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 June 13, 2007 IndianOil Stock Today :   BSE  434.60(-0.96%)    NSE 434.70(-1.10%) Update Stock
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Welcome To The World Of IndianOil
Refining
Major Projects

 The Refineries
 Pioneering Efforts In India
 Awards & Accreditations


THE REFINERIES

The year 2005-06 closed with IndianOil refineries clocking a record crude oil throughput of 38.52 million tonnes, surpassing the previous best of 37.66 million tonnes during 2003-04. The seven refineries together achieved a capacity utilisation of 93.1% – the highest in the last six years – and an overall distillate yield of 72% wt.

During the year, IndianOil became the first public sector organisation in the country to have its own Ship Chartering Cell, which started functioning from 15th June 2005 under the Refineries Division.

* (MMTPA- Million metric tonnes per annum, equal to 20,000 barrels per day)
* Million British Thermal Unit/ Per Barrel Energy Factor.
IndianOil Refineries: Installed Capacities
(In MMTPA)
 Refinery  As on 1.4.2000  As on 1.4.2001  As on  1.4.2002  As on 1.4.2003  As on 1.4.2004

 As on
1.4. 2005

 

 

 IOC              
 IOC- Guwahati
1.0
1.0
1.0
1.0
1.0
1.0
 IOC- Barauni
3.3
4.2
4.2
6.0
6.0
6.0
 IOC- Koyali
13.0
13.7
13.7
13.7
13.7
13.7
 IOC- Haldia
4.6
4.6
4.6
4.6
6.0
6.0
 IOC- Mathura
7.5
8.0
8.0
8.0
8.0
8.00
 IOC- Digboi
0.65
0.65
0.65
0.65
0.65
0.65
 IOC- Panipat
6.0
6.0
6.0
6.0
6.0
*6.0
 Sub-Total IOC
36.05
38.15
38.15
39.95
41.35
41.35
 IOC Subsidiaries
 CPCL- Chennai
6.5
6.5
6.5
6.5
9.5
9.5
 CPCL- Narimanam
0.50
0.50
0.50
1.0
1.0
1.0
 BRPL- Bongaigaon
2.35
2.35
2.35
2.35
2.35
2.35
 Sub-Total IOC  Subisdiaries
9.35
9.35
9.35
9.85
12.85
12.85
 IOC-Total(With-  Subsidiaries)
45.40
47.50
47.50
49.80
54.20
54.20

*Additional 6.00 MTPA Panipat Refinery Expansion has been completed in August 2006.


Digboi Refinery (Upper Assam)


The Digboi Refinery in North Eastern India is India’s oldest refinery and was commissioned in 1901. Originally a part of Assam Oil Company, it became part of IndianOil in 1981. Its original refining capacity had been 0.5 MMTPA since 1901. Modernisation project of this refinery has been completed and the refinery now has an increased capacity of 0.65 MMTPA. The Digboi refinery produces distillates, heavy ends and excellent quality wax from indigenous crude oil produced at the Assam oil fields. Petroleum products are supplied mainly to north-eastern India primarily through road and by rail wagons. A new Delayed Coking Unit of 1,70,000 TPA capacity was commissioned in 1999. A new Solvent Dewaxing Unit for maximizing production of micro-crystalline wax was installed and commissioned in 2003. The refinery has also installed Hydrotreater to improve the quality of diesel.


Guwahati Refinery (Assam)

The Guwahati Refinery in North East India -- the first Public Sector refinery of the country -- was commissioned in 1962 with a capacity of 0.75 MMTPA which was subsequently increased to 1.0 MMTPA through debottlenecking projects. The refinery processes only indigenous crude oil from the Assam oil fields. With its main secondary unit, a coking unit, it produces middle distillates from heavy ends and supplies petroleum products to North-Eastern India, and surplus products onward to Siliguri in West Bengal in 2003. Hydrotreater Unit for improving the quality of diesel has been commissioned in 2002. In 2003, the refinery installed an Indmax Unit, a novel technology developed by Indianoil's R&D Centre for upgrading heavy ends into LPG, Motor Spirit and Diesel oil.


