The main projects presently being undertaken by the refinery are:
Capacity Expansion cum Modernisation Project (CEMP) Phase-II
A new 30” crude oil pipeline from Jetty to the refinery
A 220 KV Gas Insulated Substation for importing power from state grid
Facilities for Induction of Central Industrial Security Force (CISF)
Replacing part of liquid fuels used in the refinery by LNG (Liquefied Natural Gas)
Replacement of Electrostatic Precipitator (ESP) in FCC unit
Of this the major on going project is the Rs 3941 crores Capacity Expansion cum Modernisation Project (CEMP) Phase-II. Revamp of CDU-II for capacity enhancement of the refinery has already been completed as part of this project.
Brief descriptions of the major projects recently completed and ongoing CEMP – Phase-II project are given below.
Capacity Expansion cum Modernisation Project – Phase-I
The phase-I of the Capacity Expansion cum Modernization Project (CEMP), that envisaged refinery modifications required to meet BS-II product specifications was completed in the year 2005. Supply of auto fuels conforming to Bharat Stage-II specifications began in April 2005.
Crude Oil Receipt Facilities Project
The Crude Oil Receipt Facilities (CORF) Project is a major infrastructure development to assist Kochi Refinery in its future growth. The CORF consists of Single Point Mooring (SPM) for berthing Very Large Crude Carriers (VLCC), a 48” Sub Sea pipeline, Shore Tank Farm for storage of crude oil and associated pipelines and facilities. The project was completed in November, 2007 and the first tanker berthed on 3rd December, 2007 with the first VLCC tanker arriving on 30th January, 2008.
Advantages of this multi crore project are multifold. The prime ones being direct savings through reduced freight charges and increased flexibility in crude oil selection.
Community development schemes were taken up by the refinery along with the construction activities of the SPM. Schemes included development of roads, drainage facilities and Fish Landing Centre, improvement of health care centres including the deployment of an ambulance at Puthuvypeen, assistance for educational facilities, augmentation of water supply and street lighting.
A new Bitumen Blowing unit using Biturox technology was commissioned on 19th June, 2008. The unit is set up to meet the demand of new grades of Bitumen products and new specifications of paving grade Bitumen as per Bureau of Indian Standards. The unit design incorporates environment friendly features of reactor off gas incinerator followed by flue gas scrubber, making it the cleanest unit of its kind in the world.
Propylene Recovery Unit
A Propylene Recover Unit has been set up by the refinery for recovering chemical grade Propylene (95% purity) from LPG produced in the Fluid Catalytic Cracking (FCC) unit. The capacity of the unit is 50,000 Tons per Annum of Propylene. The project was completed in March 2009.
Integrated Refinery Business Improvement Program
An Integrated Refinery Business Improvement Program was implemented by the refinery in association with M/s Shell Global Solutions B.V. This project focuses on improving the refinery performance by implementing various improvement programmes. After detailed investigations in the entire gamut of operations, schemes (proposals for improvement) were identified and implemented under the categories namely margin improvement, energy & loss reduction and operations & asset availability improvements. M/s. Shell Global Solutions International, Kuala Lumpur, Malaysia was appointed for conducting the study, which was co-ordinated by Centre for High Technology, New Delhi.
Capacity Expansion cum Modernisation Project – Phase-II
Phase-II of the Capacity Expansion cum Modernisation Project (CEMP) envisages to set up facilities for producing auto-fuels complying with Euro-III / IV quality specifications and to increase the refining capacity from 7.5 MMPTA to 9.5 MMPTA. Revamp of CDU-II for capacity expansion by 2.0 MMTPA has been completed in July, 2009 as part of the project.
Apart from CDU-II revamp, the new facilities envisaged in this major project include a VGO HDS unit, CCR Reformer unit, a GT for power generation and associated Utilities and Off-site facilities. The project is nearing completion. Auto fuels produced from Kochi Refinery would be Euro-III and partly Euro-IV compliant on completion of this project.