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An Insight May 2009 INDIAN INSTITUTE OF PETROLEUM DEHRADUN.

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Presentation on theme: "An Insight May 2009 INDIAN INSTITUTE OF PETROLEUM DEHRADUN."— Presentation transcript:

1 An Insight May 2009 INDIAN INSTITUTE OF PETROLEUM DEHRADUN

2 Established in September 1960 by an act of Parliament To provide technical & scientific support to the entry of public sector in the hydrocarbon industry Initial ( ) technical collaboration with IFP, France One of the 37 national laboratories under aegis of CSIR THE ORGANISATION

3 CHARTER Undertake R&D work in petroleum refining, natural gas, petrochemicals and petroleum products utilisation Train personnel for regulatory bodies, hydrocarbon, automotive & related industry Conduct market demand surveys & TEFS for petroleum products Assist in formulation of national standards for petroleum products Provide technological services to refining & related industry

4 Mandate To develop high science based innovative technologies for refining of petroleum, natural gas and petrochemicals with special emphasis to indigenous requirement. To provide technical support & analytical services to petroleum refining & related industry including technology transfer/ assimilation. Utilization of petroleum and its products in IC engines and in industrial & domestic combustion To develop human resources for the hydrocarbon, automotive and related industries and also for regulatory bodies by training their personnel through specialized training courses. Assisting the Bureau of Indian Standards (BIS) in formulating standards for petroleum products. Support to Government agencies for major policy decisions

5 Vision A nodal Organization for Scientific and Industrial research and a path setter in indigenous R&D in Petroleum Refining, Petro-chemicals, Specialty Chemicals, and Petroleum Products Application Areas A global platform providing competitive R&D and high quality science based technical services world over A vital source of S&T for Energy, Chemical and Automotive sectors of industry A learning centre for personnel from Refining, Chemicals, Automotive and Gas Industry A Think Tank for providing solutions to the problems of Hydrocarbon and related Industry

6 Areas of Competence Advanced Separation Processes Renewables Advanced Refining Technologies Petrochemicals, Specialty Chemicals Petroleum Product Applications Crude Oil & Products Evaluation Training

7 Facilities IIP is equipped with state-of-art laboratories, pilot plants and analytical facilities Fully instrumented microreactor/ pilot plant units for process and catalyst evaluation Over 15 batch reactor units for process studies State-of-art process design and simulation softwares e.g. ASPEN+, DESIGN –II, CFD(FLUENT, STAR CD), HAZOP, CHEM-CAD and host of inhouse softwares for kinetic modeling, statistical analysis and general computation Tribology & Engine Test Facilities

8 Human Resource Base Scientific Staff (Group IV) - 74

9 Human Resource Base Technical Staff (Group III) - 70

10 Human Resource Base Technical Staff (Group II) - 71

11 During last 49 years IIP has developed more than 70 technologies Several of them have been commercialized against global competition Almost every refinery in the country has technologies licensed by the Institute Technologies Licensed

12 TECHNOLOGY UNIT LICENSED CAPACITY TPA 1. AROMATIC EXTRACTION BPCL, MUMBAI97,000 (B) FOR PRODUCTION OF 17,000 (T) BENZENE(B) & KRL, KOCHI 87,000 (B) TOLUENE(T) (IIP-EIL) 20,000 (T) NOCIL, MUMBAI90,000 (B) 110,000(T) 2. FOOD GRADE HEXANE BPCL, MUMBAI25,000 (IIP-EIL) CPCL, CHENNAI25,000 HPCL, MUMBAI50, BIMETALLIC REFORMING CPCL, CHENNAI90,000 CATALYST (IIP-IPCL) 6.2 (Cat.) IPCL,VADODARA110, (Cat.) 4. CONVERSION OF LIGHT GAIL, N. DELHI8,000 NAPHTHA TO LPG AND HIGH OCTANE GASOLINE 5. LOBS THROUGH NMP IOC, BARAUNI400,000 EXTN. (IIP-EIL) IOC, HALDIA350,000 Technologies Licensed PROCESSES Contd …

