Beruflich Dokumente
Kultur Dokumente
IndianOil
R&D Centre, Faridabad
Contents
Introduction
Catalyst Management
Case Studies
Conclusion
ENVIRONMENT 33%
CHEMICALS 27%
REFINING 40%
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
First catalytic cracking AlCl3 1915 1940 1950 1960 1970 1980 1990 2000
Catalyst Management
Catalyst/
play
key
role
on
unit
catalyst vendors
offering their
Right choice of catalyst is very important Significant yield advantages can be realized through
catalyst management
Services Offered
FCC
Catalyst Selection
Services Offered
Hydrocracking
Selection of Catalyst System, Remaining Life Assessment Effects of Feedmix Change on Catalysts Performance Optimisation of Hydroprocessing Units
Services Offered
Reforming
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
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
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
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-
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
87
83
79
- 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
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
Thank You