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INDIAN OIL CORPORATION LIMITED
2012
Study Of Kinetics of
Hydro-Processing ofVegetable oil[Type the document subtitle]
I O C L R & D FA R I D A B A D S E C - 1 3 A , HA R Y A N A , I N D I A
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K I N E T I C S O F H Y D R O - P R O C E S S I N G O F V E G E T A B L E - O I L
Project Completed By:-
Atul-Goel Deepak Pandey
B.Tech B.TechSummer Training Report Summer Training Report
July-2012 July-2012
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A C K N O W L E D G E M E N T
Apart from the efforts of myself, the success of any project depends largely on the
encouragement and guidelines of many others. I take this opportunity to express my gratitude
to the people who have been instrumental in the successful completion of this project. I
would like to show my greatest appreciation to Mr.B.Ravi Kumar, SRO (AE&TD). I can't
say thank you enough for his tremendous support and help. Without his encouragement and
guidance this project would not have materialized. I wish to express my sincere gratitude to
Mr. Sarvesh Kumar, SRM (AE&TD), for his initial support and guidance. I would also like to
thank Mr. Alok Sharma, CRM (AE&TD), for allowing me to work in this department and
helping me to gain profound knowledge about various key elements. I also record my sincere
thanks to the entire staff of Refining Technology-II Department and Library for their
cooperation and guidance in successful out coming of this report. At last I would like to
express my thanks to the IOCL R&D Training and Placement Department for allowing me to
undergo my training at their organization.
.
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S U M M A R Y
The project assigned was to study the kinetics of hydro-processing of vegetable oil. The
mixture of mustard oil with diesel was made to run at different operating condition of
temperature, pressure and composition. The kinetic model for the reaction was proposed.
It was observed that the hydrogenation of vegetable oil proceeded through two different
reaction that are decarboxylation and hydro deoxygenation. The two side reaction of reverse
water gas reaction and methanation reaction were also observed.
The rate equation for different model like power law and Langmuirhinshelwood mechanism
were calculated. The decarboxylation and hydro-deoxygenation reaction were observed first
order with respect to vegetable oil. Methanation reaction was found to behave first order with
respect to carbon mono-oxide.
The mechanism and the rate determining step in the reaction were also proposed at the end of
the report.
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A B B R E V I A T I O N
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F I G U R E S
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C O N T E N T S
I. Company Profile
II. Introduction
III. Extraction Of Jatropha Oil
IV. Experimental Method And Set-Up
V. Experimental Investigation Of Rate of Hydrogenation Reactions
VI. Quality of Product Obtained
VII. Mathematic Model Of Trickle-Bed
VIII. Conclusion
Reference
Appendix A
Appendix B
Appendix C
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1 . C O M P A N Y P R O F I L E
1. COMPANY OVERVIEW
Indian Oils world class R&D centre, established in 1972, has state-of-the-art facilities & hasdelivered pioneering results in lubricants technology, refining process, pipeline
transportation, bio-fuels & fuel-efficient appliances.
Over the past three decades, Indian Oil R&D Centre has developed over thousands offormulations of lubricating oils and greases responding to the needs of Indian industry and
consuming sectors like Defence, Railways, Public Utilities and Transportation. The Centre
has also developed and introduced many new lubricant products to the Indian market like
multigrade railroad oils.
Focused research in the areas of lubricants and grease formulations, fuels, refining processes,
biotechnology, additives, pipeline transportations, engine evaluation, tribological and
emission studies, and applied metallurgy has won several awards. The R&D Centres
activities in refining technology are targeted in the areas of fluid catalytic cracking (FCC),
hydroprocessing, catalysis, residue upgradation, distillation simulation and modelling, lube
processing, crude evaluation, process optimization, material failure analysis and remaining
life assessment and technical services to operating units.
In FCC, apart from process optimization and catalyst evaluation the accent is on the
development of novel technologies aimed at value addition to various refinery streams.
IndianOil's R&D Centre is fully equipped to provide technical support to commercial
hydrocracker units in the evaluation of feed stocks and catalysts, optimization of operatingparameters, evaluation of licensors' process technologies, development of novel processes
and simulation models.
