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Visakh Refinery by night | Source: HPCL, via Fuels and Lubes (Jan 8, 2026)

History

The refinery was originally commissioned in 1957 by Caltex Oil Refining India (CORIL) with an installed capacity of just 0.675 MMTPA, making it the oldest refinery on India's east coast. In May 1978, Caltex Oil Refinery (India) was amalgamated into HPCL, transferring ownership and operations to the Indian government. Capacity expansions followed progressively:

Current Capacity & Performance

Following the completion of the Visakh Refinery Modernisation Project (VRMP), nameplate capacity reached 15 MMTPA in FY2024–25. The refinery has already surpassed this, processing over 15 MMT of crude oil in FY2024–25, setting an all-time throughput record. Management has targeted a further expansion to 20 MMTPA within 5–6 years, with an interim goal of surpassing 16 MMTPA in FY2025–26.

Processing Units

The refinery is an integrated fuel-focused facility with a Nelson Complexity Index of 11.6, comprising the following processing units:

Crude Distillation / Atmospheric Distillation

• 3 × Crude Distillation Units (CDU/ADU): CDU-I (3.0 MMTPA) + CDU-II (3.0 MMTPA) — legacy units; CDU/VDU-IV (9.0 MMTPA) — added via VRMP, licensed by EIL. Total atmospheric distillation capacity: 15.0 MMTPA
• 3 × Vacuum Distillation Units (VDUs): VDU-I, VDU-II (legacy, paired with CDU-I/II respectively); VDU-IV (9.0 MMTPA train, paired with CDU-IV, VRMP). Combined VGO production: ~4.90 MMTPA

Catalytic Cracking

• 3 × Fluid Catalytic Cracking (FCC) units:
  • FCCU-1 (1.00 MMTPA) — ExxonMobil design; feed: sour straight-run VGO
  • FCCU-2 (0.96 MMTPA) — UOP design; feed: sour straight-run VGO + OHCU bottoms
  • FCC-PC (~2.72 MMTPA) — propylene-maximisation mode; feed: hydrotreated VGO from VGOHDT; added via VRMP

Hydroprocessing

• 1 × VGO Hydrotreater (VGOHDT) (~2.80 MMTPA) — feed: straight-run VGO + DAO recycle + OHCU bottoms; product: sweet VGO to FCC-PC; added via VRMP
• 1 × VGO Hydrocracker — Once-Through Hydrocracker (OHCU); feed: straight-run VGO; products: naphtha, kerosene, diesel, UCO bottoms to FCCU-2
• 1 × Diesel Hydrodesulphurisation (DHDS) unit — BS-VI diesel production
• 1 × Diesel Hydrotreating unit (DHDT) — BS-VI diesel production
• Naphtha Hydrotreating (NHT) unit — feed preparation for CCR

Naphtha Processing

• 1 × Naphtha Hydrotreating (NHT) unit
• 1 × Isomerisation (ISOM) unit — light naphtha upgrading to high-octane gasoline blendstock
• 1 × Continuous Catalytic Reforming (CCR) unit — heavy naphtha to reformate + hydrogen; likely UOP CCR Platforming technology

Residue Upgrading

• 1 × Visbreaker (VBU) (~0.75 MMTPA) — feed: vacuum residue; products: visbroken gas oil, fuel oil
• 1 × Bitumen Blowing Unit (BBU) (~0.225 MMTPA feed capacity) — feed: vacuum residue; product: bitumen grades (~215,000–220,000 t/y)
• 1 × Residue Upgradation Facility (RUF) comprising:
• LC-Max ebullated-bed residue hydrocracker (3.55 MMTPA feed; world's first deployment; licensed by Chevron Lummus Global (CLG); commissioned 5 January 2026; ~93% conversion; 1st + 2nd stage reactors — 3 × 2,200 t reactors)
• ROSE^® Solvent Deasphalting (SDA) unit (~1.05 MMTPA; licensed by KBR; n-pentane solvent; feed: LC-Max vacuum bottoms; products: DAO recycled to LC-Max 2nd stage + asphaltenes to pitch solidification)
• Pitch Solidification & Handling Unit (~75,000–100,000 t/y pitch output)
• RUF Digital Suite (AI-driven real-time monitoring, predictive analytics, thermodynamic optimisation)

