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Industry

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PANIPAT REFINERY

PANIPAT REFINERY – A PROFILE

Panipat Refinery, the 7^th Refinery of Indian Oil, a Global Fortune 500 company having vision to become a major, diversified, transnational, integrated energy company, with national leadership and a strong environment conscience, playing national role in oil security & public distribution. Backed by global, state-of-the art technologies from Axens; France, Haldor-Topsoe; Denmark, UOP; USA, Stone & Webster; USA and Delta Hudson-Canada, Dupont, USA and ABB Luumas. Panipat Refinery is referred to as the country’s technically advanced refinery. 6 MMTPA refinery was built and commissioned in 1998 at a cost of Rs. 3868 Crore (includes Marketing & Pipelines installation). Refinery capacity has been further augumented to 12 MMTPA in June 2006 at a cost of Rs. 4165 crore. It receives crude oil from Vadinar and Mundra Ports in Gujarat coast.  The refinery is designed for processing both indigenous & imported crude oil. The refinery has processed about 30 types of imported crude oil from countries like Saudi Arabia, Iran, Iraq, Dubai, Kuwait, Malaysia, Nigeria and other African countries since commissioning. 

Refinery has also ventured into petrochemical production with the commissioning of PX-PTA Units in June 2006 at a cost of Rs. 4228 crore. With this refinery will produce 3,57,000 MT/annum Paraxylene and 5,53,000 MT/annum PTA from the complex. PTA is the basic raw material for producing Polyeter Staple Fiber (PSF), Polyester Filament Yarn (PFY) and other resins. PTA is produced from Paraxylene. One of the by products from the complex is 21,000 tonnes per annum Benzene.

HON’BLE PRIME MINISTER LAID FOUNDATION STONE OF                          PREP AND PX-PTA PROJECTS ON 18.10.03

Process units, Licensors and its capacity

v  Panipat Refinery (Commissioned in 1998)

v  Process units under Expansion Project (Commissioned in 2006)

v  Process units under Expansion Project (Commissioned in 2006)

Products from Refinery:

With the expansion of Panipat Refinery to 12.0 MMTPA total 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 balck oil like HPS and Bitumen. with state-of the-art matching secondary processing facilities was approved at a cost of Rs.4165 crore.

Petroleum products are transported through Pipeline, Rail and Road. Majority of products  would be transported through environment-friendly pipelines. Panipat Refinery meets the demand of petroleum products not only of Haryana but also of the entire North-West Region including Punjab, J&K, Himachal, Chandigarh, Uttaranchal state and part of Rajasthan & Delhi.

            LPG from the refinery is pumped through a dedicated pipeline to Kohand Bottling plant and bottling and bulk despath are done from there.   

PANIPAT REFINERY - The Eco-Friendly Refinery

Salient Features of Environment Management 

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

v   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. 

v   State-of-the art Effluent treatment plant. Two nos. of 400 M3/hr each and one more for PTA plant of capacity 225M3/hour.

v   On line stack analysers provided to monitor and control emissions.

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

v   Refinery a Zero Effluent Discharge Refinery.

    A View of State-of-the art Effluent

    teratment plant

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

Green Belt developed by Refinery on S-E

                                                                                                                    direction

      Air Monitory Station at Refinery

v Air Quality around the Refinery is monitored continuously through Air Monitoring stations and Mobile Air Quality Monitoring Van.

                                                                                                        Mobile Van for monitoring Ambient air

                                                                                                       quality

Refinery Performance

• The Refinery has been increasing its capacity utilization since inception.

• Refinery has developed new products like 96 RON gasoline ,sub-Zero  diesel for the Indian army, different grades of petrol, diesel & HPS for specific consumers.

• The refinery has started production of BS-II and Euro-III grade diesel and petrol since January, 2005.

• Refinery has started production of PTA since June 2006.

Awards & Accreditations

During the last few years of operation, Panipat Refinery has been receiving many accolades and accreditations in the following areas :

Quality Management

v        Accredited with ISO-9002 for Quality Mgt. System

v        Commendation certificate for Rajiv Gandhi National Quality award-2003 for Quality Management system in industry from Rajiv Gandhi National Foundation.

v        NABL Accreditation for Quality Control laboratory as per new system ISO/IEC –17025

v        ATF production cum certification approval from Civil aviation and Defence authorities.

v        Total Productive Maintenance (TPM) introduced in the refinery. The Refinery was the first in India to launch TPM, a unique initiative for improving shopfloor performance and employee morale. 

v First Refinery to receive CII-Exim Bank Business Excellence Award (commendation certificate) in 2004.

Environment Management

v        Accredited with ISO-14001 For Environment Mgt. System.

v       Accredited with Golden Peacock Environment Management Award –2003 from World Environment Foundation.

IN HARMONY WITH MATURE

                     Migratory birds in refinery raw water pond                        Refinery in the background of Peripheral

                                                                                                                                  Green belt (14 Km Long )
                                                                    

Energy Conservation

 v      Recipient of First prize-“National Energy Conservation Award -2003” (Refineries Sector) from

     Ministry of Power, consecutively for the second year.

v       Anil Raj Trophy for best improvement in Energy Consumption during 2002-03, consecutively for the 3^rd year.      

v       1st position in Jawaharlal Nehru Centenary award: 2001-02 by CHT for best improvement in energy consumption over past best performance.

v       Ist position in Jawaharlal Nehru Centenary award: 2001-02 by CHT for best performance in energy consumption.