Material failure analysis and remaining life assessment of refinery equipment and
installations is a highly specialized service being provided by the R&D Centre to the
refineries of IndianOil as well as other companies.
With a vision of evolving into a leader as technology provider through excellence in
management of knowledge, technology and innovation, IndianOil has launched IndianOil
Technology Ltd. The new subsidiary markets the intellectual properties developed by
IndianOil R&D Centre.
In todays dynamic business environment, innovation through a sustained process of
Research & Development (R&D) is the only cutting edge tool for organisation to thrive. With
emphasis on development & speedy commercialisation of globally competitive products,
process & technologies, the focus has now shifted from R&D to RD&D (Research,
Development & Deployment).
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Figure 1.
INDMAX, a hallmark technology developed by the Centre for maximisation of LPG and
light distillates from refinery residue, has been selected by IndianOil for setting up a 4 million
metric tonnes per annum (MMTPA) INDMAX unit as a part of the 15 MMTPA integrated
refinery-cum-petrochemicals complex at Paradip, as well as at Bongaigaon Refinery &
Petrochemicals Ltd. (BRPL). The Centre has also licensed its Diesel Hydrotreating
technology to these two refineries. These successes have catapulted IndianOil R&D into the
elite league of multinational technology licensors.
Standing in the company of six worldwide technology holders for Marine Oils, with the
second global OEM (original equipment manufacturer) approval by Wartsila, Switzerland,
IndianOil's SERVO Marine Oils are now technically qualified to cater to the lubrication
requirements of more than 90% of the world's marine engine population. In the power-
generation segment, the newly developed SERVO Marine K-Series was approved by Yanmar
Co. Ltd. of Japan for use in their engines operating on distillate fuels.
The R&D Centre continues to provide significant support to the IndianOil Group refineries in
product quality improvement, evaluation of catalysts and additives, health assessment ofcatalysts, material failure analysis, troubleshooting and in improving overall efficiency of
operations. In-house developed FCC models are not only being used in IndianOil refineries
for process optimisation but a similar model has also been sold to a multinational company.
IndianOil has formed a joint venture company, Indo Cat Pvt. Ltd., with Intercat, USA, for
manufacturing 15,000 tonnes per annum of FCC (fluidised catalytic cracking) catalysts &
additives in India, for catering to rising global demand.
As a step towards ensuring energy security for the nation, IndianOil has launched several
initiatives to exploit alternative sources of energy such as Hydrogen and Bio-fuels.
Subsequent to commissioning India's first experimental H-CNG (Hydrogen-Compressed
Natural Gas) dispensing unit at the R&D Centre campus at Faridabad, demonstration projects
are underway on use of H-CNG blends in heavy and light vehicles. IndianOil is also setting
up India's first commercial H-CNG dispensing station at one of its retail outlets in Delhi in
the year 2008 for fuelling experimental vehicles running on H-CNG blends as well as on pure
Hydrogen. IndianOil R&D is also working on production, storage, transportation, distribution
& commercialization of Hydrogen as an alternative fuel.
Bio-fuels, besides spearheading commercialisation of Ethanol-Blended Petrol in the country,
Indian Oil has been in the forefront of technology development for Bio-diesel production
from various edible and non-edible oils and its application in vehicles. Pioneering studies by
Indian Oils R&D Centre established that Bio-diesel produced from Jatropha seeds were at
par with that produced from vegetable oils. In the past few years, the R&D Centre has studied
the entire value chain of Bio-diesel, starting from Jatropha plantation to field trials on
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passenger cars, light commercial vehicles and railway locos in collaboration with several
vehicle manufacturers, railways and state transport undertakings.
Figure 2.
Indian Oil along with its subsidiary Indian Oil Technologies Ltd. has been engaged in
successful marketing of in house developed technologies, technical services & training not
only in India but abroad too.
Indian Oil has, till date, invested close to Rs. 1,000 crore in setting up world-class facilities atits R&D Centre for building world-class capabilities in analytical services, engines, test rigs
and pilot plants for all major refinery processes, catalyst characterisation & development, etc.