13 TECHNOLOGY UNIT LICENSED CAPACITY TPA 6. DELAYED COKING BRPL,BONGAIGAON 500,000 (IIP-EIL) NRL, NUMALIGARH306, VISBREAKING OF IOC, GUJARAT*1,600,000 PETROLEUM RESIDUAL IOC, MATHURA*1,000,000 FRACTIONS SOAKER IOC, HALDIA*1,000,000 MODE (IIP-EIL) CPCL, CHENNAI* 550,000 KRL, KOCHI*1,000,000 IOC, PANIPAT450,000 HPCL, VIZAG1,000, DEWAXING / DEOILING IOC, HALDIA 27,000 (IIP-EIL), REVAMPING 9. DI-TERTIARY BUTYL BALMER LAWRIE 150 PARA CRESOL (IIP) LTD., CHENNAI 10. PARA TERTIARY BUTYL BALMER LAWRIE300 PHENOL (IIP) LTD, CHENNAI * Revamp Contd … Technologies Licensed PROCESSES

14 TECHNOLOGY UNIT LICENSED CAPACITY TPA 11. Na/Ca SULPHONATE, NAL, HYDERABAD 1100 E P ADDITIVE (IIP) 12. SULFOLANE (IIP) CHPL, AHMEDABAD HOT ROLLING OIL (IIP) LIL, MUMBAI 1, DEOILING/DEWAXING DORF KETAL CHEMICALS ADDITIVE FOR INDIA LTD. LUBRICATING OIL 15. PROPANE DEASPHALTING HPCL, MUMBAI50,000# (IIP-EIL) CPCL, CHENNAI50,000# 16. LUBE OIL REREFINING (IIP) 65 FIRMS20, IMPROVED JAGGERY UTTARAKHAND STATE (3 nos.) 6 to 8 Qtl. MAKING PLANT UTTAR PRADESH (19 nos.)per day / unit 18. SWEETENING CATALYST LONA INDUSTRIES, MUMBAI CONVERSION OF VEGETABLE ARMACO CONSULT OIL FEED STOCK TO ESTERS PVT. LTD., MUMBAI USING SOLID HETEROGENEOUS CATALYST Technologies Licensed PROCESSES Contd … # Bright Stocks

15 TECHNOLOGY UNIT LICENSED CAPACITY 1. LAP BURNER SEVEN FIRMS 6, WICK STOVES THIRTEEN FIRMS 1000, LPG STOVE 80 FIRMS 720,000 Technologies Licensed PRODUCTS

16 IIP Technologies Licensed Panipat Refinery Soaker Visbreaking Baroda Visbreaking (Revamp) Bi-metallic Reformer Cat NTGG Retrofit-kit Mathura Refinery Visbreaking (Revamp) Mumbai Bio-diesel BT Extraction FGH Production Dewaxing Aid Additive Hot Rolling Oil PTBP / BHT LAP Burner Kochi BT Extraction Visbreaking (Revamp) Numaligarh Delayed Coking Calcutta LAP Burner Haldia Visbreaking (Revamp) Dewaxing / Deoiling (Revamps) LOBS NMP Extrn Vishakhapatnam Soaker Visbreaking Chennai Food Grade Hexane Bi-metallic Reformer Cat PTBP / BHT Visbreaking (Revamp) PDA Bangalore Impregnating Pitch Coimbatore LAP Burner LPG Stove Hyderabad EP Additive Sulphonates Barauni Delayed Coking Visbreaking LOBS NMP Extrn Durgapur Ethanol Dehyd. Cat. Bongaigaon Delayed Coking Indore Wick Stove Rajkot Wick Stove Ahmedabad Sulpholane New Delhi LAP Burner Wick Stove ` Faridabad LAP Burner