Barauni Refinery (Near Patna, Bihar)

The Barauni Refinery in Eastern India was commissioned in 1964 with a capacity of 2.0 MMTPA. The refining capacity was increased to 3.0 MMTPA by 1969 and further to its current capacity of 6.0 MMTPA through low cost revamping and debottlenecking. Matching secondary processing facility such as RFCC (Resid Fluidised Catalytic Cracker) and hydrotreater facilities for diesel quality improvement have been added. Earlier, refinery’s crude input was primarily from the Assam oil fields through pipeline. With the commissioning of the 6.0 MMTPA Haldia-Barauni crude oil pipeline, the refinery now receives imported crude for processing. A CRU (Catalytic Reformer Unit) was also added to the refinery in 1997 for production of unleaded motor spirit. Projects are also planned for meeting future fuel quality requirements. Barauni Refinery supplies distillate products besides eastern India to northern India through a product pipeline to Kanpur in Uttar Pradesh.


Gujarat Refinery (Near Ahmedabad)

The Gujarat Refinery at Koyali in Gujarat in Western India is IndianOil’s largest refinery. The refinery was commissioned in 1965. Its facilities include five atmospheric crude distillation units. The major units include CRU, FCCU and the first Hydrocracking unit of the country. Through a product pipeline to Ahmedabad and a recently commissioned product pipeline connecting to BKPL product pipeline and also by rail wagons/trucks, the refinery primarily serves the demand for petroleum products in western and northern India.

When commissioned, the Gujarat refinery had a design capacity of 3.0 MMTPA. It was subsequently increased to 4.3 MMTPA by the revamping of three distillation units. In 1978, its processing capacity was further increased to 7.30 MMTPA by the addition of a crude distillation unit. A fluidised catalytic cracking unit was added to the refinery in 1981 to increase production of middle distillates, such as diesel and LPG. The capacity of the refinery was further increased to 9.5 MMTPA by 1990 through low cost revamping / debottlenecking and addition of a hydrocracker in 1992 for maximisation of middle distillates. Subsequently the crude capacity was increased to 12.5 MMTPA in 1999 by addition of new Atmospheric Unit of 3 MMTPA alongwith revamp of FCC Unit. The capacity has since been increased to its present capacity of 13.70 MMTPA by low cost debottlenecking. The company has already commissioned the facilities for MTBE and Butene-1 production. The refinery also produces a wide range of specialty products like Benzene, Toluene, MTO, Food Grade Hexane, solvents, LABFS, etc. The Gujarat Refinery achieved the distinction of becoming the first refinery in the country to have completed the DHDS (Diesel Hydro De-sulphurisation) project in June 1999, when the refinery started production of HSD with low sulphur content of 0.25% wt (max.).

A project for production of high value LAB (Linear Alkyl Benzene -- which is one of the major raw materials used in manufacturing detergents) from kerosene streams has been implemented. In order to meet future fuel quality requirements, MS Quality improvement facilities are planned to be installed by 2006.

Gujarat Refinery: 1961 Onwards

 Following the conclusion of an Indo-Soviet agreement in 1961 February, a site for the establishment of a 2 million tonne oil refinery in Gujarat at Koyali near Vadodara was selected on the 17th April 1961.

 The Soviet and Indian engineers signed a contract in October 1961 for the preparation of the project report jointly.

 On 10th May 1963, the then Prime Minister of India, Pandit Jawaharlal Nehru laid the foundation stone of the refinery.

 The first million tonne Crude Distillation Unit was commissioned for trial production on 11th October 1965 and full production at the rated capacity was achieved on 6th December 1965. The throughput was further increased by 20% beyond the designed capacity in January 1966.
 Dr S Radhakrishnan, the then President of India, dedicated the refinery to the nation with the commissioning of second crude distillation unit and Catalytic Reforming Unit on 18th October, 1966.

