Site

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- HPCL Rajasthan Refinery
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- HPCL Rajasthan Refinery Limited
- Site in a Project-Phase
- 342014
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/ Barmer - Rajasthan
- Sambhra, Pachpadra
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Project Overview
The project involves setting up of a Greenfield 9 MMTPA refinery-cum-petrochemical complex at Pachpadra in Barmer district of Rajasthan. With a processing capacity of nine million tonnes of crude oil per annum (Mtpa), the refinery complex will produce environment-friendly clean fuels, as well as petrochemicals to be used as feedstock in packaging, textile, and petroleum industries.
Project Progress and Timeline
- Physical Completion: 82% as of September 2024, with crude pipelines nearing 94% completion.
- Crude Unit Start: October 2025, with phased commissioning of downstream units to follow.
- Full Operations: Expected by December 2025, ramping up to 80% capacity by year-end and full utilization by 2027.
- Petrochemical Integration: Polypropylene, LLDPE, and HDPE units to begin operations in early 2026, three months after refinery startup.
Key Features and Units
- Crude Mix: Designed to process both indigenous Rajasthan crude and imported Arab mix crude (initially 1.5 MMTPA Rajasthan crude + 7.5 MMTPA Arab mix; shifting to 9.0 MMTPA Arab mix after 8 years)[1]
- Process Units: The facility will have 29 process units; major units include[1][2]:
- Crude Distillation Unit (CDU): 9.0 MMTPA
- Vacuum Distillation Unit (VDU): 4.8 MMTPA
- Naphtha Hydrotreater (NHT): 1.8 MMTPA
- Diesel Hydrotreater (DHDT): 4.1 MMTPA
- Delayed Coker Unit (DCU): 2.4 MMTPA
- Petro Fluidized Catalytic Cracking Unit (PFCCU): 2.9 MMTPA
- Vacuum Gas Oil Hydrotreater (VGO-HDT): 3.5 MMTPA
- Isomerization Unit, Semi-Regenerative Reformer, and Continuous Catalytic Reformer (CCR)
- Dual Feed Cracker Unit: 0.82 MMTPA
- Polypropylene Units: 2 x 490 KTPA (using Lummus Novolen technology for high-performance catalysts)
- LLDPE/HDPE Swing Units: 2 x 416 KTPA
- Butene-1 Unit: 59 KTPA
- Key Technology Providers:
- Axens: Naphtha hydrotreating, semi-regenerative reformer, C5-C6 isomerization, VGO hydrotreater, Prime-G+® (cracked gasoline desulfurization), AlphaButol® (1-Butene production), sulfur block (Claus, Sultimate™ tail gas treatment), sour water stripping, and amine regeneration[3]
- Lummus: Novolen process reactors and catalysts for polypropylene units[2]
- EIL (Engineers India Limited): Project management and engineering for several units[2]
References
- REVISED ENVIRONMENTAL IMPACT ASSESSMENT STUDY FOR RAJASTHAN REFINERY PROJECT - GRASS ROOT REFINERY & PETROCHEMICAL COMPLEX, HINDUSTAN PETROLEUM CORPORATION LIMITED, REPORT NO. B068-1742-EI-1701 JULY 2017, Ministry of Environment, Forest and Climate Change, Government of India.
- Wiipedia, Pachpadra Refinery (page last edited on 13 May 2025).
- DIGITAL REFINING, 08 April 2019, HPCL Rajasthan refinery selects technologies from Axens.
System Info
- Modified by
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 Kokel, Nicolas
- Modified
- 5/26/2025 1:53 PM
- Added by
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 Kokel, Nicolas
- Added
- 3/4/2023 6:48 PM

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