VOCATIONAL TRAINING REPORT

(1st June to 30th June, 2024)

INDIAN OIL CORPORATION LIMITED (IOCL)

PARADIP REFINERY

Submitted By:
Pratyusha Majhi-020223026
MSc. Ecology and Environmental Science
NALANDA UNIVERSITY, BIHAR

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 Certificate

This is to certify that Pratyusha Majhi has successfully completed the Summer
Internship in our organisation. The matter embodied in this report is a
genuine to the best of our knowledge and belief and has not seen submitted
before, neither to this organisation not to any other institute/organisation for
the fulfilment of the requirement of any course of study during his internship
tenure in Indian Oil Corporation Limited, Paradip we found him hard working
sincere and diligent person and his behaviour and his conduct was good. We
wish him all the best for all his future endeavours.

------------------------- -------------------------
Signature Signature

Mr. Sreenu Kammara Mr. G. k. Prusty

Senior Manager, HSE CM (MS, L&D)- IOCL

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 Acknowledgement
Vocational industrial training is an integral part of undergraduate studies that
gives an insight of the practical and real-life applications in the industry. I
would like to thank the department of Learning and Development of Paradip
refinery for giving me the opportunity to be a part of this training.
Furthermore, I am grateful to the officers in IOCL who spared us their much
valuable time to nurture us with the practical knowledge and other insights of
the refinery. I would specially thank Mr. Prusty Gyanendra Kumar Sir for giving
us this opportunity to interact with the industry experts and commence our
vocational training. I would like to thank our guide and mentor Mr. Sreenu
Kamara Sir, and Shankaran Vijay Kumar who have helped us in gaining all the
valuable insights of Paradip Refinery and helped us to prepare this report. I
would also like to extend my regards to Nalanda University for making this
opportunity available to us.

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Table of content

Content Page No.

1.About IOCL 4-6

1.1 Services offered by IOCL 7

1.2 Refineries across the country 7

1.3 Refineries under IOCL 8

2. Paradip Refinery overview 8-9

2.1 Upcoming Projects 9

2.2 Major products 9

2.3 Mode of Product Dispatch 9

3. Brief Description of Unit 9-10

4. Brief Product Description 10-11

5.Environment management 11

5.1 Wastewater Management 11

5.2 Prevention of Air Pollution 12

5.3 Noise pollution control 12-13

5.4 Solid waste management 13

5.5 Hazardous waste management 13

5.5.1 Hazardous and other waste 14

(Management and Transboundary
Movement) Rules 2016

5.5.1.1 Table 1. Details of Authorization 15-16

5.5.1.1.1 Table 2. Disposal practice in 2023- 16-18

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6. Conclusion 19

7. Bibliography

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 1. ABOUT IOCL

Indian Oil Corporation Limited is an Indian government-owned oil and gas

corporation which was formed by merging Indian refineries ltd and Indian oil
company in 1969. It is under the ownership of Ministry of Petroleum and
Natural Gas, Government of India. The Company’s philosophy is embedded in
the principles of strong customer connect, quality consciousness and
transparency, where energy is tapped responsibly and delivered to the
consumers most affordably. Indian Oil corporation Limited (IOCL) is India’s
largest oil commercial enterprise. Indian Oil ranked 151st among the world's
largest corporate in Fortune's Global 500 listing in 2020.Indian Oil has a team
of strong 33,500, taking the leading in meeting India's energy demands
efficiently and effectively. Over the time not only in India but Indian Oil has
expanded its network globally especially in the Exploration and Production
(E&P) sector with the formation of subsidiaries in Sri Lanka, Mauritius, the
UAE, Singapore, Sweden, USA and the Netherlands. It is also looking up for
global opportunities as well as prospects by setting up 20 joint ventures with
the reputed business partners of India and abroad. As per the financial report
FY 2020 - ’21, the company has recorded domestic sales of 72.71 million
metric tonnes (MMT) in 2020 – ’21. Indian Oil has 80.2 million metric tonnes
per annum (MMTPA) refining capacity which is holding the share of over 32%
country’s refining capacity and over 71% downstream sector pipelines
throughput capacity. The 14,670 km pipelines across the length and breadth of
the country have made it possible to reach to deliver the service to each and
every citizen of the India at the right time and in the right possible way. In the
recent transition of the fuel norms, Indian Oil took the first lead and became
the foremost company in India to upgrade its fuel norms from BS – IV to BS –
VI directly from 16th March, 2020.

