Site

HPCL's Mumbai Refinery is an integrated fuels and lubricants refining complex located at Mahul, Chembur, Mumbai, spread over 321 acres. Originally commissioned in 1954 (as 1955 in some sources) by the erstwhile ESSO as India's first modern refinery, it has undergone multiple expansions over seven decades to become one of India's most complex refineries.

Refinery Capacity and Expansion

• Capacity Evolution
  • 1954: Original capacity 1.25 MMTPA (~29,000 bpd)
  • 1985: Expanded to 5.5 MMTPA (~126,000 bpd) post-nationalization​
  • Post-GFEC Project: Enhanced to 6.5 MMTPA (~149,000 bpd)​
  • 2014: Increased to 7.5 MMTPA (~172,000 bpd) with Diesel Hydro Treating Block commissioning
  • 2017-2021: Expansion project initiated (December 2017) to reach 9.5 MMTPA (~218,000 bpd), completed March 2021
  • Current Capacity: 9.5 MMTPA
     
• 2017-2021 Expansion Project (7.5 to 9.5 MMTPA)
  • Total investment: Rs 50.6 billion (~₹3,846-5,060 crore / ~$700 million)
  • Phase I: CDU III, new VDU, MS Block revamp, DHDS/DHT upgrade, HGU, PRU, CPP revamp
  • Phase II: Focus on hydrogen-based bottoms upgradation, targeting zero fuel oil and zero naphtha export​
     
• Future LOBS Expansion
  • Investment: Contract awarded to CLG in January 2024​
  • Target completion: 2027-2028​

Feedstock

• Bombay High crude: Primary feedstock - offshore crude from ONGC's Mumbai High field (API >38°, light crude)
• Diverse crude slate: Flexible processing capability for domestic and international crudes​
• Operational challenges: Occasional issues with high-salt, high-chloride crudes causing corrosion (e.g., Hindustan Oil Exploration crude in October 2025)

Refinery Performance and Complexity

• Refinery Complexity
  • HPCL Mumbai operates as one of India's most complex refineries with high Nelson Complexity Index reflecting extensive secondary processing including FCC, hydrotreating, catalytic reforming, isomerization, propylene recovery, and integrated lube oil production.
• Recent Performance
  • Part of HPCL's record 22.33 MMTPA combined throughput across all refineries (2023-24)​
  • HPCL targets total refining capacity of 45.3 MMTPA by FY2028 (including Mumbai, Vizag, and Barmer refineries)
  • Occasional operational disruptions requiring fuel imports (October 2025) due to problematic crude quality​

Processing Units

• Crude Distillation
  • CDU I & CDU II: Original atmospheric distillation units (pre-expansion)​
  • CDU III: New unit commissioned 2021 as part of expansion to 9.5 MMTPA​
  • Vacuum Distillation Units (VDU): New VPS unit installed to replace existing FRVPS and LRVPS units
• Conversion Units
  • Fluid Catalytic Cracking Units (FCCU): Two units (20,000 a,d 28,000 bpd capacity) producing LPG, gasoline, and light cycle oil from heavy gas oils
• Hydrotreating & Upgrading
  • Diesel Hydro-Desulfurization (DHDS): Producing BS-VI (Euro VI) specification diesel
  • Diesel Hydro-Treating (DHT): Upgraded for co-processing of diesel and vacuum gasoil​
  • Naphtha Hydrotreating (NHT): Feed preparation for reformer
• Motor Spirit (MS) Block
  • Naphtha Hydrotreating (NHDT): Feed desulfurization
  • Isomerization (ISOM): Light naphtha octane upgrading
  • Continuous Catalytic Reforming (CCR): Aromatic production and octane enhancement
  • Prime-G Unit: Gasoline quality upgrading technology
  • Units revamped in Phase I expansion (20% capacity increase)
• Lube Oil Base Stock (LOBS) Complex:
  • Current capacity: 475,000-478,000 TPA (~10,900 bpd) Group II/II+ base oils
  • Planned expansion: 764,000 TPA (~17,500 bpd) by 2027-2028​
  • New integrated hydrocracker and catalytic dewaxing unit: 550 KTPA nameplate capacity​
  • Technology: Chevron Lummus Global (CLG) for grassroots hydrocracker and catalytic dewaxing, plus Lube Oil Upgrading Program (LOUP) catalyst reload
• Petrochemical Units
  • Propylene Recovery Unit (PRU): 100,000 TPA (~2,300 bpd) chemical-grade propylene (≥95% purity, <0.1 wt% C₁+C₂, <1000 ppmw C₄, <5 ppmw sulfur) from cracked LPG, commissioned as part of 2017-2021 expansion project

