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Mangalore Refinery | Source: The Economic Times (Mar 5, 2026)

History & Capacity Expansion

The refinery was originally commissioned in 1988 as a 3.69 MMTPA joint sector venture between HPCL and the A.V. Birla Group. Successive expansion phases extended capacity progressively:

Phase	Capacity (MMTPA)	Key Addition
Phase I (original)	3.69	Grassroots refinery
Phase II	9.69	Second hydrocracker, second CCR
Phase III (2012)	15.00	CDU/VDU-III + PFCCU + PP Unit

The refinery achieved its all-time throughput record of 17.14 MMTPA in FY2023–24 — the highest ever recorded by any single-location PSU refinery in India's history — exceeding its 15 MMTPA nameplate capacity.

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Capacity & Complexity

Parameter	Value
Nameplate capacity	15.0 MMTPA (300,000 bpd)
Peak throughput achieved	17.14 MMTPA (FY2023–24)
Nelson Complexity Index (NCI)	11.3
Crude API gravity range	24° – 46° API
Petrochemical intensity	9.5% (target: 15%)

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Processing Units

Mangalore Refinery block flow diagram ^[12]

The refinery is a highly complex integrated facility comprising:

Distillation

• 3 × Crude Distillation / Atmospheric Distillation Units (CDU/ADU): CDU-I, CDU-II (Phase I/II), CDU-III (Phase III, commissioned March 2012); designed by Engineers India Limited (EIL)
• 3 × Vacuum Distillation Units (VDUs) — paired with respective CDUs

Hydroprocessing

• 2 × Hydrocracker Units (HCU) — 100% conversion of VGO to low-sulphur diesel and ATF; licensor: UOP (Honeywell); individual capacity ~1.2 MMTPA each
• Gas Oil Hydrodesulphurisation Unit (GOHDS)
• Diesel Hydrotreating units

Catalytic Cracking

• 1 × Petrochemical Fluid Catalytic Cracking Unit (PFCCU) — added Phase III; produces polymer-grade propylene as primary feedstock for PP unit

Naphtha Processing

• 2 × Continuous Catalytic Reforming (CCR / Platforming) units — technology licensed from UOP, USA; produce high-octane, lead-free motor spirit and hydrogen by-product
• Naphtha Hydrotreating units

Residue Processing

• 2 × Visbreaker Units (VBU) — technology licensed from Shell/Lummus

Hydrogen Generation

• 3 × Hydrogen Generation Units (HGU):
  • 2 units at 51.14 NM³/hr — technology by KTI, Holland
  • 1 unit at 97.29 NM³/hr — technology by Haldor Topsøe, Denmark
  • All units use UOP Pressure Swing Adsorption (PSA) for 99.9% purity hydrogen recovery

Sulphur Recovery

• Sulphur Recovery Units (SRU)

Petrochemicals

• 1 × Polypropylene (PP) Unit — 440,000 TPA capacity; feed: polymer-grade propylene from PFCCU; commissioned June 2015

Utilities

• Captive Power Plant (CPP)
• Effluent Treatment Plants (ETP) — Zero Liquid Discharge (ZLD)

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Products

The refinery produces a comprehensive slate of BS-VI compliant fuels and petrochemical products:

• LPG
• Motor Spirit (MS / Gasoline) — BS-VI
• High Speed Diesel (HSD) — BS-VI, high cetane
• Aviation Turbine Fuel (ATF)
• Naphtha
• Kerosene
• Bitumen
• Sulphur
• Pet Coke
• Polypropylene (PP) — 440,000 TPA

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Key Distinctions

• Only refinery in India with two hydrocrackers producing premium high-cetane diesel
• One of only two refineries in India with two CCR units producing high-octane unleaded petrol
• Holds the all-time Indian PSU refinery throughput record at 17.14 MMTPA
• Direct coastal crude access via SPM buoy capable of receiving VLCCs, giving significant crude slate flexibility

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References

1. MRPL Official Website — Manufacturing Units (Accessed Mar 28, 2026)
2. MRPL Official Website — Company Profile (Accessed Mar 28, 2026)
3. Wikipedia — Mangalore Refinery and Petrochemicals Limited (Accessed Mar 28, 2026)
4. Offshore Technology — Mangalore Refinery Expansion (Aug 9, 2010)
5. Offshore Technology — Mangaluru Refinery, India (Oct 27, 2021)
6. CPMA (Chemical and Petrochemical Manufacturers Association) — Mangalore Refinery and Petrochemicals Ltd (Accessed Mar 28, 2026)
7. Trade Brains — Mangalore Refinery and Petrochemicals — Company Overview (Accessed Mar 28, 2026)
8. Bajaj Broking — About Mangalore Refinery and Petrochemicals Ltd (Sep 18, 2025)
9. Finpedia — Mangalore Refinery & Petrochemicals Ltd (Accessed Mar 28, 2026)
10. Financial Times Markets — Mangalore Refinery and Petrochemicals Ltd — Company Profile (Accessed Mar 28, 2026)
11. LinkedIn — Mangalore Refinery & Petrochemicals Ltd — Company Page (Accessed Mar 28, 2026)
12. Scribd — MRPL Overview and Operations (Uploaded on Mar 1, 2011)