It plans to invest about Rs. 500 crore during the period 2007-12 to maintain its leadership in
downstream R&D activities in the hydrocarbon sector. While continuing with cutting edge
R&D in the core areas of lubricants formulations, refinery process technologies and pipeline
transportation, the thrust would now be on commercialising the developed technologies and
initiating research in new frontier areas such as petrochemicals, residue gasification, coal-to-
liquid, gas-to-liquid, alternative fuels, synthetic lubricants, nano-technology, etc. Through
these R&D initiatives, IndianOil will continuously enhance value for all its stakeholders
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2 . I N T R O D U C T I O N
This chapter discusses the basic principles involved in processing of crude oil and hydro-
processing of vegetable oil.
CRUDE OIL
Crude oil, The Black-Diamond for the world
formed due to decaying activity of the micro-
organism on the buried dead plants and animals.
The life couldnt be imagined without it.
Crude oil, complex mixture of paraffins, olefins,
aromatics, long chained carbon atom varying from
C1-C100. Around 700 refineries across the globe
are working 247 to meet the demand of its
product.
The figure 2-1 shows the regional share of world
refining, with Americas making big bite.
The extraction and refining of crude oil to finished product is a complex process. The
extracted crude oil is being purchased on the basis of API gravity and its sulphur content.
Then it is made to pass through a de-Salter removing the metals and mud from the crude.
Then the crude oil is distillated in an atmospheric distillation column, where the product cuts
are collected on the basis of their boiling point. The light ends separated are hydro-treated to
remove the sulphur content in it and to bring them below the desired limit.
FIGURE 2-0-2 SCHEMATIC REFINIG OF CRUDE OIL
The heavy end left below need to be converted to light end products for this any one of the
two techniques mentioned are used FCC: Fluid catalyzed cracking
Hydro-Cracking
C
FIGURE 2-0-1 REGIONAL SHARES OFWORLD REFINING
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The fig.2-3 shows the product obtained per barrel
of crude oil
Figure 2-0-3 products per gallon of crude oil
FIGURE 2-4 CRUDE OIL REFINING PRODUCTS
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BIO DIESEL
Diesel being a fossil fuel, rising demand of it has always raised an unanswered question of
what if, if not diesel?
The answer to this if had been bio-diesel. But because of the higher viscosity of the bio-
diesel produced and the modification in the engine it required it has lost its ground Ref[1].
The production of bio-diesel is carried out by treating vegetable oil with methanol, namely
trans-etherification reaction is order to produce the bio-diesel and glycerol.
The glycerol and ester produced are separated. Glycerol is recovered and sold to
pharmaceutical industries, ester being used as bio-diesel. The major advantage of using bio-diesel over the conventional fuel is that they produce comparatively less harmful products
like CO, CO2 and H2O in comparison to SOx and NOx.
FIGURE 0-5: FLOW SHEET FOR BIO-DIESEL
PRODUCTION
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The pre-requisite for using bio-diesel is to make major changes in the engine and these
changes could not be attained in a day. This limitation of bio-diesel has lead to strict norm by
the government to not to dope the diesel with vegetable oil by not more than 5% (w/w) Ref[2].
VEGETABLE OIL HYDRO-PROCESSING
After bio-diesel loosing it ground the hydro-processing of vegetable oil has started gaining
momentum. Many industries have already started commercializing this technology. The
vegetable oil is made to react with hydrogen at the refining hydro processing temperature and
pressure that is 360C and 55bar pressure the product obtained are C0, C02 and nC-18
paraffin.
FIGURE 0-6 HYDRO-PROCESSING REACTION OF VEGETABLE OIL REF [3 ].
The vegetable is doped with either the diesel which is about to be de-sulpharised or mixed
with heavy fraction of crude oil and send for hydro-treating.
During the hydro-processing process many reaction take place simultaneously
1.
2.
3.
The reactions of our concerned are those which directly produce n-paraffin the major
component of the diesel. The consumption of hydrogen in a particular reaction plays an
important role in deciding the price of the bio-diesel. The reaction which consumes least
amount of hydrogen is R3.
The aim of this project is to propose the kinetic model for the above reaction. And study the
effects of various operating condition on the yield of each of the reaction, the project also
discuss the quality of the diesel produced.
