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Essar Oil Refinery, Vadinar, Gujarat

The Essar Oil Ltd grass roots refinery in Gujarat, India (began in 1996) was accomplished and commissioned in 2006 (commissioned in third quarter). The refinery mission was delayed several occasions on account of environmental concerns and financial problems, including preliminary value overruns and a shortfall in fairness contributions.

beer canIn response to company reports, the refinery was 60% full in 1998 but had the misfortune to be struck by a cyclone that triggered appreciable injury. The refinery currently has the capability to produce 370,000 barrels a day (thirteen.5 million tonnes per 12 months) and plans are underway to extend the capacity to 680,000 barrels a day (34mtpa) by the tip of fiscal 2010. The refinery employs over 1,000 personnel (the construction course of required between three,000 and four,000).

The refinery is now the second largest in India after the Reliance Jamnagar refinery on an adjacent site which might produce over 27mtpa.

Essar Oil focuses on producing center distillates corresponding to excessive-grade kerosene what are 3 uses of crude oil oil and low sulphur high-pace diesel, which type over 60% of India’s domestic shopper demand.

Substituting imports will help conserve India’s foreign alternate. The refinery may also produce LPG and lead-free gasoline of various octane levels for the domestic markets and excessive-octane lead-free gasoline for export. Essar Oil what are 3 uses of crude oil has 1,300 retail stations with plans to add one other 150 retailers by the top of 2010.

Refinery start-up
In November 2006 Essar Oil began operations in its Vadinar grass roots refinery and trial production with a capability of 7.5mtpa. In December 2006, the plant dispatched its first cargo of 35,000t vacuum fuel oil.

Essar shut down the plant for 3 weeks in July 2007 to improve the capacity to 210,000bpd in addition to to add secondary items.

After the start of the industrial production of 10.5mtpa in May 2008, in August 2008 Essar Oil reported a gross sale of Rs100bn for the first two months of its commercial operations. The revenue for the quarter ending 30 June 2008 was Rs4.34bn.

Essar posted a gross turnover of INR418bn between May 2008 and March 2009. Since then it has increased by 19.7% in the primary quarter of 2010.

Commissioning course of
The items commissioned in the primary part have been the CDU, VDU, sulphur fuel unit, naphtha hydrotreater, catalytic cracker and visbreaker. The fluid catalytic cracker and a diesel hydro desulphuriser were commissioned in November 2006.

The FCC and DHDS plants have been modified so as to be compliant with the cleaner Euro III and what are 3 uses of crude oil Euro IV fuels. The refinery configuration lends itself nicely to de-bottlenecking and its capacity is believed can be enhanced to 14mtpa.

The refinery is fully built-in with its personal dedicated 77MW power plant, which it plans to expand to 1,200MW plant.

The docking services embody an SBM capable of dealing with vessels as much as 350,000DWT with a capacity of 25mtpa, tankages with interconnecting pipelines of 20mtpa capacity, marine product dispatch capacity of 12mtpa and rail-automobile and truck-loading facilities.

In early 2007 a hearth was reported at the refinery where four people have been killed and 18 injured. The fire broke out when employees have been carrying out welding work close to a naphtha pipeline (which apparently was leaking). The refinery is now back in manufacturing producing in excess of one hundred fifty,000 barrels a day.

Crude provide
Ahead of the commissioning the corporate received one million barrels at the Vadinar port in Gujarat in August 2006. The crude was a Saharan blend appropriate for refining within the Essar Oil’s refinery. The corporate additionally acquired a second cargo from Vitol in West Asia. Each cargos were of sweet crude.

The annual requirement of crude oil at the refinery is in the region of 10.5mtpa. The refinery is configured to permit flexibility to course of numerous varieties and qualities of crude. The refinery is primarily designed to handle a crude mixture of Arabian Gentle and Heavy in a 70:30 ratio. Nevertheless, ample flexibility has been offered to handle a wide range of crude mixes at refinery processing units from sweet-light crude to heavy excessive sulphur sour and bituminous crude.

The refinery refines crude oil to supply diesel, gasoline, jet gas, kerosene, fuel oil and bitumen to go well with market necessities. Imported crude oil is discharged from a single buoy mooring situated off a coastal site at a distance of 8km. A submarine / onshore pipeline transfers crude to onshore storage tanks.

Contractors and development
The principal contractor and undertaking supervisor for the mission because it was began is ABB Lummus Global of the Netherlands (ABB put Rs9,300 into the mission). The corporate answerable for detailed engineering, procurement and building (EPC) is TCE. Larsen and Toubro is another engineering company concerned in the undertaking. Semb Co E&C has secured contracts price $350m for engineering, procurement, undertaking management and building administration for the project.