Supporting Infrastructure

• Utilities & Power Generation
  • Hydrogen Generation Unit (HGU): 65,000 TPA (~7.5 MMSCFD) capacity, commissioned in Phase I expansion​
  • Captive Power Plant (CPP): Combined cycle configuration
    • Gas Turbine: 81 MW
    • Steam Turbine: 15.1 MW
    • Gross capacity: 96.1 MW; Net: 77.8 MW
    • Fuel: Natural gas/naphtha
    • Revamped as part of 2017 expansion project​
• Gas Treatment & Recovery
  • Sulfur Recovery Units (SRU): Elemental sulfur production from acid gases​
  • Amine Regeneration Unit (ARU): H₂S and CO₂ removal​
• Storage & Logistics
  • Tank Farm: MR II tankage facilities at Calico land used for new storage construction​
  • Location: 25 km from Mumbai airport; nearest rail junction is Lokmanya Tilak Terminus

Product Portfolio & Capacities

• Transportation Fuels
  • Motor Spirit (Gasoline): BS-VI (Euro VI) grade
  • High Speed Diesel (HSD): BS-VI (Euro VI) grade with ultra-low sulfur
  • Aviation Turbine Fuel (ATF): Jet fuel
  • Kerosene: Household and industrial fuel​
• LPG & Light Products
  • Liquefied Petroleum Gas (LPG): Propane/butane mix
  • Naphtha: Reformer feedstock and petrochemical exports
• Petrochemicals
  • Chemical-grade Propylene: 100,000 TPA (2,300 bpd) at 95%+ purity
• Specialty Products
  • Lube Oil Base Stocks: Group II+ and Group III premium base oils
    • Current: 475,000-478,000 TPA (~10,900 bpd)
    • Target (2027-28): 764,000 TPA (~17,500 bpd)​
  • Bitumen: Additional ~487,000 TPA (~11,200 bpd) from fuel oil upgrading​
  • Fuel Oil: Low Sulfur Heavy Stock (LSHS, ≤0.5 wt% sulfur); Phase II targets zero fuel oil production
  • Sulfur: Recovered elemental sulfur

References

1. Engineers India Limited (2016). EIA & RRA study for propylene recovery unit and revamp of CPP project at HPCL Mumbai refinery (Document No. A858-EI-1742-1601, Rev. 0). Hindustan Petroleum Corporation Limited.
2. Ministry of Petroleum and Natural Gas, Government of India (Mar 28, 2024). Hindustan Petroleum Corporation Limited.
3. Hindustan Petroleum Corporation Limited (Nov 2, 2021). Q2 Highlights: PAT at ₹ 1,924 Crore.
4. NS Energy. (Dec 24, 2024). HPCL Mumbai Refinery Expansion Project. 
5. Business Standard (Feb 6, 2017). HPCL gets green nod for Rs 3,846-cr expansion project.
6. Jayakumar P.B., Fortune India (Nov 8, 2021). Capex push! HPCL to raise refining, petchem capacity by 2024: CMD.
7. Industrial Info Resources (Apr 30, 2010). Hindustan Petroleum Corporation Targets Refining Capacity of 800,000 Barrels per Day.
8. Indian Chemical News (Jan 18, 2024). HPCL awards licensing contract to CLG for hydrocracker unit at Mumbai Refinery.
9. Fuel and Lubes (Dec 23, 2024). HPLC expands base oil capacity at Mumbai Refinery by 61%.
10. Investywise (Oct 27, 2025). Hindustan Petroleum Operational Issues Arise from High Salt Crude Parcel.
11. Reuters (Oct 28, 2025). India's HPCL issues fuel import tenders after disruptions at Mumbai refinery, sources say.
12. S&P Global (Oct 10, 2025). INTERVIEW: India's HPCL eyes refining capacity growth, flexible crude sourcing strategy.
13. SCANX (Jan 21, 2026). HPCL Sets Target of 45.3 MMTPA Refining Capacity by FY28.
14. Oil&Gas Journal (Apr 1, 2010). FCCU inaugurated at HCPL Mumbai refinery.
15. PR Newswire (Jan 17, 2024). Chevron Lummus Global Awarded New Licensing Contract for HPCL's Integrated Hydrocracker and Catalytic Dewaxing Unit.
16. O'Reilly C., Hydrocarbon Engineering (Sep 19, 2019). BPCL awards CLG new contract
17. Chevron Lummus Global. Catalysts.