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 To achieve
national as well as international standards of excellence in all aspects of
energy and diversified business with focus on customer delight through
value of products and services, and cost reduction.

 To maximise creation of wealth, value and satisfaction for the

stakeholders.

 To provide technology and services through sustained research and

development.

 To cultivate high standards of business ethics and total quality

management for a strong corporate identity and brand equity.

 To help enrich the quality and quantity according to demand of the

nation.
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 1.1Services Offered By IOCL:
 Refining
 Pipelines
 Marketing
 Training
 Research & Development

1.2 Refineries of IOCL across the country:

The following image shows different refineries of IOCL across the country

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1.3 Refineries under IOCL:
Refinery Location Capacity (MMTPA)
Barauni 6
Koyali 13.7
Haldia 7.5
Mathura 8
Panipat 15
Digboi 0.65
Bongaigaon 2.35
Guwahati 1
CPCL, Manali 10.5
CPCL, Cauvery Basin 1
Paradip 15
Total 80.7

2. Overview:
Paradip Refinery, was commissioned in 2016, is situated in Paradip,
Jagatsinghpur district in the State of Odisha situated on the Eastern Coast this
Refinery caters to the petroleum products demand & is strategically located for
export of petroleum products to South-East Asian countries.
Paradip Refinery is Indian Oil’s first refinery with single Atmospheric Column
for processing 15.0 million Metric Tonnes Per Annum. The crude receipt is by 3
nos. Single Point Mooring (SPM) located at around 30 kms inside the sea to
facilitate Crude delivery by VLCC. The refinery is designed to process 100%
High Sulphur Crude and TAN of 0.5.
Several first-time technological features have been installed at Paradip
Refinery including Flue Gas Desulphurisation facilities for firing high Sulphur
Vacuum Residue & Vapour Recovery system from jetty loading to meet the
stringent emission norms of SOx and Volatile organic emissions despite
processing heavy high Sulphur Crude. The refinery is in a synergic partnership
with the environment as this is a zero effluent discharge refinery and with
strictly monitored and controlled stack emissions which are uplinked on real
time basis to the server of Central Pollution Control Board.

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The refinery consists of an Alkylation unit to produce octane-rich low-benzene
MS blend component. The refinery configuration also consists of “INDMAX”
unit which is indigenous IOCL technology. It is capable to produce high yield of
LPG and propylene. The refinery can produce various petroleum products like
gasoline, diesel, kerosene, and aviation turbine fuel, Propylene, Sulphur and
Petroleum Coke. The refinery is also designed to produce total Premium
quality Gasoline variants for export. Major units are AVU, Coker, CCRU, VGO
Hydro-treater, Sulphur Recovery unit, Diesel hydro-treater, Sulphuric Acid
Regeneration Unit (SARU).
On the petrochemical front Paradip produces various grades of PP from its
Polypropylene unit. To expand IOCL’s petrochemical footprint a ERU (Ethylene
Recovery Unit) and MEG (Mono Ethylene Glycol) unit were installed.
2.1 Upcoming Projects:
 Para-xylene and PTA plants are under implementation stage.
 Paradip Refinery Expansion from 15 to 25 MMTPA is under
conceptualization.

2.2 Major products:

LPG, Propylene, Polypropylene, MEG, High Speed Diesel (BS-VI), Motor spirit
(BS-VI), Reformate, ATF, Superior Kerosene Oil, Sulphur, LCO, Pet Coke &
Bitumen. PTA will be produced from the refinery post commissioning of the
new petrochemical units which are under implementation.

