Transcript Hydrocarbon Fuel Technologies – Indian Overview

National Workshop
Auto Fuel Policy – Way Forward
IndianOil
R&D in Refinery Processes for Fuel Quality
Upgradation
R.P. Verma
Executive Director
Indian Oil Corporation Limited
R&D Centre, Faridabad
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Discussion on ……..
IndianOil
 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
ACID GAS
A
T
M
T
O
W
Crude E
R
T
O
W
E
R
SULPHUR PLANT TAIL
GAS TREATING
LN
ISOMERIZATION
GASOLINE
HN
JET
DIESEL
HGO
V
A
C
IndianOil
LVGO
HVGO
REFORMER
JET/DIESEL
JET/DIESEL
HT
HCU
VGO HT
LCO
FCCU
REFORMER
SR
Coker /
Visbreaker
GASOLINE
FCCG
HDT
GASOLINE
JET/DIESEL HT
HCU/FCC
LSFO
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Environmental Regulations
IndianOil
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
IndianOil
Euro-III
2005
Euro-IV
2010
WFC (*)
Year of Implementation
BS-II
2000-2001
Sulfur, ppm
RON, min.
MON, min.
Benzene, max., vol%
Aromatics, max., vol%
Olefins, max., vol%
RVP, KPa
500
88
5/3
35-60
150
91
81
1
42
21
60 max.
50
91
81
1
35
21
60 max.
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* Proposed by World Fuel Charter
10
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Effect of Gasoline Specifications on Major
Parameters
IndianOil
 Lower Sulfur content
 Lower RVP
 Lower benzene & aromatics
 Lower olefin content
 Limited Oxygen content
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Technologies for Gasoline
IndianOil
Reformer (Major technology for MS)
•Technological / operational change
Low pressure operation
Change to CCR from SR
Pre-fractionation for Benzene Spec
Integration 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 additives
Selective desulfurisation of FCCG
Treatment of heart-cut of FCCG in reformer
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Contd.
Technologies for Gasoline (Contd.)
IndianOil
Isomerisation
Ideal choice for upgrading light naphtha
Used for saturation of benzene also
Pt on Chlorinated alumina – most active catalyst
Zeolite catalyst based technology to be improved
(more activity required)
Alkylation
No unit in India (High LPG demand)
Proven technology based upon HF / H2SO4
hazardous
Solid acid based process at development /
demonstration stage
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Diesel Specifications
- Trend
Year of Implementation
Sulfur, ppm
Cetane Number
Density, kg/cm2
95% recovery, oC
PAH, wt%
BS-II
Euro-III
2000-2001 2005
500
48
820-860
370
-
350
51
820-845
360
11
IndianOil
Euro-IV
2010
WFC (*)
50
51
820-845
360
11
10
55
340
2
* Proposed by World Fuel Charter
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Effect of Diesel Specifications on Major
Parameters
IndianOil
 Low sulfur
 Low aromatics / PAH
 High cetane number
 Lower density
 Lower distillation end point
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Technologies to meet Diesel specifications
IndianOil
DHDS for meeting sulfur specifications
 Intensive research on DHDS catalyst for improving
activity
 Development of high performance internals
High Pressure DHDT/MHC for Cetane improvement
 Single stage units based upon non-noble metal
catalysts
 MHC an attractive option along with FCC
Hydrocracking process for best quality diesel
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R&D’s role
IndianOil
 Technologies For Environ-friendly Fuels
 Tailor-made Catalysts / Additives
 Technologies For Future
 Alternate Fuels
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Technologies For Environ-friendly Fuels
IndianOil
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
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Contd.
Technologies For Environ-friendly Fuels (Contd.)
IndianOil
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 catalyst
Hydrodynamic studies & development of reactor
internals (with EIL)
Adsorptive desulfurisation
Reactive adsorption based process for desulfruisation
Most suitable as a finishing reactor
Isomerisation
Development of zeolyte based catalyst (jointly with IIP)
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Process development
Tailor-Made Catalysts / Additives
IndianOil
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
IndianOil
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
IndianOil
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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Technologies for future
IndianOil
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
IndianOil
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
IndianOil
 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
IndianOil
 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
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