IOC – Mathura Refinery

1.0 Brief History and Overview

(The brief history given below was provided by the refinery for the last compendium
prepared in Feb 2015. Refinery to correct/modify the contents)

Mathura Refinery, the 6th Refinery of IndianOil was commissioned in 1982 to meet the
demand of petroleum products in North Western region of the country, which includes
National Capital Region. Refinery is located along the Delhi-Agra National Highway,
about 154 km from Delhi. It was commissioned with single atmospheric distillation
column of 6.0 MMTPA capacity, which was augmented to 7.5 MMTPA with minor
modifications in 1989. The major secondary processing units provided were Fluidised
Catalytic Cracking Unit (FCCU), Visbreaker Unit (VBU) and Bitumen Blowing Unit (BBU).
The technology for these units was sourced from the erstwhile USSR, UOP etc. For
production of unleaded gasoline, Continuous Catalytic Reforming Unit (CCRU) was
commissioned in 1998 with technology from IFP, France. A Diesel Hydro
Desulphurisation (DHDS) Unit was commissioned in 1999 for production of HSD with low
Sulphur content of 0.25% wt. max. With the commissioning of Once-through
Hydrocracker Unit (OHCU) licensed from Chevron, USA in July 2000, capacity of Mathura
Refinery was increased to 8.0 MMTPA.

Mathura Refinery is having its own captive power plant, which was augmented with the
commissioning of 3 Gas Turbines (GT) and Heat Recovery Steam Generator (HRSG) in
2005 using Natural Gas (NG) as major fuel to take care of environment.

Diesel Hydro-Treating unit (DHDT) & MS Quality Up-gradation Unit (MSQU) were
installed with world class technology from M/s Axens and UOP respectively in 2005 for
production of Bharat Stage-III (BS-III) grade HSD and MS w.e.f. 1st April 2005 as per Auto
Fuel Policy of Govt. of India. Project for FCC Gasoline Desulphurization (FCCGDS) and
Selective Hydrogenation Unit (SHU) was commissioned in February 2010 and supply of
Bharat Stage-IV (BS-IV) Grade MS and HSD started on continuous basis from February
2010.
In 2013 FCC revamp was carried out to increase propylene yield and refinery margin. In
January’ 2018, Indian Oil’s own project conceived by R&D division was commissioned
increasing Refinery MS production due to additional margin by octamax product (high
RON MS blend stream).

Mathura Refinery started 100% BS-VI fuel production since 1st Feb’20. Achievement was
accomplished by revamp of DHDS and Prime-G units, earlier these units were having
constraints in production of BS VI fuels with respect to product rundown sulphur.

Subsequently, to maximize the MS production, EBMS (10% Ethanol Blended MS)

production was started in Mar’19.

The Nelson Complexity of the refinery is 6.66.

(Refinery to provide high resolution JPG image of the recent photograph)

 For upgrading environmental standards, old Sulphur Recovery Units (SRU) were replaced
with new ones in the year 1999 having 99.9% recovery. Additional Sulphur Recovery
Unit (SRU-IV) was commissioned on 18th June 2011 as a hot standby. Refinery had also
set up 4 Nos. of continuous Ambient Air Monitoring Stations (AAMS) far beyond the
working area as a mark of its concern towards the community and archaeological sites.
Its close proximity to Taj Mahal adds extra responsibility towards a cleaner environment.
Mathura Refinery has planted 167,000 trees in surrounding areas including Refinery and
town-ship and 115,000 trees in Agra region around Taj Mahal.

The Ecological Park which is spread across 4.45 acres, is a thriving green oasis in the
heart of sprawling Refinery. At Mathura Refinery, technology and ecology go hand in
hand with continuous endeavour for Product Quality up-gradation, Energy Conservation
and Environment Protection. Mathura Refinery is the 1st in Asia and 3rd in the world to
receive the coveted ISO-14001 certification for Environment Management System in
1996. It is also the first in the World to get OHSMS certification for Safety Management
in 1998.