2.3 Mode of Product Dispatch:

 Pipeline: PRRPL, PHPL, PSHPL, PHBMPL
 Jetty: A total 10 loading arms consisting of 5 liquid product
loading, 3 vapor return and 2 crude unloading arms are provided.
 Rail
 Road

3. Brief Description of Unit:

Indian Oil is India's flagship National Oil Company, with business interests that
straddle the entire hydrocarbon value chain from refining, pipeline
transportation and marketing of petroleum products. Indian Oil and its
subsidiaries own and operate 11 of India's refineries and its cross-country
network of crude oil, product and gas pipelines is the largest in the country,
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meeting the vital energy needs of consumers in an efficient and environment-
friendly manner.

Paradip Refinery-The Energy Gateway to Eastern India, Indian Oil's Flagship

Refinery, is currently operating a 15 MMTPA grass root refinery cum
petrochemical complex at Paradip in the State of Odisha, India at approx. 5 kms
from Paradip Port. Honourable Prime Minister Shri. Narendra Modi dedicated
the refinery cum petrochemical complex to the Nation on 7th February 2016.
Paradip.

The major secondary processing units are INDMAX (developed indigenously by

IOCL's R&D Centre), VGO-HDT, DHDT, DCU, NHT, CCRU, Alkylation, Poly
Propylene Unit. Paradip Refinery is rapidly transforming into mega-
petrochemicals complex with commissioning of MEG unit in Feb 23.

4. Brief Product Description: -

The refinery can process 100% high sulphur crude oil to produce various
petroleum products such as LPG, Propylene, BS-VI compliant Petrol and Diesel,
Kerosene, Aviation Turbine Fuel, Sulphur and Petroleum Coke. The product
from the Refinery meets the energy demands of domestic market and partly
exported. With an aim to add more value, a 680 KTA capacity Polypropylene
(PP) Plant, based on Propylene recovered from cracker product generated from
INDMAX unit, has been implemented at an approved cost of Rs. 3150 crores.

As India's leading oil & gas corporate, Indian Oil remains steadfast in its
commitment to excellence in, Health, Safety and Environmental (H,S&E)
performance. Paradip Refinery is always dedicated towards its environmental
responsibilities. Effective management of environment impacts has been a
fundamental part of the business and has always maintained positive legal
compliance to environmental regulations and conforms to the requirements of
IOCL sustainability Framework. The unit progressively develops, implements,
and maintains an internationally accepted environmental management system
in the operations and in new projects.

Paradip Refinery takes initiative towards efficient use of natural resources and
energy; reduction and prevention of pollution; and promoting waste avoidance
and recycling measures in line with internationally disseminated technologies
and practices. Enhance environmental awareness through participation and

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consultation with employees and contractors by training and effective channels
of communication. The unit continually improves environmental performance
of current and future products, services and infrastructure and monitor,
measure, report the progress, performance of environmental conservation and
management initiatives in compliance with internationally recognized
protocols.

During refinery operations, wastewater, flue gases and fugitive emissions and
solid wastes are generated. Refineries are also significant consumers of scarce
resources like water and energy. Thus, pollution control and resource
conservation activities are a priority area for environment management at
Indian Oil. Effective treatment of wastewater and recycling, energy
conservation and pollution abatement are examples of integrated activities
that result in both pollution control and resource conservation.

5. Environment management

Heath, Safety & Environment: The three pillars to ensure safe communities
and happy stakeholders. During refinery operations, wastewater, flue gases and
fugitive emissions and solid wastes are generated. Refineries are also
significant consumers of scarce resources like water and energy. Thus, pollution
control and resource conservation activities are a priority area for environment
management at Indian Oil. Effective treatment of wastewater and recycling,
energy conservation and pollution abatement are examples of integrated
activities that result in both pollution control and resource conservation.