17 CSIR Technology Awards  PRODUCTION OF BENZENE / TOLUENE :1990 THROUGH SULFOLANE EXTRACTION  BIMETALLIC Pt-Re REFORMING CATALYST:1992  SHIELD FOR PROCESS TECHNOLOGY :1993 FOR FOOD GRADE HEXANE  LOW AIR PRESSURE FILM BURNER:1994  BUSINESS DEVELOPMENT & TECHNOLOGY:1996 MARKETING  SULFOLANE PRODUCTION TECHNOLOGY:1997  VISBREAKING TECHNOLOGY:1998  PROPANE DEASPHALTING OF:1999 PETROLEUM RESIDUE  SHIELD FOR PROCESS TECHNOLOGY FOR:2000 NMP BASED LOBS PRODUCTION TECHNOLOGY  FOOD AND PETROCHEMICAL GRADE HEXANE:2001 USING NMP  DEVELOPMENT OF COMB TYPE POLYMERIC:2006 WAX CRYSTAL MODIFIER AND DEWAXING AID AND ADDITIVES FOR PRODUCTION OF LOBS  DEVELOPMENT OF NEW CATALYST FOR: 2007 SWEETENING OF LIGHTER AND HEAVIER PETROLEUM FRACTIONS

18

19 FINANCIAL RESOURCE BASE CSIR Grants

20 Ongoing Sponsored R&D Projects YearNo. of Projects Value (Rs. in Lakh)

21 Extra Budgetary Resources Refineries and PSU’s Govt. Organizations Private Organizations Overseas TOTAL (Figures Rs. in Lakhs)

22 Patents Filed 168  Indian 76  Foreign 92 Patents Granted 107  Indian 96  Foreign 21 Knowledge Generation (2000−2009)

23 Sponsored Projects Completed YearNo. of Projects Value (Rs. in Lakh)

24 Doctoral Theses 39 M. Tech. Theses 50 Short term projects 2424 of Engineering & Science Students - Sponsored from Industry Vocational Trainees 212 from academic institutions Extramural R&D (2000−2009)

25 Advanced Separation Processes Liquid Liquid Extraction Adsorptive Separation Absorption Aromatic Recovery Unit BPCL, Mumbai

26 Commercialized Light Aromatic Extraction Technologies

27 CURRENT RESEARCH PROJECTS Oxidative desulphurization of diesel Synthesis of room temperature ionic liquids for their applications in extraction of sulfur and aromatic compounds from petroleum streams TECHNOLOGIES READY FOR COMMERCIALIZATION Re-extraction technology for dearomatisation of middle distillate Production of pure aromatics from straight run naphtha Oxidative desulphurization of diesel Upgradation of light cycle oil for value addition using low cost solvent extraction route Production of cyclopentane from light naphtha /NGL fraction TECHNOLOGIES HAVING POTENTIAL FOR COMMERCIALIZATION

28 Highlights… Quality Products…. Eco-friendly process Reduced Solvent Losses Low cost option to de- aromatize Naphtha, Kerosene and Diesel in single plant 2 Indian Patents filed & 1 US patent being filed RE-EXTRACTION TECHNOLOGY A Low Cost Revamp Option for SO 2 Based Kerosene Treating Unit, Mainly in Eastern Sector Some Recent Contributions

29 International Footprints in the Area of Aromatics Extraction  IIP has been identified as a key knowledge-holder in this area  Recently two major projects were awarded by UK based petrochemical Company  IIP has been identified as a key knowledge-holder in this area  Recently two major projects were awarded by UK based petrochemical Company  Production of pure aromatics (BTX) from straight run naphtha (SRN) using NMP solvent  Revamp of sulpholane extraction unit for processing high severity pyrolysis gasoline (PG) cut  Production of pure aromatics (BTX) from straight run naphtha (SRN) using NMP solvent  Revamp of sulpholane extraction unit for processing high severity pyrolysis gasoline (PG) cut  Expertise in the area of extraction was successfully used for production of pure BTX/Benzene from challenging feed stocks such as St. Run naphtha, Pure PG/C6 cut of PG  Technology successfully developed and demonstrated on lab scale  Technology information package (TIP) submitted  Gained confidence of the client from abroad & formulated long term relationship  Expertise in the area of extraction was successfully used for production of pure BTX/Benzene from challenging feed stocks such as St. Run naphtha, Pure PG/C6 cut of PG  Technology successfully developed and demonstrated on lab scale  Technology information package (TIP) submitted  Gained confidence of the client from abroad & formulated long term relationship

30 Technology for Ultra Low Sulphur Gasoline Production from FCC Naphtha Designed for Euro IV gasoline production Raw material is FCC naphtha containing 1000ppm sulphur Product <30 ppm sulphur Process a novel combination of conventional naphtha HDS with vapor phase adsorption based on a highly selective adsorbent Process tested in bench scale. Technology Information Package ready Lab-scale Adsorption Unit for Gasoline Desulphurization

