Client
Mangalore Refinery and Petrochemicals Limited (MRPL)
Location
Mangalore, India
Capacity
40,000 m3/d, expandable to 70,000 m3/d
Seawater Desalination Ensures Reliable Industrial Water Supply for MRPL Refinery
The 40 MLD Seawater Reverse Osmosis (SWRO) plant developed for Mangalore Refinery and Petrochemicals Limited (MRPL) is a landmark industrial desalination project that reduces dependency on freshwater sources and ensures uninterrupted refinery operations. Designed for long-term water security, the plant supplies high-quality desalinated water to the refinery through a dedicated 11 km cross-country pipeline. The infrastructure is engineered for future expansion up to 70,000 m³/day, supporting energy efficiency and operational resilience.
High-Efficiency Desalination and Advanced Treatment for Industrial Applications
The plant incorporates a modern intake system and comprehensive pretreatment to handle seawater variability, followed by a two-stage RO process that delivers consistent, industrial-grade permeate. Key system features include lamella clarification, ultrafiltration, advanced RO design with energy recovery of approximately 47%, and post-treatment remineralisation to ensure compatibility for refinery use. The outfall system ensures environmentally compliant brine discharge.
Long-Term Water Sustainability for Energy Sector Operations
By supplying desalinated water for process and utility applications, the SWRO facility helps MRPL reduce extraction of freshwater resources while safeguarding refinery continuity during climatic variations. Its scalable design enables phased growth from 40,000 to 70,000 m³/day, ensuring readiness for increasing industrial demand.
DBO Scope for a Future-Ready SWRO Plant
- EPC + DBO delivery, including design, engineering, procurement, construction, installation, testing, and commissioning
- 10-year Operations & Maintenance (O&M)
Advanced Treatment Line-Up for Seawater Desalination
- Seawater intake system
- Electrochlorinator
- Lamella clarifiers + ultrafiltration
- Two-pass RO system
- Energy recovery through pressure exchanger (~47% efficiency)
- Remineralisation
- Outfall system
Impact on Industrial Water Security and Sustainability
The plant provides a reliable, sustainable, and cost-effective source of industrial water for the refinery, significantly reducing dependence on freshwater supplies and mitigating drought-driven water risks. Its continuous output ensures uninterrupted refinery operations even during seasonal fluctuations, strengthening overall production resilience. The project also stands as a proven model for industrial desalination in the Oil & Gas sector, demonstrating how seawater-based solutions can secure industrial water needs while promoting long-term environmental and operational sustainability.