5.1 Wastewater Management

Use of water and quality of effluent discharged are carefully monitored. The
Refinery is equipped with a network of underground sewers for segregated
collection of various wastewater streams, which are subjected to precise
treatment in well-designed effluent treatment (ETP) facilities involving physical,
chemical and biological processes. State of art equipment have been provided
in the ETP's like Tilted Plate Interceptor (TPI), Dissolved Air Floatation (DAF),
Bio-tower, activated sludge basins, dual media filters for treating oily
wastewater and hydrogen peroxide / wet air oxidation treatment for spent
caustic streams etc. These treatment facilities are backed by sophisticated
instrumentation and real time monitoring systems for close and precise

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monitoring. In Marketing and Pipeline locations, effluent water is routed
through oil water separator.

5.2 Prevention of Air Pollution:

The utmost attention is given to controlling / reducing emissions in the refinery

complex Major sources of air emissions are flue gases from boilers and heaters,
FCC regenerators and Sulphur Recovery Units. Hydrocarbon leaks and
evaporation during storage, handling and transportation of petroleum products
and crude oil are sources of fugitive emissions. Indian Oil has adopted the
following measures to control emissions & effectively disperse pollution from
flue gases.

 Tall stacks for effective dispersion of pollutants.

 Use of low sulphur fuel oil/ sweet natural gas/ desulphurized refinery gas
in boilers and heaters to minimize SO2 emission.
 Use of low NOx burners.
 Hydrogen Sulphide generated during desulphurization of refinery gas is
converted to elemental sulphur in Sulphur Recovery Units. Sulphur
dioxide emissions from
 Catalytic Crackers are controlled by effective feed sulphur management.
Carbon monoxide from FCCU regenerator is incinerated in CO Boilers and
the resultant energy is utilized for steam generation. Use of floating roof
tanks for crude and other light product services & Mechanical seals in
pumps for minimizing fugitive emission of hydrocarbons.
 Use of closed blow down vessels & safety release to flare system for
arresting any emission of hydrocarbons during all situations, normal,
abnormal as well as emergencies.
 Continuous reduction in fuel consumption by ENCON measures, heat
integration and increased use of hot feed in downstream processing
units. Flare gas recovery systems.

5.3 Noise Pollution Control

Major sources of noise pollution are engines, compressor houses,

turbine hall, furnace etc. Refinery has adopted the following measures to
control noise at source:
• Regular maintenance of machines
• Use of low noise machines

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 • Suitably designed enclosure for both source and receiver
• Use of sound absorbing material

Personnel Protective Equipment (PPEs) like ear plugs, earmuffs, etc. are also
used in identified high noise areas.

5.4 Solid Waste Management:

Prevent, Reduce, Reuse and Recover are the fundamental principles that
govern all our activities, more so in case of solid waste management.
Oily/chemical/biological sludge generated from storage tanks during refinery
turnarounds or from the basins & storage tanks of effluent treatment facilities
are mechanically handled. Melting pits with skimming pumps, sophisticated
hydro cyclones, centrifuges etc. are employed forde-oiling the sludge. After
de-oiling, residual sludge is recycled in Coker units or bio-remediated in well-
designed environmentally safe sites. Bioremediation in confined bioreactor is
the latest innovation in bioremediation of residual oily sludge developed the
house by Indian Oil R&D. Called Oilivorous-S, this environmentally safe and
clean technique was called to the fore to manage the oil spill at Ennore near
Chennai Jan-Feb. 2017, validating Indian Oil's focus on environment
protection.

5.5 HAZARDOUS WASTE MANAGEMENT

Hazardous wastes are wastes that have property of Ignitability, Corrosivity,

Toxicity, Reactivity etc. in nature. Hazardous wastes are found to be different
physical states such as gaseous, liquids, or solids. Hazardous waste cannot be
disposed-off by common means like other waste products of the industry. The
waste disposal methods are governed by Hazardous and Other wastes
(Management and Transboundary Movement), Rules 2016. Depending on the
physical state of the waste, treatment and solidification processes may be
required. Industrialization has had the effect of generation of huge quantities
of Hazardous wastes. The hazardous waste required adequate and proper
control and handling. Efforts are required to minimize its generation.

