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SERVICES & TECHNOLOGIES IN HYDROPROCESSING
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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
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HYDROPROCESSING
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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
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MIDDLE DISTILLATES MAXIMIZATIONIdentification of Catalyst
SystemsOptimization of Operating Conditions (Relative Conversions
in 1st & 2nd Stages, Leading to Total Extinction)HYDROCRACKER
OPTIMIZATION- Case Study
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HYDROCRACKER OPTIMIZATION- Case Study
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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
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HYDROCRACKER TROUBLESHOOTING- Case Study
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~ 60
53
> 95
349
393
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
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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
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HYDROCRACKER CATALYST REMAININGLIFE ESTIMATION THRU KINETIC
STUDIES
K
270
273
274
275
276
277
278
282
284
285
286
288
289
303
6472903463110680
6938657610318890
6814270276459320
6787561759489810
6622674037369050
5616017733619380
5278088685089640
5190098296754070
5328110068250420
5651757150647930
6372589823911270
5814904546627530
5551416517578340
5805758390190580
5670036481782620
5453946227168540
5202939026568750
4917275543891710
4667453226987460
4859170732590420
4347620370901340
4153184573578010
5016218915892520
5230985872618140
5303676964541590
4982409300552690
5163798542427850
5844855011526500
5469067919144650
5826028763908160
6090777940447000
5072759436858540
5258223249628800
5566042348792940
5494540831474710
5558868635895140
5965052934517470
4423434985585090
4258293291298350
4441169356096520
4616616582601500
4842703967866020
5213023102571650
5197051219506430
5044970399162820
4950049782931910
4658839392238570
4785178057771790
4790333172879810
4978833020123350
5274510652890350
5645913821637900
5932977048738370
5441511444295850
4908977183075970
4461136039549490
4535341024028370
5852701309804640
5585540343741780
5548429893116490
5250559756706950
5351725627362450
5189686328180100
5260640988089030
5265924973755770
5104802151668200
4836510764271500
5403690460150450
5358741036979040
5667121359944260
5806918973597400
5402334514818950
5518008111826930
5226260539575280
5515505227949720
5779912647235440
5647560843577100
5425308530471780
5086056307729960
4729690997251370
5211977658873290
4926738755928300
4995377253151320
7744078014392020
7342061301628210
8438768609569800
5002124720564360
5044056459414600
5041203467037040
4593451565806160
4650714945071470
5888043186369290
5061289486809730
4629436325518380
4684040263991590
5404794932670760
5337896555212760
5709100134058300
5449944754155290
5622883336773290
6615704487860950
7307351085660220
6881934500326650
6569394638710230
5454327497780490
5564628336142210
6077352559339340
5550657927679940
4733930369502210
6033420611941680
6315923034580870
6426566344052620
5902460305330370
6455065838114900
6063957590177010
5610157448332300
6076548987257220
5922354736783080
5631557615540850
5169927686826420
5231112554003170
6004243534941120
4977182521568000
4911232379126330
5110107589445890
5444036508775370
5401995655666120
5808031680298940
5073962916799210
4347766619581630
3964723279300110
4343288052143250
4943938691266520
5122453834520140
5607738768890630
4564400558911070
4652070695916970
4541003441612120
4984174865206380
5549406610004500
5147126274921710
5164992252117180
4746730271717270
5347309271103280
5134861114765380
5700654952865170
5649695564067850
6173479921328760
5920416554634670
6274407059630930
6154023561957310
5514763193214060
5682134406154120
5520982410182780
4938761987356960
5108258911004800
5466800745077170
4934094547739380
4521934175589300
6054726401851950
5673108958992350
4983582819821950
5329210443284680
5265072511331120
5170755860731910
5405283488629550
5632886106927670
5311528099884070
5440709616402680
5134755581668790
5530103412322260
5554621164392110
4468688685127170
4181483854385260
4379053949389380
4409483032983830
5872144600883230
5722359618676590
5877886551528870
4457705317601520
4424228157928000
4751638637762330
4414929527481920
4778205918948690
4611564589033720
4496078397197550
4257495400496820
4498342615351880
4355072309115820
4749252702993870
4393451996807740
4761759172061440
5318949253708690
5070574597325410
5397958311092430
5291318386352870
4428325936671870
4053796378480020
4934605060232810
Life : 2 years
k-EOR
K0
Days on Stream
K
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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)
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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
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PROCESS TECHNOLOGY FORPOLYMER GRADE HEXANE
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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
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Comparison of Typical Product Properties (Merox with IOC R&D
Process)
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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
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High LPG demand in IndiaPossibility of use of auto grade LPG as
transportation fuelNaphtha disposal problemLPG THROUGH NAPHTHA
HYDROCRACKING NAPHTHA HYDROCRACKING: A PROFITABLE ROUTE
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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
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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
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LPG THROUGH NAPHTHA HYDROCRACKING
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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
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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
