Hydroprocessing Catalyst Evaluation

Hydroprocessing - Catalyst Evaluation

State-of-the-art pilot plant facilities :
Micro-reactors (5-20 ml cat) (Twin reactors-once through) Catalyst screening units (150 ml cat) (Twin reactors- gas-liquid recycle) Bench scale unit (500 ml cat) (Twin reactors- gas-liquid recycle) Micro-flow reactor (1-5 ml catalyst) (High throughput multi-reactor)

Advanced characterisation facilities

Catalysts, Feed / Products

Data / Knowledge Bank

Hydroprocessing Catalyst Evaluation - Objectives

Selection of Process / Catalyst System

Technical Services / Technological Solutions

Effects of Feedmix Change on Catalysts Performance

Optimisation, Troubleshooting & Debottlenecking Studies

Performance monitoring - Remaining Life Assessment

Development of New Catalysts / Technology

Services for Hydrocracking & Hydrotreating

Selection

of Hydrocracker catalyst system for existing as well as grass root refinery

Selection Catalyst

of DHDS catalyst system

health assessment & performance monitoring for several Hydrocracker units

Troubleshooting

of Hydrocracker unit for obtaining design conversion at design throughput

Optimization

of hydrocracker units for maximization of middle distillates

Troubleshooting

of DHDS unit

Hydrocracker Troubleshooting - Case Study

Very low conversion in a new hydrocracker

Licensor failed to solve

problem of negligible conversion in 2nd stage of a two stage recycle hydrocracker

unit

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

Life : 2 years
0 200 400 600 800 1000 1200 1400 1600 1800 2000

k-EOR

Days on Stream

Optimization of HCU - Maximization of Middle Distillates

91

Overall MD Yield (wt %)

87

Cat-B Cat-A Cat-A

83

79

Base Case (Design)

75 15 20 25 30 35 40 45 50 55

1st Stage Conv. (%)

- All catalyst systems are more MDs selective than existing one - Excellent products properties and low pay back period

New Technologies
Hydroprocessing Technologies for
Distillate Hydrotreatment
Naphtha HDS / HDT
Selective Diene Saturation Low Pressure ATF Hydrotreatment

Diesel HDS / HDT (Patented Catalyst)

Hydrocracking (Patented Process)

Naphtha to LPG

Polymer Grade Hexane / Food Grade Hexane

(Patented Process)

Ultra Low Sulfur Diesel

IOC R&Ds Approach

DIESEL SPECIFICATIONS IN INDIA

Parameter
Sulfur, ppm
Cetane Number Density, kg/m3 95% Recovery, 0C PAH, wt%

BIS-2000
2500
48 820-860 370

BS-II
500
48 820-860 370

BS-III
350
51 820-845 360 11

Euro-IV
50
51 820-845 360 11

Year of Implementation

2000-2001

April 1, 2005

April 1, 2010

Studies at IOC-R&D

Low cost options for ultra desulfurisation

Evaluation of best catalysts available
Evaluation of catalysts in stacked bed for increased performance

Characterization of feed stocks detailed S speciation for identification of refractory components

Segregation of feed as per their refractoriness and processing in hydrotreating units of different severity level Co-processing of middle distillate streams in HCU

Studies at IOC-R&D
Cetane improvement
Evaluation of high hydrogenation catalyst for high pressure DHDT units

Upgradation of low Cetane streams, e.g., LCO, CGO etc. in HCU

Evaluation of MHC units vis--vis high pressure DHDT units

Options for end point reduction

DHDS-MHC combination

DHDS-Isomerisation dewaxing combination

Development of New Technology / Catalyst

DHDS / DHDT Technology based upon commercial open catalysts

Data generation in pilot plants
Internals / hydrodynamic studies Kinetic & Hydrodynamic models Design package being made for a 1.2 MMTPA DHDT unit

DHDS catalyst for ULSD

Laboratory formulation US patent Being scaled up

Process Development for ring opening (Collaborative)

Adsorption process for ULSD (Currently under laboratory scale)

Evaluation / Development of Reactor Internals

Reduction of 95 % boiling point

Cat Feed ASTM 95% boiling point (D2887) (C) Operating conditions Temp. Bed I/ Bed II (C) P LHSV H2/HC ratio Decrease in ASTM 95 % (D2887) boiling point (C) Increase in 127 C-

(wt%)

(bar)

(hr-1)

(Nm3/ m3)

HDT + ISOM

390 390 390

345/360 345/375 345/380

49 49 49

1.5 1.5 1.5

400 400 400

2 8 10

2 2 2

HDT + MHC)

390

345/390

49

1.5

400

15