Case Study: Supraflux Ultrafiltration Membranes Delivering High-Performance Pretreatment at IOCL, Haldia for Petroleum Plant Water Treatment
- Theway Scholar
- Feb 2
- 3 min read
Introduction
Petroleum refineries depend heavily on reliable, high-quality water for boiler feed preparation, cooling systems, and critical process utilities. River water, a common source for refineries, often contains high turbidity, suspended solids, colloidal silica, and organic matter, which can severely impact downstream Reverse Osmosis (RO) and DM plant performance if not effectively treated.
At Indian Oil Corporation Limited (IOCL), Haldia, the variability and poor quality of river water posed significant challenges to the existing pretreatment system. To ensure stable RO operation and long-term membrane reliability, IOCL partnered with Theway Membranes to deploy Supraflux Ultrafiltration (UF) Membranes. This case study highlights the durability, consistency, and superior performance of Supraflux UF membranes in a demanding petroleum refinery application.
The Challenge
River water at IOCL, Haldia is known for wide seasonal and operational fluctuations, creating multiple challenges for membrane-based treatment systems:
High Turbidity & Suspended Solids: Feed water turbidity reached up to 50 NTU, with TSS levels up to 80 ppm, increasing fouling risk.
Colloidal Silica Presence: Fine colloidal particles threatened UF and downstream RO membrane performance.
Organic Matter Load: Organic contaminants contributed to elevated SDI and membrane fouling.
RO System Protection: Consistently low turbidity and SDI were essential to safeguard the DM plant.
Operational Cost & Reliability: Existing UF membranes required replacement due to performance limitations.
The refinery required a robust UF solution capable of handling variable river water quality while delivering stable, high-quality permeate.
The Solution: Supraflux Ultrafiltration Membranes
After technical evaluation, Supraflux UF Membranes from Theway Membranes were selected for their proven performance in high-turbidity surface water applications and petroleum refineries.
Key Features of Supraflux UF Membranes
Advanced Ultrafiltration Technology: Efficient removal of suspended solids, colloidal silica, and organic matter.
Ultra-Low Turbidity Permeate: Consistently produces high-quality water suitable for RO pretreatment.
High Fouling Resistance: Designed to withstand wide fluctuations in feed water quality.
Robust & Durable Design: Engineered for continuous refinery operations.
Low Maintenance Requirement: Reduced cleaning frequency and extended membrane life.
Deployment at IOCL, Haldia
The Supraflux UF system was commissioned in 2025 at IOCL, Haldia as pretreatment to RO in the DM plant, replacing the existing Hyflux UF membranes. The system treats river water with an installed capacity of approximately 8 MLD, ensuring reliable water supply for refinery operations.
Key Deployment Details
Location: IOCL, Haldia
Industry Segment: Petroleum Plant
Technology: Supraflux – Ultrafiltration
Source Water: River Water
User Application: Pretreatment to RO in DM Plant
Capacity: ~8 MLD
Commissioning: 2025
Replacement: Existing Hyflux UF membranes
Results and Impact
Field validation of Supraflux Ultrafiltration Membranes at IOCL, Haldia demonstrated exceptional performance under challenging feed water conditions.
Key Results Achieved
Consistent Permeate Quality:
Turbidity: < 0.1 NTU
Suspended Solids: Nil ppm
SDI: < 2Achieved consistently over the last 3 months, even with feed turbidity up to 50 NTU, TSS up to 80 ppm, and SDI > 5.
Stable RO & DM Plant Operation:High-quality UF permeate ensured reliable downstream RO performance.
No Module Replacement Required:Supraflux UF membranes have demonstrated excellent durability, with stable operation and no replacement required since commissioning.
Reduced Fouling & Maintenance:High resistance to fouling minimized cleaning cycles and operational interruptions.
Operational Cost Savings:Improved membrane performance reduced overall O&M costs and extended system life.
Conclusion
The successful implementation of Supraflux Ultrafiltration Membranes at IOCL, Haldia demonstrates Theway Membranes’ capability to deliver robust and reliable pretreatment solutions for petroleum refinery applications. The system consistently handled high turbidity, suspended solids, colloidal silica, and organic matter while producing ultra-low turbidity permeate suitable for RO pretreatment.
By adopting Supraflux UF technology, IOCL achieved enhanced DM plant reliability, extended membrane life, reduced operational costs, and stable long-term performance—reinforcing the importance of advanced ultrafiltration in refinery water management.
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