IndianOil Technologies Ltd.

Catalyst Management Solutions for Refining Processes

IndianOil
R&D Centre, Faridabad

Contents

Introduction

Catalyst Management

Case Studies
Conclusion

Catalyst Demand Scenario

ENVIRONMENT 33%

CHEMICALS 27%

REFINING 40%

Refining Catalyst Market

REF, ISOM 15%

ALKYLATION 15%

OTHERS 5%

HT, HC 25%

FCC 40%

Trends in Catalysis
Liquid acids Zeolites New Catalysts Non-selectivity High selectivity Very high Hazardous Min. by-products selectivity Capital, Energy Knowledge base Clean intensive process Highly knowledge . based Knife Hammer Inorganic catalysts Improved selectivity By-products concerns
Last 50 Years Present

Brute Force
Olden days

Relative complexity

Scalpel

Future

Growth of FCC Catalysts Formulations

Sox additive Nickel passivation (Bi) CO promoter Y zeolite based catalysts High alumina catalyst

BCA,, Resid FCC

Octane additive USY zeolite

Nickel passivation (Sb) First commercial FCC, natural clay

First catalytic cracking AlCl3 1915 1940 1950 1960 1970 1980 1990 2000

Catalyst Management

Why Catalyst Management ?

Catalyst/

Additives performance products

play

key

role

on

unit

There are many

catalyst vendors

offering their

Right choice of catalyst is very important Significant yield advantages can be realized through
catalyst management

Scope for tailor made catalyst/ additive

Components of Catalyst Management

Catalyst selection Change over Decision Health monitoring Remaining Life Assessment Physical Properties Check-up Troubleshooting

Services Offered

FCC

Catalyst Selection

FCC Additive Selection

Fresh Catalyst Quality Check

Equilibrium Catalyst Monitoring

Trouble Shooting, Technological Solution

Services Offered

Hydrocracking
Selection of Catalyst System, Remaining Life Assessment Effects of Feedmix Change on Catalysts Performance Optimisation of Hydroprocessing Units

Troubleshooting / Debottlenecking Studies

Services Offered
Reforming

Fresh Catalyst Selection

Catalyst Residual Life Prediction

Catalyst Health Monitoring

Methodology of Selection
Fresh catalyst

Pretreatment
Poor Physico-Chemical Characterization

Poor
Poor

Standard testing
Performance prediction using model Pilot plant test Recommendation for plant trial

Poor

Indianoil has Rigorous Simulation Models for all these Processes to Support the Catalyst Management Services

Simulation Models
FCC MOD Kinetics of riser/ regenerator and hydrodynamics of catalyst
stripper

Extensively used for catalyst performance prediction, process optimization and troubleshooting

HC MOD

Rigorous hydro-cracking kinetic model based on continuum

theory of lumping approach

Used for simulation studies for process optimization,

trouble shooting and catalyst performance assessment

Simulation Models
DHDS MOD

Prediction of total sulfur, concentration of individual S compounds and estimation of chemical Hydrogen consumption

REFMOD MOD
Model for simulating SR and CCR units Plant performance optimization, monitoring and troubleshooting

Catalyst Development Expertise

Developed Lotus 24 FCC catalyst formulation
Successfully tried at a refinery

Novel LPG additive for FCC unit- iMAX

Successfully tried at a refinery Technology licensed to a catalyst manufacturer

4 Indian, 4 USA, 1 Canadian and 1 EU patent granted

Process Improvements and Troubleshooting

FCC
Feed Throughput Maximization in Gujarat Refinery Increase in Feed FBP in Gujarat FCC High CRC with High catalyst loss in Gujarat FCC unit

Hydroprocessing
Troubleshooting of DHDS & HCU units showing abnormal behaviour Persistent high diesel pour point problem in existing HCU Catalyst activity problem in a DHDS unit

Case Studies

Benefits of Catalyst Switchover

Year Unit Benefits

1995

Mathura

Increase in LGP & diesel yield by 1% &1.35%, CLO reduction 3.8% & increase in gasoline octane by 1.5 units Increase in gasoline & TCO yield by 0.7 % & 2.29%, CLO reduced by 2.89% Increase in LPG and gasoline by 2.35 and 0.9 wt% respectively, reduction in CLO yields by 2.7%. Increase in gasoline yield by 1%, LPG by 0.7% & reduction in bottoms by 1.7% Diesel yield increased by 2.5%, CLO yield reduced by 1.5 wt%.

1998

-do-

2000

-do-

1995

Gujarat

1999

-do-

Benefits of Additive Switchover

1994 BCA
Mathura

Increase in diesel yield by 1 wt%. Reduction in CLO yield by 1.3 wt%, reduction in SOx emission also. Increase in LPG yield by 1 wt %, gasoline by 1.5 %, octane by 1 unit Increase in LPG yield by 1.58 %, gasoline by 3.48 %, Reduction in CLO yield 1.3 %

1993

ZSM-5

Mathura

1993

ZSM-5

Gujarat

91

Maximization of Middle Distillates HCU Optimization Studies

Cat-B Cat-A Cat-A

Overall MD Yield (wt %)

87

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

Catalyst Health Monitoring & Remaining Life Assessment Studies for HCU

1E+16 8E+15 6E+15

K

4E+15 2E+15
Life : 2 years k-EOR 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000

Days on Stream

Conclusion
Catalyst- critical input to refineries Proper Catalyst/ Additive management provides a
competitive edge to refinery operation and profitability Custom catalyst-need of the refiners

ITL, backed by world class facilities and expert

manpower provide
Catalyst/ Additive management solution Technical solutions related to revamp, yield optimization,
etc.

Thank You