Hydroprocessing Technologies and Services

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SERVICES & TECHNOLOGIES IN HYDROPROCESSING

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Hydroprocessing Technologies

Transcript of Hydroprocessing Technologies and Services

  • SERVICES & TECHNOLOGIES IN HYDROPROCESSING

  • State-of-the-art pilot plant facilities (15 units) :Micro-reactors (5-20 ml catalyst, twin reactors-once through)Catalyst screening units (150 ml catalyst, twin reactors-recycle)Bench scale unit (500 ml catalyst, twin reactors-recycle)Micro-flow reactor (1-5 ml catalyst, once through)In-house developed rigorous ModelsHydrocracker, DHDS, Catalytic ReformingCatalysts, Feed / Products Characterisation facilitiesData / Knowledge BankHYDROPROCESSING- RESEARCH FACILITIES

  • HYDROPROCESSING

  • Optimisation of Hydroprocessing UnitsTroubleshooting / Debottlenecking Studies for Hydroprocessing UnitsSelection of Catalyst System for Grass-root / Existing Hydroprocessing UnitsCatalysts Health / Remaining Life AssessmentEffects of Feed-mix Change on Catalysts PerformanceUnits Performance Monitoring StudiesHYDROPROCESSING SERVICES

  • MIDDLE DISTILLATES MAXIMIZATIONIdentification of Catalyst SystemsOptimization of Operating Conditions (Relative Conversions in 1st & 2nd Stages, Leading to Total Extinction)HYDROCRACKER OPTIMIZATION- Case Study

  • HYDROCRACKER OPTIMIZATION- Case Study

  • Very low conversion in hydrocrackerLicensor failed to solve problem of negligible conversion in 2nd stage of a two stage recycle hydrocracker unitHYDROCRACKER TROUBLESHOOTING- Case Study

  • HYDROCRACKER TROUBLESHOOTING- Case Study

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    SUBSTANTIAL INCREASE IN PROFITABILITY

    Successful troubleshooting of Commercial HCU On Implementing the Recommendations Generated by In-House HC-MOD

    Akzo Nobel Catalyst Testing Workshop; May,2003

  • HYDROCRACKER PERFORMANCE MONITORINGAnalysis of historic operating data (through HC-MOD)Detailed analyses of units samplesLong duration pilot plant testing for data generationCatalysts health & remaining life assessmentStrategies to extract maximum performance from existing catalysts through optimization

  • HYDROCRACKER CATALYST REMAININGLIFE ESTIMATION THRU KINETIC STUDIES

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  • NEW TECHNOLOGIES Hydroprocessing Technologies for Distillate Hydrotreatment Naphtha HDS / HDT Selective Diene Saturation Low Pressure ATF Hydrotreatment Diesel HDS / HDTHydrocracking Naphtha to LPG Polymer Grade Hexane / Food Grade Hexane (Patented Process)

  • NEW TECHNOLOGIES - ADVANTAGESOptimised catalyst system based on close interaction with reputed catalyst vendorsBackup of data bank and evaluation facilities at IOC R&D Analytical and characterisation supportFull process guaranteeAdvanced mathematical models for accurate predictionsCommercial experience Expert manpower

  • PROCESS TECHNOLOGY FORPOLYMER GRADE HEXANE

  • Range of Operating Conditions

    LOW PRESSURE HYDROPROCESSING TECHNOLOGY FOR ATF / KERO PRODUCTIONATF Product Mercaptan < 1 ppm from ~ 100 ppm in Feed

    Operating Conditions Low High Reactor Temp.(o C) 200300System Pressure (bar) 510H2: Hydrocarbon Ratio 60250Liquid LHSV (h-1) 2.06.0

  • Comparison of Typical Product Properties (Merox with IOC R&D Process)

  • ADVANTAGES OF THE NOVEL TECHNOLOGY OVER CONVENTIONAL MEROX TYPE ROUTES

    No requirement of handling hazardous chemicals like caustic

    Lesser post treatment required

    Besides reducing mercaptans and improving colour, the process leads to partial removal of sulphur, which is difficult to achieve through conventional methods.

    Flexibility with respect to feedstock type

    Possible to apply reformer off-gas instead of pure hydrogen

    Possible to revamp existing units for this processThe process can be applied for production of premium products

  • High LPG demand in IndiaPossibility of use of auto grade LPG as transportation fuelNaphtha disposal problemLPG THROUGH NAPHTHA HYDROCRACKING NAPHTHA HYDROCRACKING: A PROFITABLE ROUTE

  • State of the art proprietary catalyst formulation (jointly developed with Zeolyst / Criterion) Process technology developed by IOC R&D Centre (Process design package in collaboration with EIL/Shell)Extensive pilot plant testingEmploys easy to operate Fixed Bed Reactor TechnologyLPG THROUGH NAPHTHA HYDROCRACKING

  • LPG THROUGH NAPHTHA HYDROCRACKINGFeed : SR or cracked naphthaLPG Yield: Very High (> 80 wt.%)Low operating pressure : 30-60 barHydrogen Consumption : 3.5 wt%Excellent Quality of LPGSuitable for Auto-GradeResidual Naphtha Light with high iso-paraffins & suitable as Feed to Isomerisation UnitsOff- Gas Yield Low

  • LPG THROUGH NAPHTHA HYDROCRACKING

  • Fresh Feed

    Hydrogen

    HPS

    REACTOR

    DEBUTAN I SER

    DEETHANI SER

    ABSORBER

    Sour Wash

    Fuel Gas

    LPS

    Naphtha

    Fuel Gas

    LPG Product

    Gas Concentration Section

    Flow Scheme for Naphtha to LPG Hydrocracking

    Recycle liquid for 100% conversion

    RecycleHydrogen

  • Implementation ApproachLPG THROUGH NAPHTHA HYDROCRACKINGDetailed evaluation of feed stockPilot plant data generation with optimised catalyst systemOptimisation of operating parameters for desired LPG yieldPreparation of basic design engineering packageDetailed engineering & Project management in association with detail engineering firmRegular technical services & troubleshooting