31 Technology for Helium Recovery from Natural Gas Of strategic importance Raw material :Natural gas containing 2000ppm helium Product Grade A helium %purity Process a uniquely designed combination of cryogenic distillation utilizing available pressure of natural gas and Pressure Swing Adsorption Three Bed PSA Unit Commercially available adsorbent used Technology Information Package ready

32 Other Technical Breakthroughs Regenerative process for sulphur dioxide removal from lean gas streams Super critical propane deasphalting Short path distillation Flue gas desulphurization

33 Renewables Bio fuels Bio lubricants Additives

34 Technical Breakthroughs Process for biodiesel Production using Heterogeneous Catalyst Process for ethanol Production from starch and sugars using thermophilic biocatalysts Processes for Production of Bio lubricants Sulphur free Multi Functional Additives for Gasoline, Diesel Hydrogen from Biomass Characterization and Enumeration of oil Reservoir Biodiversity through Ribotyping or DNA Technique

35 Technologies Ready For Commercialisation Biodiesel from vegetable oils, waste oils and fats Specialty chemicals & products from Jojoba oil Biolubricants from vegetable oils, starch and cellulose Biosurfactant for recovery of oil from crude tank bottom sludge

36 Raw Material Chemically modified non-edible vegetable oil (Neem, ricebran, Karanja, Mahua, Castor, Linseed or mixture thereof) or Heavy Alkyl Benzene (LAB) Technology for Lubricants from Vegetable Oil / Heavy Alkyl Benzene Vegetable Oil Based 100% Biodegradable HAB based – Non-toxic Products Yield 100 % Meeting BIS Specification Cost Competitive Helps in Energy Security & Agro Development Soluble cutting oil Gear oil Lithium Grease Solvent /De-greaser 2T Engine oil Hydraulic oil Transformer oil

37 High Performance Additives Additive grade HAB sodium sulfonate of high purity Overbased calcium HAB sulfonate as temporary rust preventer (TBN 300) Extreme pressure additives (equivalent to USS-224) Additive pack for soluble cutting oil, 2t oil, gear oil, hydraulic oil, lithium greases and transformer oil Low cost process for 2- mercapto benzimidazole (2MB, zinc salt and alkylated) Additive pack for diesel to reduce nozzle fouling THE ABOVE TECHNOLOGIES ARE PROTECTED BY INDIAN / FOREIGN PATENT APPLICATIONS Additive for furnace oil for better combustion Additive for cracked naphtha for stability

38 Advanced Refining Technologies Gas to liquid conversion Residue upgradation Isomerization Sweetening Desulfurization Catalytic cracking Soaker Visbreaking Unit at Mathura Refinery

39 SWEETENINGSWEETENING NOVELMATERIALNOVELMATERIAL REFORMINGREFORMING GAS PROCESSING LIGHTSTOCKPROCESSINGLIGHTSTOCKPROCESSING FLUIDCATALYTICCRACKINGFLUIDCATALYTICCRACKING Catalysts&CatalysisCatalysts&Catalysis

40 IPR 2001 Reforming Catalyst

41 IIP has developed in collaboration with BPCL a globally competitive catalyst Thoxcat ES useful for extractive sweetening of LPG and liquid phase sweetening of lighter petroleum fractions like LSRN/light cracked naphtha. Sweetening is a process of extraction/conversion of mercaptans Economical due to lower price No additional investment needed for plant modification Protected with 8 international patents Applicable in both conventional and fibre-film sweetening processes Successful trial runs of the catalyst in LPG Merox units of BPCL (Mumbai), RIL (Jamnagar) and MRPL (Mangalore) have shown better performance than commercial ones. Catalyst production technology has been transferred to Lona Industries Ltd, Mumbai Better Activity in LPG sweetening depicted by lesser regeneration/conversion time Better performance than commercial catalyst at high sulfur level in the feed Sweetening

