Gujarat Refinery at Koyali

The Gujarat Refinery at Koyali in Western India is Indian Oil’s largest refinery. The refinery was commissioned in 1965-1966. Its facilities include five atmospheric crude distillation units. The major units include CRU, FCCU and the first Hydrocracking unit of the country. 

Gujarat Refinery, operating with an installed crude processing capacity of 18 million metric tonnes per annum, processes indigenous and imported, both low sulphur and high sulphur grades of crude oil. The product slate includes besides fuels, petrochemical products such as Linear Alkyl Benzene (LAB), Polypropylene Feed Stock, Food & Polymer Grade Hexane. 

Gujarat Refinery is implementing a mega project worth around Rs.7000 crore to comply with the road map for supplying eco-friendly Bharat Stage-III and IV compliant MS and HSD and to upgrade the bottom of the barrel to improve the gross margin of the Refinery. 

The Refinery has invested about 40% of the project cost for producing eco-friendly products to take care of environment at the consumer’s end. Quality Improvement units like Diesel Hydrotreater, Sulphur Recovery Plant with 99.9% conversion alongwith state-of-art Sulphur Pelletisation Unit and Hydrogen Unit have already been commissioned. The Refinery has already started dispatching both BS-III and -IV compliant products to the market. The project related to the upgradation of the bottom of the barrel is at an advance stage of construction / commissioning. 

To take care of environment, Gujarat Refinery has registered its Clean Development Mechanism project “Flare Gas Recovery” under the United Nations Framework for Combating Climate Change, and the facilities have already been installed. State-of-art Central Effluent Treatment facilities have been made installed to meet the revised MINAS specifications. Total treated effluent recycling in the cooling tower is already been in place as a part of IndianOil’s fresh water conservation policy. 

Gujarat Refinery has given top most priority to tree plantation as a part of air pollution control measures. About 2 lakh trees have been planted over 139 acres land in the periphery of the Refinery. By setting up a pond spread over 3 acres, a home away from home has also been created for birds, both migratory and non-migratory. 

It is Gujarat Refinery’s sustained endeavour to conserve energy by adopting well hydrogen recovery and management system, recovery of heat from residual heat of hot streams, selecting high efficiency and latest technology / equipment and minimising the specific energy consumption through reduction of fuel & loss. The specific energy consumption expressed in terms of MBN (Thousand British Thermal Units / Barrel / Energy Factor) has come down from 100 to 64 within a span of 15 years. Efforts are on to achieve the industry benchmark level. 

Committed to safe operations, Gujarat Refinery has achieved accident free 89 million man-hours till July 2010. All process units - existing and under implementation - comply with all applicable safety standards and norms which includes installation of gas detectors, centralised fire call monitoring system, fire fighting facilities, process interlocks etc. Gujarat Refinery has two fire stations with fire fighting network spreading all over the refinery with monitors, hydrants and remote operated monitors. A three-Tier safety review level operates proactively to avoid any untoward incident. As a part of disaster management, mutual aid facilities among the adjoining industries are in place to supplement a well-defined disaster management policy of the Refinery. 

Gujarat Refinery is accredited with ISO-9001: 2008, ISO-14001 : 2004 OHSAS 18001 : 2007.