Pakistan Refinery Limited (PRL) was built and commissioned in October 1962 at Karachi in alliance with major foreign oil companies like Burmah Oil California, Texas Oil Corporation, Shell Petroleum Corporation and Esso Standard Eastern Inc. PRL is a hydro-skimming refinery with a crude processing capacity of 50,000 barrels per operating day.
The process configuration constitutes of desalting, crude distillation, hydrodesulphurization, platforming and LPG units. Though designed to process Iranian Light, it has acquired the ability to process a variety of imported and indigenous crude oils to produce products namely-LPG, MS Unleaded 90 RON, Naphtha, Kerosene, HSD, JP-1, JP-4, MMT and Furnace Oil.
PRL, since inception has been the principle manufacturer and supplier of petroleum products to the domestic market and Pakistan Defense Forces. It continues to serve the energy needs of the country with professional excellence and high degree of commitment.
PRL takes pride in the competitive edge over other competitors in respect of efficiency; lower operating cost, high quality human resources, reliability and introduction of newer generation technologies.
PRL has demonstrated its excellence as a first-rate corporate citizen by serving the community and demonstrating total commitment to the cause of Health, Safety and Environment. PRL is proud to be the leader in HSE Management System, being the first in Pakistan oil industry to achieve integrated OHSAS 18001:1999 and ISO 14001:1996 certifications in November 2002.
VISION: To be the Refinery of first choice for all stake holders.
MISSION STATEMENT: PRL is committed to remaining a leader in the oil refining business of Pakistan by providing value added products that are environmentally friendly, and by protecting the interest of all stakeholders in a competitive market through sustainable development and quality human resources.
HSE COMMITMENT: PRL is committed to the protection of environment and to ensure health and safety of its employees, customers, contractors and communities where it operates and to work for continual improvement of health, safety and environment.
PROCESS SUMMARY: Refinery produces three fractions from the primary fractionating column:
1. Residue from the bottom, which is used as Fuel Oil.
2. Gas oil from the side, used as High Speed Diesel (HSD) engine fuel.
3. Combined kerosene, naphtha, gasoline and gas fractions from the top, which is used as feedstock for the Catalytic Hydrodesulphuriser Unit.
DESULPHURIZED PRODUCT IS FURTHER FRACTIONATED TO PRODUCE:
1. Kerosene from the bottom, which is suitable for use as Aviation Turbine fuel and also for cooking and illumination.
2. Unstabilized gasoline from the top.
3. Naphtha from the side, which is used as feedstock for the Platformer Unit.
THE UNSTABILIZED GASOLINE IS FURTHER STABILIZED TO PRODUCE:
1. Gasoline from the bottom, which is suitable for use in Motor Spirit production.
2. LPG and Fuel Gas from the top, which are then separated.
PRODUCTION: The objective of the oil refining process is to separate the crude oil into number of fractions, each of which then contains a narrower range of hydrocarbons, which are more suitable for conversion into saleable products.
The oil consumption in the country has posted an overall growth of 22% due to recovery of economy as GDP growth is expected to reach 7.0 to 7.2%. The production level of the company has been optimised according to the economic requirement.
Crude throughput during the year was 2.05 Million Tons as PRL introduced light and sweet crude 'Murban' to extract favourable product yield structure. The financial benefit of this strategic decision has resulted in better profitability.
The high fuel consumption is a cause of great concern for the company's profitability and steps are being taken to address this issue. Various options to upgrade Fuel oil into value added products and to meet the upcoming product quality challenges are under study.
FINANCIAL RESULTS: Company has managed to deliver an encouraging performance despite unfavourable external factors with profit after tax of Rs 734.0 Million in FY 2003-04 compared to Rs 824.0 Million in FY 2002-03. The positive impact of profitability is visible in the shape of improved liquidity and significant reduction in financial charges.
The company has achieved the highest ever profit after tax of Rs 1, 040.0 Million, during July-December 2004, an increase of 190% from the corresponding period last year due to better refining margins applicable to topping/reforming refineries in the region and efficiency factors built in the operation of PRL.
The continuation of the Refinery Tariff Protection Formula, various efficiency improvement steps and sustained management efforts has contributed to achieving this profitability.
ACHIEVEMENTS: Today, products derived from refining of crude oil meet an overwhelming part of the world energy needs. PRL since its inception has been an important supplier of petroleum products to the domestic market, Pakistan Defence Forces.
PRL TAKES PRIDE FOR ITS FOLLOWING ACHIEVEMENTS:
-- Implementation of HSE Management Systems (ISO 14001 & OHSAS 18001)
-- ISO 9001 certification of PRL's high-tech laboratory.
-- Achieved 8.1 Million man-hours without Lost Time Injury (LTI) till to date.
-- Implementation of SAP.
-- Conversion of Fuel Oil X-country pipeline for HSD service.
-- Induction of Desalting Unit to improve quality of Fuel Oil in respect of salt contents.
-- Modification of crude-heaters to increase HSD yield by 2% & improve efficiency by 10%
-- Installation of Desalination plant, which currently meets 30% of Refinery's water needs.
-- Revamp of Platformer Unit to increase its throughput from 340 MTSD to 400 MTSD.
-- Installation of a Texas Tower to improve Energy Efficiency.
-- All furnaces equipped with Low Noise, High Efficiency burners.
-- Effluent Water Treatment Plant (EWTP) installed at Korangi to bring the effluents within NEQS limits.
-- Domestic Waste Water Treatment Plant installed at Keamari.
-- DCS installed on all the three boilers/ Crude Unit to modernise Control System
-- Rerouting of JP-1 line to Karachi Airport
-- Additional Tankage of 10,000 Mtons built for naphtha export
FUTURE PROJECTS: PRL is actively engaged in collaboration with Foster Wheeler Energy Ltd and USTDA to study the Refinery Fuel oil Up- gradation. The objective of the study is to evaluate and finalise the best possible route to minimise Fuel oil production, maximise middle distillate production and to meet revised product specifications. The targets need to be met through most efficient use of capital. The estimated project cost would be $250-300 million and the time frame is 3-4 years.
HEALTH, SAFETY & ENVIRONMENT MANAGEMENT SYSTEM: At PRL HSE Management System is an integration of ISO 14001:1996 and OHSAS 18001:1999.The scope of PRL's Health, Safety and Environment Management System covers refining, storage and distribution of crude oil and petroleum products at Korangi Refinery and Keamari Terminal.
===============================
Crude Recipe (%age)
Arabian Light 50
Iranian Light 30
Local Crude 20
-------------------------------
Revenue Break-Up
Cost of Crude 92.6%
Operating Expenses 3.1%
Taxes 1.7%
Financial Charges 0.1%
Profit 2.5%
===============================
Comments
Comments are closed.