 The third 1.0 mmtpa crude distillation unit (AU-3) was commissioned in September 1967 to process Ankleshwar & North Gujarat crudes thus raising the refining capacity to 3.0 mmtpa.

 In December 1968, Udex plant was commissioned for production of benzene & toluene using feedstock available from CRU.

 By 1974-75 with in-house modifications, the capacity of the refinery was further increased by 40% to a level of 4.2 mmtpa.

 To process imported crude the refinery was expanded during 1978-79 by adding another 3 mmtpa crude distillation unit (AU-4) along with downstream processing units like Vacuum Distillation, Visbreaker & Bitumen Blowing Unit. By 1980-81 this unit started processing Bombay High crude in addition to imported crudes. It was for the first time in Indian petroleum industry that Indian engineers independently handled such a big project.

 To recover high value products from the residue, the secondary processing facilities consisting of Fluidized Catalytic Cracking Unit (FCCU) of 1.0 mmtpa capacity along with a Feed Preparation Unit (FCCU) of 1.0 mmtpa capacities, were commissioned in December 1982. Refinery also set up Pilot Distillation Facilities (PDF) for the production of N- Heptane & light Aluminum Rolling Oils (LARO). Meanwhile, to enable absorption of increased indigenous crudes the crude processing capacity of the refinery was further increased to 9.5 mmtpa.

 In 1993-94, Gujarat commissioned the country's first Hydrocracker Unit of 1.2 mmtpa for conversion of heavier ends of crude oil to high value superior products.

 Country's first Diesel Hydrodesulphurisation Unit (DHDS) to reduce sulphur content in diesel was commissioned by Gujarat Refinery in June 1999. Also commissioned in September eliminate lead in MS. Also MTBE Unit was commissioned in September 1999 to eliminate lead in MS.

 Conceptualised and commissioned South-East Asia's largest centralised effluent treatment plant by dismantling all the four old ETP's in June 1999.

 By September 1999 with commissioning of atmospheric distillation unit-5, Gujarat Refinery further augmented its capacity to 13.7 mmtpa making it the largest PSU refinery of the country.


Haldia Refinery (Near Kolkata, West Bengal)

Haldia Refinery, the fourth in the chain of seven operating refineries of IndianOil, was commissioned in January 1975. It is situated 136 km downstream of Kolkata in the district of East Midnapur, West Bengal, near the confluence of river Hoogly and river Haldi. The refinery had an original crude oil processing capacity of 2.5 MMTPA. Petroleum products from this Refinery are supplied mainly to eastern India through two Product Pipelines as well as through Barges, Tank Wagons and Tank Trucks. Products like MS, HSD and Bitumen are exported from this refinery.

The strategic significance of this Refinery lies in its being the only coastal refinery of the Corporation and the lone lube flagship, apart from being the sole producer of Jute Batching Oil and Russian Turbine Fuel. Capacity of the Refinery was increased to 2.75 MMTPA through de-bottlenecking in 1989-90. Refining capacity was further increased to 3.75 MMTPA in 1997 with the installation/commissioning of second Crude Distillation Unit of 1.0 MMTPA capacity. Diesel Hydro Desulphurisation (DHDS) Unit was commissioned in 1999, for production of low Sulphur content (0.25% wt) High Speed Diesel (HSD). With augmentation of this unit, refinery is producing BS-II and Euro-III equivalent HSD (part quantity) at present.

Resid Fluidised Catalytic Cracking Unit (RFCCU) was commissioned in 2001 in order to increase the distillate yield of the refinery as well as to meet the growing demand of LPG, MS and HSD. Refinery also produces eco friendly Bitumen emulsion and Microcrystalline Wax. In addition, a Catalytic Dewaxing Unit (CIDWU) was installed and commissioned in 2003, for production of high quality Lube Oil Base Stocks (LOBS), meeting the API Gr-II standard of LOBS. This is the only refinery in the country to produce such high quality LOBS.