The TCE remit for building consists of offsite facilities, storage and transfer of crude, intermediates and products, blending amenities, despatch amenities, fuel oil / fuel system, effluent treatment and disposal amenities. Utilities embody energy / steam generation services (two 38.5MW / three 150t per hour) with distribution network, compressed air (three three,120Nm³ per hour) and nitrogen system (1,900Nm³ per hour), demineralising plant (775m³ per hour), desalination plant (two 390m³ per hour), salt cooling water amenities (64,000m³ per hour) and tempered water services.

A refinery-extensive built-in Distributed Control System (DCS), safe guarding system, fire and gasoline detection system and electrical control system is provided with hardware located in satellite buildings and operator consoles provided within the crude oil tank management building and central control building. A complicated Tank Gauging System (TGS) has been supplied – one each for crude oil tank farm, product and intermediate tank farm and despatch tankages – comprising radar, servo and hydrostatic techniques. Over seven-hundred motor-operated valves with clever actuators are linked to DCS and emergency shutdown methods. The despatch automation system is built-in with the TGS and DCS techniques.

The refinery is being constructed with a view to the longer term since it may have sufficient infrastructure for a low-cost enlargement to a production capability of 27mmtpa. The refinery also has two desalination plants each with a capability to supply eight,450m³ a day of much less-than-5ppm total dissolved solids (TDS) from feed water of forty,000ppm TDS (sea water).

Port and shipping
The refinery has its personal port and terminal services. Vadinar port is an all-weather, deep-draft, natural port with loading services for railcars and trucks.

Vessels as much as 350,000dwt can be handled via single level mooring (SPM) and there can be a marine product dispatch with a capacity of 14mtpa.

Essar Transport has an agreement with Essar Oil to ship crude oil as required by the refinery. Essar Oil has arrange a new firm, Vadinar Oil Terminal, to administer all affairs of the brand new deep-water port on behalf of Essar Oil and Essar Transport.

The refinery is ideally located on the west coast of India at Vadinar, Gujarat, near both suppliers and clients. This is the nearest point to the Center East, which is a significant supply of crude supply. The site is linked to the Kandla-Bhatinda product pipeline by means of the Vadinar-Kandla pipeline, giving it easy accessibility to the key markets of North India.

Essar constructions has bagged several pipeline tasks over the previous few years. The tasks embody the INR2bn Baroda – Ahmedabad – Kalol gas pipeline undertaking, a Rs740m product pipeline challenge in Tamil Nadu, a Rs1.3bn gas pipeline venture from GAIL and most not too long ago a Rs1.9bn, 504km pipeline mission.

Essar Oil additionally has a stake within the pipe-holding firm Petronet India.

Funding for the mission, which quantities to an estimated INR98,740 ($2.26bn), has been an advanced arrangement.

Monetary closure by Essar Oil has now been achieved for the mission. In January 2005, Essar Initiatives raised Rs3,750 by means of Global Depository Receipts (GDR) and Essar Delivery raised $213m by the issuing of Foreign Forex Convertible Bonds (FCCB), to make a complete of $299m (this was a condition of the remaining funds being released).

The financial institutions, together with ICICI financial institution, the Industrial Development Bank of India (IDBI) and the Industrial Finance Company of India (IFCI) bank, then released the remainder of the RS80,000 funding held in escrow for the challenge.

In October 2008, Essat Oil ordered 4 steam turbine generators from Siemens Vitality for the Vadinar Oil refinery processes in Gujarat. The $50m deal includes two steam turbines every rated at 105MW, two 93MW steam turbines and four generators.

Supply of the steam turbine generators is scheduled by the third quarter of 2010.

Essar Oil Refinery will probably be expanded in two phases to attain a capability of 36mmtpa. The primary section comprises capacity enlargement to 18mmtpa. An funding of Rs78bn is being made in the primary part, which is scheduled to be commissioned by March 2011. Hydrogen Peroxide Equipment By the end of the first half of 2009 33% of part I had been completed.

In section II, there are plans for establishing a new processing unit with a capacity of 18mmtpa. An funding of $4bn is being made within the section II growth, which is predicted expected to be accomplished by March 2013.

Essar’s building arm, Essar Building (I), is undertaking the enlargement of the refinery. As of Janauary 2010, 28% of the development was accomplished and general refinery enlargement of forty one% was achieved.