SERVICES & TECHNOLOGIES IN HYDROPROCESSING

HYDROPROCESSING - RESEARCH FACILITIES

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 Models

Hydrocracker, DHDS, Catalytic Reforming

Catalysts, Feed / Products Characterisation facilities Data / Knowledge Bank

HYDROPROCESSING

HYDROPROCESSING
SERVICES
Optimisation of Hydroprocessing Units Troubleshooting / Debottlenecking Studies for Hydroprocessing Units

Selection of Catalyst System for Grass-root / Existing

Hydroprocessing Units Catalysts Health / Remaining Life Assessment Effects of Feed-mix Change on Catalysts Performance Units Performance Monitoring Studies

HYDROCRACKER OPTIMIZATION - Case Study

MIDDLE DISTILLATES MAXIMIZATION

Identification of Catalyst Systems Optimization of Operating Conditions (Relative Conversions in 1st & 2nd Stages, Leading to Total Extinction)

HYDROCRACKER OPTIMIZATION - Case Study

91

Overall MD Yield (wt %)

87

83

79

Base Case (Design)

75 15 20 25 30 35 40 45 50 55

1st Stage Conv. (%)

HYDROCRACKER TROUBLESHOOTING - Case Study

Very low conversion in hydrocracker Licensor failed to solve problem of negligible conversion in 2nd stage of a two stage recycle hydrocracker unit

HYDROCRACKER TROUBLESHOOTING - Case Study

HYDROCRACKER PERFORMANCE MONITORING Analysis of historic operating data (through HC-MOD) Detailed analyses of units samples Long duration pilot plant testing for data generation

Catalysts health & remaining life assessment

Strategies to extract maximum performance from existing catalysts through optimization

HYDROCRACKER CATALYST REMAINING LIFE ESTIMATION THRU KINETIC STUDIES

1 E+1 6 9 E+1 5 8 E+1 5 7 E+1 5 6 E+1 5

5 E+1 5 4 E+1 5 3 E+1 5 2 E+1 5

Li f e : 2 y e a r s

1 E+1 5 0 k-EOR

200

400

600

800

1000

1200

1400

1600

1800

2000

Days on Stream

NEW TECHNOLOGIES

Hydroprocessing Technologies for

Distillate Hydrotreatment
Naphtha HDS / HDT
Selective Diene Saturation Low Pressure ATF Hydrotreatment

Diesel HDS / HDT

Hydrocracking
Naphtha to LPG

Polymer Grade Hexane / Food Grade Hexane

(Patented Process)

NEW TECHNOLOGIES - ADVANTAGES

Optimised catalyst system based on close interaction with reputed catalyst vendors Backup of data bank and evaluation facilities at IOC R&D Analytical and characterisation support Full process guarantee Advanced mathematical models for accurate predictions Commercial experience Expert manpower

PROCESS TECHNOLOGY FOR POLYMER GRADE HEXANE

To Flare To Fue l Gas

Ele ctrical He ate r Nitroge n Charge He ate r

To Flare

To Fue l Gas

Re actor Hydroge n Gas/Liquid Se parator

Fe e d/Efflue nt Exchangr

Food Grade Hexane

Fe e d Pump

LOW PRESSURE HYDROPROCESSING TECHNOLOGY FOR ATF / KERO PRODUCTION

Range of Operating Conditions Operating Conditions
Reactor Temp.(o C) System Pressure (bar) H2: Hydrocarbon Ratio Liquid LHSV (h-1)

Low
200 5 60 2.0

High
300 10 250 6.0

ATF Product Mercaptan < 1 ppm from ~ 100 ppm in Feed

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

Merox (6 bar / 250oC) Mercaptans Acidity 15 - 30 About 40% reduction Lower than the feed Negative to Slightly Positive ~ 1000 IOC-R&D Process (5 bar / 300oC) <1 About 40% reduction +24 (5-8 units improvement) Negative ~ 100

Colour (Saybolt) Doctor's Test

"S" (ppm)

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 process The process can be applied for production of premium products

LPG THROUGH NAPHTHA HYDROCRACKING

High LPG demand in India Possibility of use of auto grade LPG as transportation fuel Naphtha disposal problem

NAPHTHA HYDROCRACKING: A PROFITABLE ROUTE

LPG THROUGH NAPHTHA HYDROCRACKING 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 testing Employs easy to operate Fixed Bed Reactor Technology

LPG THROUGH NAPHTHA HYDROCRACKING

Feed : SR or cracked naphtha
LPG Yield: Very High (> 80 wt.%) Low operating pressure : 30-60 bar

Hydrogen Consumption : 3.5 wt%

Excellent Quality of LPG
Suitable for Auto-Grade

Residual Naphtha
Light with high iso-paraffins & suitable as Feed to Isomerisation Units

Off- Gas Yield Low

LPG THROUGH NAPHTHA HYDROCRACKING

Gas Concentration Section Hydrogen Fuel Gas
D E E T H A N I S E R

Fuel Gas

Fresh Feed

R E A C T O R

Recycle Hydrogen

A B S O R B E R

D E B U T A N I S E R

LPG Product Naphtha

HPS

LPS Sour Wash

Recycle liquid for 100% conversion

Flow Scheme for Naphtha to LPG Hydrocracking

LPG THROUGH NAPHTHA HYDROCRACKING

Implementation Approach
Detailed evaluation of feed stock

Pilot plant data generation with optimised catalyst system

Optimisation of operating parameters for desired LPG yield

Preparation of basic design engineering package

Detailed engineering & Project management in association with detail engineering firm Regular technical services & troubleshooting