42 Highlights… Value addition to light Naphtha LPG production along with a good gasoline pool blending stock, no sulfur and high octane IIP & GAIL have joined hands to put first semi commercial plant at Vaghodia, Gujarat. 2 US Patents Sealed and 4 Indian Patents filed NTGG PROCESS Converts Light Naphtha To LPG and High Octane Gasoline Some Recent Contributions

43 Pitch - a precursor for various industrial/ advanced carbon materials like : Fullerenes CNT Graphene Adsorbents for chemical/ biological protective suits Binder & impregnating pitch for graphite electrodes Needle Coke for UHP graphite electrodes Mesophase Pitch for carbon fibers IIP has developed a process for making high value industrial carbon materials (Pitches) from low value aromatic rich refinery/ petrochemical streams. Technology for Making Petroleum Based Pitches

44 Petrochemicals & Speciality Chemicals Hydrocarbon oxidation Value addition to petroleum products Specialty additives

45 Technologies Commercialized Dewaxing Filter-Aid - Licensed to Dorf Ketal Adipic acid - bromine free process Isophthalic acid from m-xylene -Patents Assigned / sold to M/S ACFL

46 Technologies Ready for Commercialisation Microcrystalline wax from crude oil tank bottoms Petroleum based electrode pitches Carbon beads and fibres for various applications Pour point depressants and VI improvers Additives for fuels – Antioxidants, lubricity improvers

47 Biotechnology on Future Fuels Research Area:  Biocatalytic refining of fossil fuels  Production of bioethanol and biobutanol from renewable resources using thermophilic biocatalysts  Bioprospecting for novel enzymes and antimicrobials  Metagenomic technique for rapid and low cost oil prospecting  Environmental clean-up Petroleum Upgradation  Biocatalytic desulphurization of crude oil  Biocatalytic desulphurization of diesel fuel Bioethanol Production from Biomass Development of a process for bioethanol production at high temperature from different feed stocks comprising of lignocellulose, starch, sugar cane juice, molasses and flowers of mahua. Mission : To develop eco-friendly energy efficient technologies for the future fuels

48 Petroleum Product Applications Mass emission studies Tribology Industrial & domestic combustion

49 Fuel Efficient Technologies for Rural Area Cooking Appliances Kerosene Wick Stove  Thermal efficiency 60-63%  Oil Consumption gm/h  Fuel Saving ~ %  Technology licensed – 10 firms Kerosene Pressure Stove (offset burner type) Thermal Efficiency 60-63% Oil Consumption gm/h Fuel Saving ~15-20% Technology licensed - Under process LPG Stove Thermal Efficiency 70% Gas Consumption Large burner 75 Lt/h Small burner 63 Lt/h Fuel Saving ~ % Technology licensed - 80 firms

50 Kerosene Deva Lamp Conventional Design Improved Design Luminosity 0.22 (cd) 0.50 Luminous Efficiency 0.14 (cd/gm/h) 0.16 Kerosene Lantern Luminosity 4.90 (cd) 6.60 Luminous Efficiency 0.22 (cd/gm/h) 0.30 Luminosity 6.30 (cd) 8.80 Luminous Efficiency 0.30 (cd/gm/h) 0.40 Kerosene Table Lamp Fuel Saving %. Lighting Appliances

51 Improved Jaggery (Gur) Making Plant Main Characteristics Improved furnace and chimney system Saving in bagasse – upto 10% Increased gur production – upto 20% Better quality gur production Less smoke from chimney Increased furnace life – (8 to 10 years) Installed Near I.I.P. Dehradun

52 Crude Oil & Products Evaluation Crude assay Petroleum products testing Fuel Testing Laboratory

53 Major Clients  IOCL  RIL  ONGCL  OIL  CAIRNS  GSFC  GOVERNMENT AGENCIES

54 Fuel Testing Laboratory Govt. of India had set up EPCA for effective pollution management in NCR EPCA decided to set up a fuel testing laboratory for checking the fuel quality in NCR Laboratory at Noida was entrusted to IOC R&D & IIP Key role of IIP – framing specification, selection, commissioning & calibration of equipment Functioning of FTL – SFPL The management and operation entrusted to IIP

55 Fuel Testing Laboratory Facilities at FTL Noida FTL has all facilities, including engine tests for testing Gasoline, Diesel and Kerosene as per BIS specifications Sample collection is independently arranged More than 5000 samples have been analyzed so far since Nov. 2000