 Safety

v  International Safety Rating System (ISRS)- Level - 9 for Safety Management System from M/s DNV. 

v Five star rating and Sword of Honour from British Safety Council.

v       Occupational Health & Safety Management System as per OHSAS-18001 by M/s DNV since May’2000

v         “Yogyata Praman Patra” instituted by National Safety Council for the Safety performance of the year 2002 & 2004.    

                                                                                                                                                              Fire fighting facilities designed for

v        Greentech Safety Silver Award 2002-03 for safety performance from Greentech Foundation.

Project Management 

v        Accredited with ISO-9001 for Project Mgt. System

v        National Petroleum Management Programme (NPMP) award for excellence in project management in the installation of Gas Turbine and Standby Sulphur Recovery Unit (SSRU).

PRISM- PANIPAT REFINERY INTEGRATED SYSTEM OF MANAGEMENT

Integrated Policy on Quality, safety, Health & Environment (QSHE) 

We are committed to :

1. Customer’s delight by meeting and exceeding their requirements & expectations.
2. Health & Safety of people, while safeguarding material and equipment from damage.
3. Environment protection by minimizing pollution and optimizing the use of natural resources.
4. Compliance of all safety & regulatory requirements.
5. Continual improvement to maximize wealth creation through teamwork, innovation, technology, skill and competence.
6. Spreading awareness on QSHE among employees, contractors and interested parties.

COMMUNITY DEVELOPMENT PROGRAMMES:

IOCL, Panipat Refinery is committed to the improvement of life of the people in the vicinity in which it operates 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 IOCL, Panipat Refinery to utilize 25% of its Community Development funds towards Special Component Plan.

The community development initiatives at Panipat Refinery started way back in 1996, during the project stage of the Refinery. Some of the illustrative initiatives taken by Panipat Refinery under the community development schemes are as under:

Health & Hygiene:

The Refinery has undertaken various health camps in the nearby villages through reputed hospitals/doctors. The villagers are provided with free consultancy services besides free medicines. Pulse Polio vaccination is covered under the Health camp programme.

The Refinery also contributed to Civil Hospital, Panipat for construction of Burn ward and a Mortuary for the benefits of people of the State. In addition, vocational training course on health care nursing assistance has been conducted for the rural women.

                                                                                                                                                      A view of health checkup camp by

                                                                                                                                                       Panipat Refinery at Baholi village

Drinking Water:

Various projects for providing clean drinking water to the nearby villagers were undertaken by the Refinery. Construction of ring wells, tube wells, installation of hand pumps, overhead tanks with water pipelines etc. are few examples of the initiatives.

Education:

To enhance quality of education amongst the villagers, the Refinery provides assistance in construction of classrooms for various primary & secondary schools besides distribution of books & stationery to needy children.   Basic infrastructure like desk, bench, audio-visual teaching aids and sports materials are also provided. Moreover, cash incentives are also awarded to meritorious children of the nearby villages every year.

    A view of school building donated by

                Panipat Refinery

Empowerment of Women :

The Refinery believes in empowering under privileged rural women by providing income generating opportunities.  Accordingly training was conducted on tailoring and durry-making for their livelihood and consequently improving the living standards of rural women with dignity.

Youth Welfare :

As a measure towards physical development and welfare of youths, recognizes the potentials of outstanding Sportsman, not only in the vicinity of Refinery/Township but also in the state of Haryana as a whole by organizing rural sports meet for neighbouring schools every year and also sponsoring Haryana Sports Team for participation in national and international events. 

PROJECTS UNDER IMPLEMENTATION :

Indian Oil has decided to invest about Rs.12,000 Crore for Naphtha Cracker Complex and about 850 cr for  further expansion of refining capacity from 12 MMTPA to 15 MMTPA.  This is the highest investment in the country at any single location.

NAPHTHA CRACKER COMPLEX 

Indianoil with its long term plans to convert Panipat Refinery Complex into a central hub of its operations, has decided to put up Naphtha cracker & downstream polymer units (Naphtha Cracker complex) at Panipat. After storming into the field of petrochemicals with the PX-PTA project, Panipat Refinery is now consolidating its position in this sector by setting up of Naphtha Cracker Complex with an estimated capital investment of about Rs. 12000 crore. The site finalized for the project is near village Baljatan, which is on the southern side of the existing Panipat Refinery Complex. The Naphtha Cracker complex is scheduled for commissioning by mid 2009.  

This project aims at utilizing the surplus Naphtha available from IOCL refineries and creating valuable polymer products and other key intermediates. The Naphtha Cracker Complex will consist of a World scale Naphtha Cracker Unit and its Downstream Polymer units.

 Units under Naphtha Cracker Complex 

ABB Lummus Global, USA has been chosen as the licensor for the Naphtha Cracker Unit. The primary feed for Naphtha Cracker Unit is Naphtha, which will be thermally cracked to produce polymer grade ethylene and propylene, which will then undergo processing in downstream units such as LLDPE, HDPE, Polypropylene as well as key intermediates such as Butadiene, Mono Ethyl Glycol and Benzene. These product find application in a wide range of end uses.

End use of Petrochemical products

PTA and MEG are used for the production of Staple Fibre, Yarn, PET bottles, Tapes etc.

The Naphtha Cracker complex along with the PX-PTA project will have synergic 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 is going to 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.

Expansion of refining capacity from 12 to 15 MMTPA

Work on this project has already been started and project is expected to be commissioned in 2009.

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