Case Study: Puran Max Ultrafiltration Membranes Delivering Reliable Performance at IOCL, Panipat for Refinery Effluent Water Treatment
- Theway Scholar
- Jan 31
- 3 min read
Introduction
Refinery operations generate complex effluent streams containing high turbidity, suspended solids, oil traces, COD, and organic matter. Effective treatment of refinery effluent water is essential to protect downstream RO systems, ensure reliable DM plant operation, and meet stringent environmental and operational standards.
At Indian Oil Corporation Limited (IOCL), Panipat Refinery, treated refinery effluent required advanced pretreatment to handle wide variations in water quality and high contaminant loads. To address these challenges, IOCL partnered with Theway Membranes to implement Puran Max Ultrafiltration (UF) Membranes. This case study highlights the robust performance and durability of Puran Max UF membranes in a demanding refinery effluent application.
The Challenge
Refinery effluent water is known for its fluctuating quality and high contaminant load, posing significant challenges for membrane-based treatment systems. At IOCL, Panipat, the following issues were identified:
Very High Turbidity & Suspended Solids: Feed water turbidity reached up to 100 NTU with 150–200 ppm TSS, increasing fouling risk.
High COD & Organic Load: Elevated COD and organic matter stressed conventional pretreatment systems.
Variable Feed Conditions: Wide fluctuations in effluent quality impacted system stability.
RO System Protection: Consistent low SDI water was required to safeguard RO membranes in the DM plant.
Operational Cost Control: Replacement of existing membranes and high maintenance costs needed to be minimized.
The refinery required a highly durable UF solution capable of handling extreme feed conditions while delivering stable, high-quality permeate.
The Solution: Puran Max Ultrafiltration Membranes
After technical evaluation, Puran Max UF Membranes from Theway Membranes were selected for their proven ability to treat high-strength industrial effluent and replace existing UF membranes while improving performance.
Key Features of Puran Max UF Membranes
Advanced Ultrafiltration Technology: Effective removal of suspended solids, TSS, and organic contaminants.
Consistent Permeate Quality: Produces low-turbidity water suitable for RO pretreatment.
High Resistance to Fouling: Designed to withstand high COD and variable refinery effluent conditions.
Robust & Durable Construction: Ensures long service life in harsh industrial environments.
Low Maintenance Operation: Reduced cleaning frequency and stable long-term performance.
Deployment at IOCL, Panipat
The Puran Max UF system was commissioned in 2025 at the IOCL Panipat Refinery as pretreatment to RO in the DM plant, replacing existing Hydranautics UF membranes. The system treats refinery effluent water with a capacity of approximately 4.0 MLD.
Key Deployment Details
Location: IOCL, Panipat
Industry Segment: Refinery / Power Plant Utilities
Technology: Puran Max – Ultrafiltration
Source Water: Refinery Effluent Water
User Application: Pretreatment to RO in DM Plant
Capacity: ~4.0 MLD
Commissioning: 2025
Replacement: Existing Hydranautics UF membranes
Results and Impact
Field validation of Puran Max Ultrafiltration Membranes at IOCL, Panipat demonstrated excellent performance under highly challenging feed water conditions.
Key Results Achieved
Consistent Permeate Quality:
Turbidity: < 1 NTU
Suspended Solids: < 1 ppm
SDI: < 3Achieved consistently over the last 6 months, even with feed turbidity up to 100 NTU, TSS of 150–200 ppm, and SDI > 6.
Stable RO Operation:High-quality UF permeate ensured reliable protection of downstream RO membranes.
No Module Replacement Required:Puran Max UF membranes have operated reliably with no replacement required as of date, confirming excellent durability.
Reduced Fouling & Maintenance:High resistance to fouling minimized cleaning cycles and operational interruptions.
Operational Cost Savings:Improved performance and long membrane life reduced overall O&M costs.
Conclusion
The successful implementation of Puran Max Ultrafiltration Membranes at IOCL, Panipat demonstrates Theway Membranes’ capability to deliver robust and reliable pretreatment solutions for complex refinery effluent water applications. The system consistently handled very high turbidity, suspended solids, and COD while producing high-quality permeate suitable for RO pretreatment.
By adopting Puran Max UF technology, IOCL achieved enhanced DM plant reliability, extended membrane life, reduced operating costs, and improved overall water treatment performance—reinforcing the importance of advanced ultrafiltration in refinery wastewater management.
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