Major Products from the refinery are Propylene, LPG, MS, Naphtha, Aviation Turbine
Fuel, Kerosene, Diesel, Furnace Oil, Bitumen and Sulphur.

2.0 Details of Process Units

(The details of the process units as given below, was provided earlier. Refinery to
correct/modify the figures as required. New units, if any, already commissioned may
also be included)

Installed Capacity
Year of
Name of the Unit TMTPA Licensor
commissioning
(as on 01-04-2018)
CDU 1982 8000 (6000) USSR/ EIL
3000 - BH
VDU 1982 USSR
3800 - HS
NSU 1998 1600 EIL/ In-house
VBU 1982 1000 UOP, USA
USSR/ Poerner
BBU 1982 750
Austria
CCRU 1998 466 IFP, France
FCCU 1983 1300 UOP, USA
 Installed Capacity
Year of
Name of the Unit TMTPA Licensor
commissioning
(as on 01-04-2018)
HGU-I 1999 34 HTAS, Denmark
New SRUs (I-III) 1999 3 x 60 TPD Stork, Netherland
OHCU 2000 1200 Chevron, USA
DHDS 1999 1100 IFP, France
PRU 1996 144 EIL
DHDT 2005 1800 IFP, France
HGU-II 2005 60 Technip, KTI
NHDT 2005 440 UOP, USA
Penex 2005 440 UOP,USA
PX-PTA Splitter 2005 636 Technip, KTI
Prime-G 2010 525 Axens, France
SRU-IV 2011 60 TPD Stork, Netherland
Octamax 2018 55 IOCL-R&D, India

Note: Figs in Bracket indicate the original capacities

3.0 Details of Revamp/Capacity Expansion of Existing Units and New Units under
Implementation

Year of Installed Capacity

Name of the Unit Licensor
commissioning TMTPA
DHDS Revamp 2019 1250 HTAS, Denmark
Prime-G Revamp 2019 525 Axens, France

Note: Capacity expansion and quality upgradation is for DHDS. Prime-G revamp is for
quality upgradation only.

4.0 Simplified Block Flow Diagram

A simplified Block Flow Diagram (BFD) of the Refinery is shown below which was
provided earlier. Softcopy of BFD files to be sent (high resolution JPG) separately.
New/proposed units are to be shown with dotted lines.
5.0 Power and Utilities

(The details of the steam /power generation units as given below, was provided by the
refinery earlier. Refinery to correct/modify the table as required. Please include
details of any other additional power /steam generation facility.)

The steam and power generation facilities are as under:

Steam Generation Power Generation

Particulars MT/hr Particulars MW
Boiler-1 150 STG-1 12.5
Boiler-2 150 STG-2 12.5
Boiler-3 150 STG-3 12.5
Sub-total 450 Sub-total 37.5
HRSG-1 103 GT-1 20.2
HRSG-2 103 GT -2 20.2
HRSG-3 103 GT -3 20.2
Sub-total 309 Sub-total 60.6
 Steam Generation Power Generation
Particulars MT/hr Particulars MW
Total 759 Total 98.1

6.0 Crude Receipt Facilities

Crude Pipelines Length, km Capacity, MMTPA

Salaya Mathura Pipeline 197 Km 7.5 MMTPA
(Chakshu-Mathura Section)

7.0 Product Pipelines

Product Products Handled Length, Capacity,

Pipelines km MMTPA
MDPL HSD(IV/VI),MS(IV/VI),ATF,SKO,PNCP/PXPT 146.6 3.7
MTPL HSD IV, MSIV , SKO 58 1.2
(combined
MBPL HSD IV, MSIV , SKO 21 for MT/MB)

8.0 Mode-wise Share of Product Dispatch (2017-18)

Mode % on Total
Pipeline 36.42
Rail 37.58
Road 1.45
Coastal --
MMT(Mathura marketing
24.54
terminal)

9.0 Overall Refinery Material Balance(ALL FIGURES IN MT)

Detail Material Balance attached as Excel