Hydrogen & Utilities

• 2 × Hydrogen Generation Units (HGU) — 113 ktpa each (total 226 ktpa); licensed by Technip Energies; added via VRMP
• 1 × PSA unit (36 ktpa hydrogen recovery); added via VRMP

Sulphur Management

• Sulphur Recovery Plants (SRU) — EPC by Petrofac International; added via VRMP; licensor not publicly confirmed

Propylene Recovery

• 1 × Propylene Recovery Unit (PRU) — 23,000 MTPA polymer-grade propylene; feed: combined FCC off-gases (note: PRU capacity likely reflects pre-VRMP sizing; expansion probable post FCC-PC commissioning)

Sustainable Aviation Fuel

• 1 × SAF demonstration plant — co-processing of used cooking oil; target ~10,000 MT/year from January 2027; aligned with India's SAF blending mandates (1% by 2027, 5% by 2030)

Complexity & Technology

The Nelson Complexity Index (NCI) of the Visakh Refinery stands at 11.6 following the VRMP, positioning it among India's most advanced deep-conversion refineries. The RUF uses LC-Max licensed residue hydrocracking technology, an industry-first deployment at scale in India, and is supported by an AI-driven RUF Digital Suite integrating real-time monitoring, predictive analytics, and thermodynamic optimisation models. The distillate yield improved by up to 10% versus pre-VRMP levels.

Products

The refinery is exclusively fuel-focused, with primary products including:

• Motor Spirit (MS / Gasoline) — BS-VI compliant
• High-Speed Diesel (HSD) — BS-VI compliant
• LPG
• ATF / Jet Fuel
• Bitumen
• Propylene
• Sustainable Aviation Fuel (SAF) — demonstration plant inaugurated (co-processing of used cooking oil); target ~10,000 MT/year from January 2027

Key Developments (2025–2026)

• VRMP fully commissioned — RUF (LC-Max) unit inaugurated by PM Modi in January 2026, praised as a major boost to India's energy security
• SAF demonstration plant inaugurated in line with India's SAF blending mandates (1% by 2027, 2% by 2028, 5% by 2030)
• Reduced Energy Intensity Index (EII) through improved heat integration

References

1. NS Energy — HPCL Visakh Refinery Modernisation (Jan 5, 2021)
2. Bharatpedia — Visakhapatnam Refinery (Page version: Oct 9, 2021)
3. DD India (Government of India) — HPCL's Visakh Refinery upgrade boosts energy security, strengthens Aatmanirbhar Bharat: PM Modi (Jan 6, 2026)
4. The Tribune — Ani, Visakh Refinery's processing capacity increases to 15 million tonnes (Jun 10, 2025)
5. Hydrocarbon Engineering — Brosnan E., HPCL commissions upgrade to Visakh Refinery (Jan 8, 2026)
6. Hindustan Petroleum Corporation Limited (Official Website) — HP Refineries (Accessed Mar 27, 2026)
7. Global Energy Monitor — HPCL Vizag Refinery Power Station (Page version: Jan 30, 2026)
8. Offshore Technology — Visakh Refinery Modernisation Project, Visakhapatnam (Mar 27, 2017)
9. HPCL Official Newsroom — HPCL Commissions Residue Upgradation Facility with World's First LC-Max Unit at Vizag Refinery (Jan 5, 2026)
10. Larsen & Toubro Press Release — L&T Delivers Feed-in at World's First LC-Max Residue Upgradation Facility at HPCL Visakh Refinery (Jan 6, 2026)
11. Offshore Technology — HPCL Starts Up Residue Upgradation Facility at Visakh Refinery (Jan 6, 2026)
12. Indian Chemical News (ICN) — India's First LC-MAX Unit Goes Live with Integrated AI-Led Intelligence at HPCL Visakh Refinery (Jan 6, 2026)
13. Argus Media — Q&A: HPCL's Vizag Upgrade to Boost Gasoil, Crude Slate (Jan 30, 2026)
14. Technip Energies — HPCL Visakh Facility Case Study (Accessed Mar 27, 2026)
15. Penta Global — Visakhapatnam Refinery Modernisation (VRMP) Sulphur Recovery Unit (Accessed Mar 27, 2026)
16. Hindustan Petroleum Corporation Limited— HP²FCC Technology: Catalyst & Process (Accessed Mar 27, 2026)
17. Environment Clearance (Government of India) — Detailed Feasibility Report for Visakh Refinery Modernisation Project — HPLC Visakh (Document date: 05 Jan 5, 2013)