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Extraction of jatropha oil
Jatropha oil can be extracted from the seeds by three ways. They are:
Mechanically
Chemically
Enzymatically
Here is a chart that describes the process of oil extraction from the seeds, Jatropha oil
extraction chart
Below are some of the methods that are usually followed to extracts the oils from jatropha
seeds.
Oil Presses
Oil presses method is used to extract the oil using simple mechanical devices. It is also done
manually. The most commonly used oil presses method is the Bielenberg ram press method.
Bielenberg ram press method is a simple traditional method that uses simple devices to
extract the oils. With the help of this method 3 liters of oil can be obtained with 12 kg of
seeds.
Oil Expellers
Oil expellers method is also use for jatropha oil extraction. The most commonly used method
is the Sayari oil expeller method. This method is also called as Sundhara oil expeller. Komet
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oil expellers are also used. These sayari oil expellers was developed in Nepal and is a diesel
operated one. Now it is developed in Tanzania and Zimbabwe mainly for the production
jatropha oil. Heavy oil expellers are made of heavy cast iron and the light ones are made up
of iron sheets. Electricity driven models are also available.
Komet oil expeller is a single oil expeller machine that is used not only to extract the jatropha
oil as well for the preparation of the oil cakes.
Traditional MethodsTraditional methods are used in the rural and developing areas for extracting the oils.
Traditional methods are simple and the oil is extracted by hand using simple equipment.
Hot oil extraction
The process of extracting the oil at high pressure is called as hot oil extraction method. Since
jatropha oil can regulate the operating temperature it is extracted using the hot oil extraction
method.
Then the cold oil extraction method it is easy to extract the oil from the hot oil extraction
since the oil flows more easily due to higher viscosity. And the press cake that remains afterextracting the oil also have less oil content which might be 3 to 7 % approximately. These
two reasons make the oil press method very interesting.
During the oil extraction method many stuffing of the seeds are converted into gum like
substances and some non organic substances. These are unwanted products and so they have
to be refined.
Modern Concepts
Modern methods are followed to extract more oils from the jatropha seeds. In these modern
concepts chemical methods like aqueous enzymatic treatment is used. The maximum yield byfollowing this modern method is said to be about 74/5.
The main idea in researching the modern concepts is to extract a greater percentage of oil
from the jatropha seeds.
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4 . E X P E R I M E N T A L S E T U P A N D M E T H O D S
The chapter describe about the experimental set up on which the major part of the project was
carried out, various techniques that were used in analysis of the product are also discussed in
brief.
EXPERIMENTAL SET UP
The experiment was carried out at laboratory scale reactor. The reactor was typical Trickle
bed reactor, throughout the project reactor is assumed to be ideal fixed bed plug flow reactor.
The schematic diagram of the micro-reactor unit
Fig: 2.1 Schematic Dig of experimental set-up, HPS-high pressure separator, LPS-low
pressure separator, GC-gas chromatography, PDT-product.
The reactor was charged with activated Ni-Mo catalyst, the reactor had ID-12mm and length
of 1.5-m. The reactor was charged with 20cc of catalyst, the glass beads were placed above
and below the catalyst. Three electrically heated coils surrounded the catalyst, the Pt-based
Gas
FEED
REACTOR
PRODUCT
HPS
GAS
LPS
GC
PDT
GAS
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thermostat were arranged to measure both the skin temperature and the temperature inside the
bed.
PRODUCT ANALYSIS TECHNIQUES
Gas Chromatography:
The common technique to analyze the compounds which can vaporize without
decomposition. Gas chromatography consists of two phase, the mobile phase (or "movingphase") is a carrier gas, usually an inert gas such as helium or an un-reactive gas such
as nitrogen.
Thestationary phase is a microscopic layer of liquid or polymer on an inert solid support,
inside a piece of glass or metal tubing called a column. The gaseous compounds being
analyzed interact with the walls of the column, which is coated with different stationary
phases. This causes each compound to elute at a different time, known as the retention
time of the compound. The temperature inside the column is generally controlled by the
heaters. Based on the retention time of each component its composition in sample is
calculated.