Like other industries IOCL, Paradip Refinery generates hazardous and other
wastes. These wastes are categorized based on their characteristics. Then these

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wastes are treated and recycled by proper treatment procedures, further re-
use and safe disposal.

 Hazardous wastes once generated from process units are shifted to

Intermediate Storage Facility (ISF) with an area of 1000 m² with proper
marking and display of the MSDS at each category of waste. The wastes
are then disposed of withing 90 days either to recycler or for co-
processing by SPCB authorized 3rd parties.
 Other hazardous materials are disposed-off in Secured Land Fill Area
available inside refinery premises in accordance with prescribed
Hazardous Waste Authorization available with Paradip Refinery
 The Hazardous Waste Authorization has been timely and periodically
renewed by the PDR team with the latest available Authorization.
 Proper record keeping of the movement of wastes generated is being
maintained by the PDR team. Hazardous Wastes are being disposed of
within the 90 days period based on the audit of records.
 Waste having less than 2500 Kcal/kg of calorific values are being stored
in Secured Land Fill (SLF) Area and no non-compliance observed with
respect to calorific values data.
 Oily / chemical / biological sludge generated from storage tanks during
refinery turnarounds or from the basins & storage tanks of the effluent
treatment facilities are mechanically handled. Melting pits with
skimming pumps, sophisticated hydro-cyclones, centrifuges etc. are
employed for de-oiling the sludge. After de-oiling, residual sludge is
recycled in Coker units or bio-remediated in well-designed
environmentally safe sites. Bio-remediation in confined bioreactor is the
latest innovation in bio-remediation of residual oily sludge, developed in-
house by Indian Oil R&D. Called Oilivorous-S.
 Spent catalyst that contains recoverable metals is sold to authorised
recyclers, including cement manufacturing facilities approved by the
SPCB and producers of refractories, ceramics, and other materials. Spent
catalysts that cannot be recycled are either given to approved
Treatment, Storage, and Disposal Facilities (TSDF) The E-waste is sold to
authorised recyclers or collected under repurchase agreements by
equipment providers.
5.5.1 Hazardous and other waste (Management and Transboundary
Movement) Rules 2016: -

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IOCL, Paradip Refinery unit has got the Hazardous waste authorization to
handle the hazardous waste by State Pollution Control Board, Odisha as per the
detail given below: -

5.5.1.1 Table 1. Details of Authorization

SL. No Existing HW Waste Description Authorized

Authorization Quantity/
Annum

1. Schedule 1, Oily Sludge 50000 T

Stream
1.3/4.1/4.3

2. Schedule 1, Spent catalyst 6200 T

Stream 4.2

3. Schedule 1, Organic residue from 200 T

Stream 4.4 process

4. Schedule 1, Spent Clay containing 1300 T

Stream 4.5 oil

5. Schedule 1, Used/ spent oil 200 T

Stream 5.1

6. Schedule 1, Sludge & filters 1000 T

stream 3.3/5.2 contaminated with oil

7. Schedule 1, Empty 20000 T

Stream 33.1 barrel/containers/line
r contaminated with
hazardous
chemicals/wastes

8. Schedule 1, 35.2 Spent resin from DM 1000 T

plant

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 9. Schedule 1, 36.2 Spent carbon/filter 500 T
medium

10. Schedule 1, 37.2 Ash from incinerator 50 T

11. Schedule 1, Chemical Sludge from 500 T

stream 35.3 ETP

12. Schedule 1, Spent catalyst and 2500 T

Stream 1.6 molecular sieves
(Adsorbent)

The various major regular wastes generated and their source of generation,
approximate quantity, and likely constituents with the present mode of
disposal practice is given below: -

5.5.1.1.2 Table 2. Disposal practice in 2023-24

SL. No Waste Waste Source of Disposed Quantity Disposal

Description category Generation in FY 2023-24 Methods

1. Oily Sludge/ Sch-I, Effluent Nil The amount

Emulsion/ Slop Stream- Treatment of oily sludge
Oil 1.3/4.1/4.3 Plant generated is
totally
processed in
delayed
Coker unit
(DCU)

Spent Catalyst Sch-I, Process units 4331.36 MT The spent

2. Stream-4.2 mainly FCC catalyst is co-
processed
cement
industries.
IOCL has
already lined
up with
cement
industries for
lifting of FCC

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 spent
catalyst.