56 R&D Services Evaluation of crude oils Catalyst evaluations (Pilot / lab scale) Analytical services Performance evaluation of fuels, lubes, additives on IC engines including field trials Problem identification and providing solution to industry

57 Knowledge Based Services Technology forecasting and assessment Assistance in technology selection and absorption Preparation of project profiles / reports Techno-economic feasibility studies Process improvement and revamping Process design and scale up Training of personnel Information sourcing and services Process simulation and modelling Process integration and APC

58 Training Developing human resource for hydrocarbon and related industries has been one of the major activities of IIP since its establishment IIP has maintained its leading role in imparting training to personnel from petroleum refining, petrochemical and related industries and Government bodies

59 Over 4000 technical personnel from industry have been trained so far During , IIP imparted training to more than 1600 engineers/ managers from refining, petro- chemicals and other user industries through 70 training programmes Training

60 Training Programmes Organized Year Year Year Year Sponsored Training Programmes No. of Participants HRD Programmes (No. of Participants)

61 Training Programmes MAJOR CLIENTS:  Reliance Industries Ltd.  IOCL  Kochi Refineries Ltd.  UOP India  Essar  HPCL  Flour Daniel Pvt. Ltd., Gurgaon  MSRTH, New Delhi  NTPC

62 Support to Government Agencies for Major Policy Decisions Participation in activities of Bureau of Indian Standards Auto Fuel Policy Committee Prime Minister’s Hydrocarbon Vision 2025 National Gas Hydrates Programme National Helium Policy Road Map to Hydrogen Economy India DME Consortium Contd…

63 Carbon Sequestration Leadership Forum (CSLF) Re-refining of used Lubricants Standing Committee on Implementation of Emissions Legislation Technical Committee on Automotive Industry Standards (CMVR) Certification of Defence Lubricants Certification of CNG, LPG conversions Task Force of the Planning Commission on Bio-fuels Policy framework for Hazardous Substances Support to Government Agencies for Major Policy Decisions

64 Core Competence Catalyst and conversion processes Advanced separation processes Process development for petrochemicals intermediates, biofuels and bio-catalytic processes Development of additives and specialty chemicals Tribological studies including nano- tribology IC engine studies including emissions and alternative fuels studies

65 Core Competence (Contd.) Industrial and domestic combustion Molecular level characterization of petroleum products and related products Crude evaluation and physicochemical characterization of petroleum products Simulation, modeling and process design Advanced training in refining and petrochemicals

66 THANK YOU

67 SUPRA INSTITUTIONAL PROJECT Sector : Energy Title: To develop know-how and technology for environmental friendly conversion and utilization of biomass to fuels, lubricants and additives

68 Development of know how for eco-friendly biofuels from non-edible oils including utilization of by products. Development of know how for cost effective and clean conversion of bio mass to next generation fuels, additives and lubricants. Development of know how for gasification of carbonaceous feed stocks. Development of performance evaluation methods for bio fuels, bio lubricants and additives. Objectives

69 R & D Approach Development of Core Technologies Development of Enabling Technologies Development of Supporting Technologies

70 Development and improvement of heterogeneous catalyst for biofuel including utilization of by products for value added products. Bio ethanol production from cellulose and starchy bio mass by thermophiles To develop the process and technology for the production of liquid fuels by fast pyrolysis of bio mass feed stocks. Core Technologies

71 Core technologies ………………………….contd. Up gradation of biofuels to meet future fuel specifications. Gasification studies on carbonaceous feedstock's to produce syn gas and substituted natural gas for down stream processing. Development of technology/process for 2 nd generation fuels (green diesel)

72 Enabling Technologies Eco-friendly additives for bio-degradable fuel and lubricants. Adsorption and absorption based technologies to capture CO 2. Additives for oxidative stability of biofuels and lubricants.

73 Modeling of the value chain for conversion of biomass to fuels and lubricants. Development of methods for compositional analysis of biofuels, biolubricants and additives Long term stability and corrosion behavior of biofuels, biodiesel on engine parts. Engine performance studies on biofuels, bio- lubricants and additives Tribological studies of bio-lubricants Supporting Technologies


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