CATALYSIS
The first introduction of the word catalysis was by Berzelius in 1836, while Ostwald
presented the first correct definition of a catalyst in 1895. He described a catalyst as a
substance that changes the rate of a chemical reaction without itself appearing in the
products. The reaction of hydro-processing is a typical heterogeneous solid catalyzed reaction
carried in trickle bed reactor.
A catalyst accelerates a chemical reaction. It does so by forming bonds with the reacting
molecules (i.e. adsorption), such that they can react to a particular product, which detaches
itself from the catalyst (i.e. desorption), and leaves the catalyst unaltered so that it is ready to
interact with the next set of molecules. In fact, we can describe the catalytic reaction as a
cyclic event in which the catalyst participates and is recovered in its original form at the end
of the cycle. A catalyst cannot alter the chemical equilibrium of a given reaction; it only
creates a favourable reaction pathway. This is done by decreasing the activation barrier
(Ea,cat) compared to the gas phase reaction (Ea, gas) and thus increasing the reaction rate.
Consequently, the reaction can take place at lower temperatures and pressures, which
decreases costs and amounts of energy for e.g. a chemical plant. Furthermore, if for a certain
reaction different paths are possible that lead to various products, the catalyst can selectively
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decrease the activation energy of one of the possible reaction paths, thereby altering the
selectivity of the reaction. In general a successful catalyst increases the yield of the desired
product while decreasing that of other products, which has advantages for both economic and
environmental reasons.
Figure 0-1: Potential energy diagram for a heterogeneous catalytic reaction (solid line), i.e.
reaction of A and B to form AB, compared with the non-catalytic gas-phase reaction (dashed
line). The presence of a catalyst lowers the activation energy (Eact) considerably.
NI-MO CAT ALYST
The catalyst used in our project to carry hydro-treating reaction is a Ni-Mo catalyst.
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4. EXPERIMENTAL INVESTIGATION OF RATE OF HYDROGENATION REACTIONS
The chapter summarizes the path followed during the hydro-processing of vegetable oil.
The proposed mechanism in literature estimates the production of CO2,CO and H2O
directly from vegetable oil. But it became difficult to account for the moles of carbon mono-
oxide.
As there is no fixed mechanism in the literature regarding the conversion of vegetable oil to
carbon mono-oxide.
And the same could be commented as there was no trending graph for production of CO2
from vegetable oil. As depicted in the graph shown below.
Fig 4.1 Moles CO,CO2 and H2O V/S Moles Of VO Following A Direct Production Path
with the number of hit and trial
0.0017254290.011694570.017129189 0.0192924650
0.0365183110.071347203
0.165795511
0
0.185
0.315
0.63
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 0.05 0.1 0.15 0.2
Molesofproduct
Moles of VO initially
CO2 v/s VO
CO v/s VO
H2O v/s VO
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# Proposed Mechanism
#Moles of CO2 V/S moles of VO
#Moles of H2O V/S moles of VO
0.001725429
0.052430896
0.086836597
0.187266364
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
0 0.05 0.1 0.15 0.2
MolesofCO
2produced
Moles of VO initial
CO2 V/s VO
CO2 V/s Vo
Linear (CO2 V/s Vo)
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# Moles of propane V/S Vo
#Moles of HC V/S moles of VO
0.070389577
0.0310948160.028932256
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 0.05 0.1 0.15 0.2
MolesofH2OviaHDO
Moles of VO initial
H2O via HDO
H2O via HDO
0.01607096
0.029492131
0.061695992
0.011731596
0.005182469 0.004822043
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0 0.05 0.1 0.15 0.2
Molesofpropanevia
Moels of VO initially
decarboxylation
HDO
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#Moles of CO2 V/S moles of CO reverse water gas shift reaction