Organic residue Sch-I, Nil There is no

3. from process Stream-4.4 generation of
organic
residue from
operation
process.

Spent clay Sch-I, Process unit 128.6 MT Spent clay is

4. containing Oil Stream-4.5 disposed in
plant own
secured land
fill (SLF)
inside the
plant
premises.

Used/ Spent oil Sch-I, 12.6 MT There is no

5. Stream-5.1 generation
and storage
of used/spent
oil in FY-21-
22

Sludge Filters Sch-I, Nil There is no

6. contaminated Stream- generation
with oil/ Waste 3.3/5.2 and storage
containing oil record of
sledge
filtered
contaminated
with
oil/waste
containing oil
in FY-21-22

Empty barrels/ Sch-I, 101 MT Barrel has

7. Containers/ Stream-33.1 total 5317
Liners chemicals numbers of
drums has
been
disposed
through

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 MSTC.

Spent Resin Sch-I, 27.6 MT There has not

8. from DM Plant Stream-35.2 been any
generation
and disposal
of spent
Resin from
DM plant in
FY-21-22

Spent carbon/ Sch-I, 36 MT

9. Filter medium Stream-37.2

Ash from Sch-I, Captive Nil Disposed in

10. Incinerator Stream-37.2 power plant captive SLF

Chemical sludge Sch-I, 453.87 MT 100% of oily

11. from ETP Stream-35.3 and chemical
sludge from
ETP is
processed in
DCU.
Therefore,
there is no
storage of
chemical
sludge from
ETP.

12 Spent Catalyst Sch-1, FCC Unit 11.4 MT Disposed in

and molecular Stream 1.6 plant own
sieves secured land
(Adsorbent) fill (SLF)
inside the
plant
premises.

The estimation of above waste has been arrived from submission of annual
return form-4, for FY 2023-24 under Hazardous and other Waste
(Management and Transboundary Movement) Rule 2016. Special care must be
taken for its management and handle the hazardous waste out of them.
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 6. Conclusion
Solid wastes, flue gases, fugitive emissions, and waste water are produced
during refinery operations. Refineries utilize a considerable amount of energy
and water. Therefore, at Indian Oil, pollution prevention and resource
conservation are top priorities when it comes to environmental management.
It places a high value on operating in a way that respects the environment,
promoting sustainable growth, safe working environments, and improvements
to the standard of living for its clients, staff, and the community at large. In
addition to having fully functional occupational health centres, all of its
refineries are certified to meet ISO:14064 criteria for sustainable development
and the Occupational Health & Safety Management System (OHSMS/OHSAS-
18001). Unit, division, and corporate compliance with safety systems,
procedures, and environmental regulation is monitored.
As a student of environmental science, I had the wonderful chance to work
directly in the Health, Safety, and Environment department of IOCL, Paradip
Refinery, utilizing my theoretical knowledge of the environment. During my
internship, I gained knowledge of the locations, movements, and disposal
methods of hazardous material in addition to the inventory database. It was
also good to see special emphasis on safety during the training period. I had a
wonderful time here filled with learning and enjoying amidst the beautiful and
peaceful environment.
I will take this experience forward throughout my life. Thank you.

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7. Bibliography
 https://iocl.com/occupational-health
 IOCL Paradip Refinery Vocational Training Presentations
 Hazardous Waste Audit Report FY-2023-24 for Paradip Refinery

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