In order to meet the Euro-III fuel quality standards, the MS Quality Improvement Project has been incorporated for production of Euro-III equivalent MS. Currently the unit is under stabilisation. At present, the Refinery is operating at a capacity of 5.5 MMTPA. Refinery expansion to 7.5 MMTPA as well as a Hydrocracker project has been approved for Haldia Refinery, commissioning of which shall enable this Refinery to supply entire Euro – III HSD to the eastern region of India.


Mathura Refinery (Near Delhi)

The Mathura refinery was commissioned in 1982 with an original capacity of 6.0 MMTPA. The capacity was increased to 7.5 MMTPA by debottlenecking and revamping. With its fluid catalytic cracking units, the refinery mainly produces middle distillates and supplies them to Northern India though a product pipeline to Jalandhar, Punjab via Delhi. The company commissioned a two-stage desalter in 1998 for improving the on-stream availability of the crude distillation unit and a CCRU for production of unleaded Motor Spirit. A DHDS Unit was commissioned in 1999 for production of HSD with low Sulphur content of 0.25% wt (max). A hydro-cracker for increasing middle distillates was also completed in 2000. The present capacity of the refinery is 8 MMTPA.

In order to meet future fuel requirements, facilities for improvement in quality of MS & HSD are under installation and planned to be completed by 2005.


Panipat Refinery (Near Delhi)

Panipat Refinery – A Profile


Panipat Refinery has doubled its refining capacity from 6 MMT/yr to 12 MMT/yr with the commissioning of its Expansion Project. Panipat Refinery is the seventh refinery of IndianOil. It is located in the historic district of Panipat in the state of Haryana and is about 23 km from Panipat City. The original refinery with 6 MMTPA capacity was built and commissioned in 1998 at a cost of Rs. 3868 crore (which includes Marketing & Pipelines installations).

The major secondary processing units of the Refinery include Catalytic Reforming Unit, Once Through Hydrocracker unit, Resid Fluidised Catalytic Cracking unit, Visbreaker unit, Bitumen blowing unit, Sulphur block and associated Auxiliary facilities. In order to improve diesel quality, a Diesel Hydro Desulphurisation Unit (DHDS) was subsequently commissioned in 1999.

Referred as one of India’s most modern refineries, Panipat Refinery was built using global technologies from IFP France; Haldor-Topsoe, Denmark; UNOCAL/UOP, USA; and Stone & Webster, USA. It processes a wide range of both indigenous and imported grades of crude oil. It receives crude from Vadinar through the 1370 km long Salaya-Mathura Pipeline which also supplies crude to Koyali and Mathura Refineries of IndianOil.

Petroleum products are transported through various modes like rail, road as well as environment-friendly pipelines. The Refinery caters to the high-consumption demand centres in North-Western India including the States of Haryana, Punjab, J&K, Himachal, Chandigarh, Uttaranchal, as well as parts of Rajasthan and Delhi.

The LPG produced from the refinery is pumped through a dedicated pipeline to IndianOil’s Kohand Bottling plant where bottling and bulk despatches are done. Panipat Refinery has also developed new products like 96 RON petrol, and sub-Zero diesel for the Indian army. It is already operating above 100% capacity for the last four years.

Panipat Refinery Expansion

Due to a growing deficit of petroleum products in the high demand centres of North India, it was decided to expand the capacity of Panipat Refinery from 6 million tonnes to 12 million tonnes with matching secondary processing facilities. M/s ElL was chosen as the Project Management Consultant.