#Moles of CH4 V/S moles of CO methanation reaction
0.048212881
0.088476392
0.185087976
0.035194789
0.015547408 0.014466128
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
0 0.05 0.1 0.15 0.2
MolesofHC
via
Moles of VO initially
HC via
decarboxylation
HC via
HDO
0.036518311
0.071347203
0.165795511
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0 0.05 0.1 0.15 0.2
MolesofCOformed
Total moles of CO2 formed
moles of CO2 v/s CO
moles of CO2 v/s CO
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#Assuming 50%error in water estimation via HDO
#Moles of propane V/S Vo 50% error in water estimation via HDO
0.020147667
0.038969092
0.09005001
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
MolesofCH4formed
Total moles of CO formed
CH4 V/S CO
CH4 V/S CO
0.1823
0.309
0.632
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18
MoleofwaterviaHDO
Moles of VO initially
H2O V/S VO
H2O V/S VO
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#Moles of HC V/S moles of VO 50% error in water estimation via HDO
#Kinetic order for de-carboxylation Rxn assuming first order kinetics (k=0.803479 sec-1
)
W/Fao (Kg/moles) Cao(moles/volume) Conversion Rate constant
0.01607096
0.029492131
0.061695992
0.030383333
0.0515
0.105333333
0
0.02
0.04
0.06
0.08
0.1
0.12
0 0.05 0.1 0.15 0.2
Molesofpropaneformmed
Moles of VO initially
Moles of propane v/s moles of vo with 50%
error in water estimation
decarboxylation
HDO 50% error
0.016070960.029492131
0.061695992
0.09115
0.1545
0.316
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 0.05 0.1 0.15 0.2
MolesofH
C
Moles of VO initially
Moles of HC v/s moles of VO
decarboxylation
HDO 50%error
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10.19157 0.05 0.344818 0.829787
5.822268 0.1 0.361497 0.77054
2.837434 0.2 0.368544 0.81011
#Kinetic order for HDO Rxn assuming first order kinetics(k=1.848858 sec
-1
)
W/Fao (Kg/moles) Cao(moles/volume) Conversion Rate constant
10.19157 0.05 0.65083 2.064837
5.822268 0.1 0.6385 1.747589
2.837434 0.2 0.626227 1.734147
#Kinetic order for methanation Rxn assuming first order kinetics(k=1.437302 )
W/Fao (Kg/moles) Cao(moles/volume) Conversion Rate constant
10.19157 0.0391767 0.551714 1.574486
5.822268 0.0874532 0.546189 1.356989
2.837434 0.1980774 0.543139 1.38043
# Conversion data for reverse water gas shift reaction.
Moles of CO2 Conversion
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0.048213 0.757439
0.088476 0.806398
0.185088 0.895766
#Conversion v/s moles of CO2
#Summary of rate constant
Reaction Order Rate constant Rate determining step
Decarboxylation 1st
wrt VO 0.803479
HDO 1st
wrt VO 1.848858
Methanation 1st
wrt CO 1.437302
Reverse water gas shift
reaction
Kp 0.063
0.7574388870.8063982010.895765974
1.416501587
1.641951811
2.261116655
0
0.5
1
1.5
2
2.5
0 0.05 0.1 0.15 0.2
conversion
Moles of CO2
Conversion v/s moles of CO2
conversion v/s moles of CO2
ln(1-Xa) v/s moles of CO2
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#PONA
Composition Aromatics Olefins Saturates Naphthalene
100%PRDHDS 17.9 0 82.1 12.8
5%MOSLX+95%PRDHDS 15.1 0 84.9 13.5
10%MOSLX+90%PRDHDS 15.4 0 84.6 13.3
20%MOSLX+80%PRDHDS 15.9 0 84.1 13.2
#PONA
# Conclusion from PONA analysis
17.915.1 15.4 15.9
82.184.9 84.6 84.1
12.8 13.5 13.3 13.2
0
10
20
30
40
50
60
70
80
90
0 0.05 0.1 0.15 0.2
Mg/lit???
Moles of VO initially
Aromatics
Saturates
Napthalenes
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The aromatics increases, with increase in the moles of vegetable oil doped
Where as there is decrease in moles of saturates and naphthalene with increase in
vegetable oil doped.
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3. MATHEMATIC MODEL FOR TRICKLE BED
This chapter summarizes the mathematical model for trickle bed as follows:
Figure a. Sketch showing the resistances involved in the G/L reaction on a catalyst
surface.
Graphically we show the resistances as in Fig. a. We can then write the following general rate
equations:
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