BPCL plans to install a new crude and vacuum distillation unit of 6 million tons per annum capacity as a replacement of old crude and vacuum units, a company official said.
Old units will be disposed off post stabilisation of the new plant.
With the entire 12 million tons Mumbai refinery will have new crude distillation units - the primary unit that converts crude oil into fuel, as other half was built only a few years back.
Full commissioning of the project is expected by May 2015.
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BPCL is also looking at expanding its Kochi refinery by installing a new crude distillation unit (CDU) of 10.5 million tons so as to replace the existing old 4.5 million tons CDU-1 which is not energy efficient.
This would raise Kochi refinery capacity to 15.5 million tons from current 9.5 million tons.
The company is also planning to almost double the combined capacity of its Numaligarh refinery in Assam and Bina refinery in Madhya Pradesh at a cost of about Rs 13,500 crore.
Numaligarh refinery capacity is being planned to be raised to 9 million tons from current 3 million while Bina capacity would go up to 8 million tons from 6 million.
"The Numaligarh refinery expansion is on drawing-board stage and its viability hinges on tax concessions and other benefits from the state and central government," the official said.
India currently has a refining capacity of 217 million tonnes.