IndianOil 1 R&D in Refinery Processes for Fuel Quality Upgradation R.P. Verma Executive Director...
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Transcript of IndianOil 1 R&D in Refinery Processes for Fuel Quality Upgradation R.P. Verma Executive Director...
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IndianOil
R&D in Refinery Processes for Fuel Quality Upgradation
R.P. VermaExecutive Director
Indian Oil Corporation Limited
R&D Centre, Faridabad
National Workshop Auto Fuel Policy – Way Forward
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IndianOil
Discussion on ……..
Current/future fuel
specifications
Status & trends in technology
for fuel quality upgradation
R&D’s role
Summary
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Technologies used in Indian refineries for fuel quality upgradation
Technologies used in Indian refineries for fuel quality upgradation
SULPHUR PLANT TAIL
GAS TREATING
ACID GAS
ISOMERIZATION ISOMERIZATION
JET/DIESEL
HT
JET/DIESEL
HT
GASOLINE
REFORMER REFORMER GASOLINE
JET/DIESEL
LN
HN
JET
DIESEL
HGO
ATM
TOWER
GASOLINE
SR Coker / Visbreaker
REFORMER JET/DIESEL HT
HCU/FCC
LSFO
LVGOVAC
TOWER
HCU HCULCO
HVGO
VGO HT VGO HT FCCU FCCG HDT
FCCG HDT
Crude
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Environmental Regulations
Rapid changes in combustion
technologies & fuel specifications induced
by Legislative bodies
Recommendation of Euro / BS
specifications for India by Mashelkar
Committee
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Gasoline Specification - Trend
BS-II Euro-III Euro-IV WFC (*)Year of Implementation 2000-2001 2005 2010
Sulfur, ppm 500 150 50 10RON, min. 88 91 91MON, min. - 81 81Benzene, max., vol% 5/3 1 1Aromatics, max., vol% - 42 35Olefins, max., vol% - 21 21 10RVP, KPa 35-60 60 max. 60 max.
* Proposed by World Fuel Charter
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Effect of Gasoline Specifications on Major Parameters
Lower Sulfur content
Lower RVP
Lower benzene & aromatics
Lower olefin content
Limited Oxygen content
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Technologies for Gasoline
Reformer (Major technology for MS)•Technological / operational change
Low pressure operationChange to CCR from SRPre-fractionation for Benzene SpecIntegration with Isomerisation unit
FCC (Major technology for MS)•Technological / operational change
Use of low ‘S’ crude, Hydrocracker bottom/ Hydrotreated feed for ‘S’ spec
Use of desulfurisation additivesSelective desulfurisation of FCCGTreatment of heart-cut of FCCG in reformer
Contd.
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Technologies for Gasoline (Contd.)
IsomerisationIdeal choice for upgrading light naphthaUsed for saturation of benzene alsoPt on Chlorinated alumina – most active catalystZeolite catalyst based technology to be improved
(more activity required)
AlkylationNo unit in India (High LPG demand)Proven technology based upon HF / H2SO4
hazardousSolid acid based process at development /
demonstration stage
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Diesel Specifications- Trend
BS-II Euro-III Euro-IV WFC (*)Year of Implementation 2000-2001 2005 2010
Sulfur, ppm 500 350 50 10Cetane Number 48 51 51 55Density, kg/cm2 820-860 820-845 820-84595% recovery, oC 370 360 360 340PAH, wt% - 11 11 2
* Proposed by World Fuel Charter
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Effect of Diesel Specifications on Major Parameters
Low sulfur
Low aromatics / PAH
High cetane number
Lower density
Lower distillation end point
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Technologies to meet Diesel specifications
DHDS for meeting sulfur specifications Intensive research on DHDS catalyst for improving
activityDevelopment of high performance internals
High Pressure DHDT/MHC for Cetane improvementSingle stage units based upon non-noble metal
catalystsMHC an attractive option along with FCC
Hydrocracking process for best quality diesel
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R&D’s role
Technologies For Environ-friendly Fuels
Tailor-made Catalysts / Additives
Technologies For Future
Alternate Fuels
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Technologies For Environ-friendly Fuels
Conversion of Naphtha to LPG & MS:
Hydrocracking Low pressure process of conversion of naphtha to
auto-LPG and high octane, very low S MS component
Indalin + Catalytic cracking process for conversion of
naphtha to LPG and high-aromatics, low S MS component
Treating Process: IndeTreat/IndeSweet Non-dispersive extractive process for
desulfurisation of LPG and Naphtha
Contd.
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Technologies For Environ-friendly Fuels (Contd.)
DHDS / DHDT Development of Hydroprocessing technology for
production of ultra low sulfur and high Cetane diesel Commercialisation at BRPL (with EIL) and at Paradip (with
EIL and Shell)Development of high performance DHDS catalystHydrodynamic studies & development of reactor
internals (with EIL)
Adsorptive desulfurisationReactive adsorption based process for desulfruisationMost suitable as a finishing reactor
IsomerisationDevelopment of zeolyte based catalyst (jointly with IIP)Process development
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Tailor-Made Catalysts / Additives
FCC catalysts & additives – Developed & commercialized by Indian Oil
Lotus-24 (Catalyst with higher LPG yield)i-Max / Super i-Max (ZSM-5 additive)
Hydrocracking catalyst – Developed by Indian Oil
IZV (Along with M/s Zeolyst International) – For increase in LPG make (Commercialised)IZN (Naphtha hydrocracking to LPG)
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Technologies for future
Coal/residue/biomass gasification - Production of premium liquid fuels, hydrogen and / or power
Reactivity studies for Indian coal, petroleum residue, biomass and combination
Pilot plants for feasibility data generation
Gas to liquid technologies - High quality middle distillates
Development of catalysts Pilot plant studies
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Technologies for future
Bio-oil refining
Thermochemical Routes from Biomass to H2
Gasification/Water-Gas Shift
Supercritical Steam/Water Conversion
Pyrolysis/Steam Reforming
Does not require tricky gas clean-up step
Processing biomass has nearly zero net CO2 impact
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IndianOil
Technologies for future
Pyrolysis/Steam Reforming
Liquid bio-oil can be pumped and has higher energy volumetric density than biomass
Can be processed in distributed systems • or at locations with existing hydrogen
infrastructure in large-scale centralized reformers (earlier concept)
Can be co-processed with traditional fossil feedstocks
Biorefinery Integration• Produce from residues
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Alternate Fuels
Alternate fuels currently in use CNG LPG Ethanol & Biodiesel
Emerging fuels & engine technologies Bio-fuels Hydrogen Electric vehicles Fuel cells
Considerable R&D activities in progress on bio-fuels, H2, HCNG, Fuel cells etc.
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Hydrogen
Developments in H2 production from various sources – renewable & non-renewable
Environmental benefits realizable with use of H2 as neat fuel or in admixture with CNG in existing IC engines
High-energy conversion efficiencies & associated environmental benefits of emerging fuel cell technology
National Hydrogen Energy Board prepared an extensive report
IOC-R&D the nodal agency for research on Hydrogen fuel
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Summary
Environmental regulations have led to • Development in new processes / catalysts• Significant enhancement of catalyst
performance• Re-orientation of technologies• Prominence of hydroprocessing
Innovative approach & new technologies and willingness to look beyond fossil fuels would sustain the industry in longer term