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HydroprocessingCatalyst Evaluation

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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

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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

Hydroprocessing Catalyst Evaluation

- Objectives

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Selection of Hydrocracker catalyst system for existing aswell as grass root refinery

Selection of DHDS catalyst system

Catalyst health assessment & performance monitoring forseveral Hydrocracker units

Troubleshooting of Hydrocracker unit for obtaining designconversion at design throughput

Optimization of hydrocracker units for maximization ofmiddle distillates

Troubleshooting of DHDS unit

Services for Hydrocracking & Hydrotreating

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Licensor failed to solve

problem of negligible

conversion in 2nd

stage of a two stage

recycle hydrocracker

unit

Hydrocracker Troubleshooting

- Case Study

Very low conversion in a new hydrocracker

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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

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Days on Stream

K

Life : 2 years

k-EOR

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Optimization of HCU- Maximization of Middle Distillates

75

79

83

87

91

15 20 25 30 35 40 45 50 55

1st Stage Conv. (%)

OverallMDYield(wt%)

Base Case (Design)

- All catalyst systems are more MDs selective than existing one

- Excellent products properties and low pay back period

Cat-A

Cat-B

Cat-A

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New Technologies

Hydroprocessing Technologies forDistillate 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)

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Ultra Low Sulfur DieselIOC R&Ds Approach

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DIESEL SPECIFICATIONS IN INDIA

Parameter BIS-2000 BS-II BS-III Euro-IVSulfur, ppm 2500 500 350 50Cetane Number 48 48 51 51Density, kg/m3 820-860 820-860 820-845 820-84595% Recovery,0C

370 370 360 360PAH, wt% 11 11

Year of

Implementation

2000-2001 April 1, 2005 April 1, 2010

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Low cost options for ultra desulfurisationEvaluation of best catalysts available

Evaluation of catalysts in stacked bed for increased

performance

Characterization of feed stocksdetailed 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

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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

Studies at IOC-R&D

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DHDS / DHDT Technology based upon commercial open catalystsData 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 formulationUS patent

Being scaled upProcess Development for ring opening (Collaborative)

Adsorption process for ULSD (Currently under laboratory scale)

Development of New Technology / Catalyst

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Evaluation / Development of Reactor

Internals

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Cat FeedASTM 95boiling point(D2887)(C)

Operating conditions Decrease inASTM 95(D2887)boiling point

(C)

Increase in127 C-

(wt )

Temp.Bed I/Bed II(C)

P

(bar)

LHSV

(hr-1)

H2/HC

ratio

(Nm3/

m3)

HDT+

ISOM390 345/360 49 1.5 400 2 2390 345/375 49 1.5 400 8 2

HDT+

MHC)390 345/380 49 1.5 400 10 2390 345/390 49 1.5 400 15 2

Reduction of 95 boiling point