinery was commissioned on 23rd September 1966.
From the date of commissioning to date, the refinery undertook three expansions in the refining capacity and installation of secondary processing facilities. The capacity was first expanded from 2.5MMPTA to 3.3MMPTA in September 1973.The production of Liquefied Petroleum Gas and Aviation Turbine Fuel commenced after this expansion. Bombay High crude was first processed in 1977. Crude processing capacity of KRL was further increased from 3.3MMPTA to 4.5MMPTA by revamping the crude unit. During the year 1984 along with the addition of 1MMPTA capacity fluid catalytic cracking unit company also commissioned an Aromatic Recovery Unit. The crude capacity was further revamp to 7.5 MMPTA in the year 1994, with the addition of a new crude unit and consequently the FCCU capacity was further increased to 1.4MMPTA, in order to process the increased quantity of VGO generated. In 2005 FCCU capacity again increased to1.75MMPTA.
A captive power plant of 26.3MW ISO rating (Gas Turbine) was commissioned in March 1991and steam turbo generator (STG) of 17.8MW.ISO rating was commissioned in March 1998 to meet the enhanced power requirements of the refinery.
Light Ends Feed Preparation Unit (LEFPU) to supply feedstock to the joint stock venture, Kochi Refineries Blamer Laurie Limited (CRBL) was commissioned in March 1993. KRL also commissioned a Raffinate Purification Unit for manufacture of 8800TPA of petroleum hydrocarbons solvent unit in January 1994.
DHDS unit was commissioned in year 2000 which will reduce sulphur content in diesel from 1.0% or higher to below 0.25%. Today the sulphur content in the diesel of KRL is 500 PPM that is 0.5% (EURO-II)
It is the responsibility of each and every employee not only to operate the plant safely but also profitably, consuming minimum energy at maximum efficiency. We must be capable of building environmentally clean plant and outline their expected life cycles, providing many years of clean efficient services to nation. This is the most important duty of all.
1.2 COMPANY PROFILE- KOCHI REFINERIES
Kochi refinery started on 27 April 1963 when government of India, Philips petroleum company of USA and Duncan brothers of Calcutta signed an agreement for the construction of a petroleum refinery in south India, in kochi, kerala. Erstwhile kochi refineries limited, formerly known as cochin refineries ltd (CRL), was formally registered on 6 September 1963 at Ernakulum. Philips petroleum International Corporation was the prime contractors for the construction of the refinery. Construction work started in March 1964 and the first unit came on stream just after 29 months in September 1966. Former prime minister of India Ms Indira Gandhi inaugurated it on 23 September 1966. Kochi refinery which is owned by Bharat Petroleum Corporation Limited is one of the best run refineries in India with global level of excellence. Kochi refinery learning centre managed by the refinery is regularly running various kinds of training and education programmes relevant to oil and gas operation.
The refinery had an original design capacity of 2.5 million metric tons per annum (mmtpa) which was increased to 3.3 mmtpa in 1973. Production of liquefied petroleum gas (LPG) and aviation turbine fuel (ATF) commenced after this expansion. Refining capacity was further enhanced to 4.5 mmpta in November 1984 when a fluidized catalytic cracking unit (FCCU) of 1MMTPA capacity was added. In Dec 1994, refining capacity was increased to 7.5 mmpta (150,000bpsd) along with revamp of FCCU to 1.4 MMTPA . A fuel gas de-sulphurisation unit was installed as part of this project to minimize sulphur dioxide emission. CRL entered into petrochemical sector in 1989 when aromatic production facilities with a design capacity of 87,200 tons as per annum of benzene and 12,000 tons per annum of toluene was commissioned. In the year 2000, a 2 MMTPA diesel hydro de-sulphurisation(DHDS) plant was added to reduce the sulphur content in diesel.A captive power plant of 26.3 MW was commissioned in 1991. An additional captive power plant of 17.8MW was commissioned in1998 thus making the refinery self sufficient in power. An LPG bottling plant of capacity 44,000 TPA was commissioned in 2003. A Bitumen emulation plant of 10,000 TPA capacity has also been commissioned in 2004. A Biturox Bitumen Oxidation Unit of 378,000 TPA capacity was successfully commissioned and started up in 2008.
Bharat petroleum corporation limited (BPCL) acquired the government of India’s shares in KRL in march 2001. Consequent to the merger order dated 18 august, 2006 issued by ministry of company affairs, the refinery has been amalgamated with Bharat Petroleum Corporation, hence forth to be known as BPCL – kochi refinery