Built at a cost of Rs. 4165 crore, the Refinery expansion units have been designed to process 100% high sulphur crude. This has enhanced the processing of high sulphur crude to 75% of the total refinery processing. The major secondary units envisaged in the expansion are Hydrocracking unit, Delayed Coking unit, Diesel Hydrotreating unit, Hydrogen Generation unit, Sulphur block and other associated auxiliary facilities. The technologies have been supplied by M/s Axens; France, Haldor-Topsoe; Denmark, UOP USA and Black & Veatch, USA and ABB Luumas. For supply of crude oil for the expansion units, the Kandla-Panipat product pipeline has been converted to crude oil service. The crude oil is received from Mundra Port in Gujarat coast and supplied to the Refinery through Kandla-Panipat Pipeline.

Products from Refinery

With the expansion of Panipat Refinery to 12 million tonnes, the total quantity of high speed diesel produced from entire refinery will meet BS-II and BS-III Grade required for NCR. After stabilisation of units, the high value product yield from the refinery will be further improved by reducing the production of black oil like HPS and Bitumen.

Naphtha Cracker Complex

Making a committed foray into the petrochemicals, IndianOil has already set up a world class PX/PTA plant in the Panipat Refinery. Further, it is setting up a Naphtha cracker & downstream polymer units (Naphtha Cracker complex) in the Refinery, thereby making it an integrated refinery-cum-petrochemicals complex.

The Naphtha Cracker Complex will see an estimated capital investment of about Rs. 12000 crore and is scheduled for commissioning by mid 2009. This project aims to utilize the surplus Naphtha available from IndianOil refineries and create valuable polymer products and other key intermediates.

The Naphtha Cracker complex along with the PX-PTA units will have synergistic impact in the growth of downstream industries for the production of Polyester Staple Fibre (PSF), Polyester Filament Yarn (PFY) and Textiles. Based on the above raw material availability, there will be steady growth of related industries in this region and Panipat will develop into a world scale petrochemical hub of the country. The Hub will push Haryana to one of the top states in petrochemicals productions in the country.

In addition to this, the capacity of Panipat Refinery is currently being expanded from 12 to 15 million tonnes. Work on this project has already been started and project is expected to be commissioned in 2009.


Panipat Refinery - The Eco-Friendly Refinery

Only Desulphurised Fuel Gas and Low Sulfur Fuel Oil with Sulphur content below 0.5% is used in Refinery furnaces.

Sulfur Recovery Plant helps in reduction of Sulfur Dioxide emission. There are 4 Sulphur recovery unit.2 no.of 115 TPD and 2 no. of 225 TPD. Two Sulphur Recovery Unit always remain in operation to keep the environment clean.

Two state-of-the art Effluent treatment plant.

On line stack analysers provided to monitor and control emissions.

Treated effluent meeting Minimal National Standards (MINAS) totally reused within Refinery making Panipat.

Refinery a Zero Effluent Discharge Refinery.

500 acres of land around Refinery has been developed as Green Belt and Ecological Park. Around five lakh trees already planted.

Community Development Programmes

The Refinery is committed to the improvement of life of the people in its vicinity with the objective of making them self-reliant. Such social responsibility includes support community initiatives in the field of health, water management, vocational training, education and literacy etc. Panipat Refinery encourages the villagers to develop social accounting systems to carry out social audit of their operations. It has been the endeavor of the Refinery to utilize 25% of its Community Development funds towards Special Component Plan.

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Updated as on January 4, 2007.



PIONEERING EFFORTS IN INDIA: IndianOilFIRSTS


Environemental Management Systems - ISO-14001 

Mathura Refinery of IndianOil was the first in Asia and the third in the world to receive ISO - 14001 accreditation in the year 1996 for its environmental management systems. All the seven refineries of IndianOil now have the distinction of receiving ISO-14001 certification.

First To Set Up In India:
 

 Hydrocracker

 Riser FCC

 Soaker in Visbreaker

 Inferential Control Systems

 Diesel Hydro de-sulphurisation Units

 Microcystalline Wax production facilities


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