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An Insight

An Insight. INDIAN INSTITUTE OF PETROLEUM DEHRADUN. May 2009. THE ORGANISATION. Established in September 1960 by an act of Parliament To provide technical & scientific support to the entry of public sector in the hydrocarbon industry

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An Insight

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  1. An Insight INDIAN INSTITUTE OF PETROLEUM DEHRADUN May 2009

  2. THE ORGANISATION • 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 (1962-66) technical collaboration with IFP, France • One of the 37 national laboratories under aegis of CSIR

  3. 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

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

  5. 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

  6. Human Resource Base Scientific Staff (Group IV) - 74

  7. Human Resource Base Technical Staff (Group III) - 70

  8. Human Resource Base Technical Staff (Group II) - 71

  9. Technologies Licensed PROCESSES TECHNOLOGY UNIT LICENSED CAPACITY TPA 1. AROMATIC EXTRACTION BPCL, MUMBAI 97,000 (B) FOR PRODUCTION OF 17,000 (T) BENZENE(B) & KRL, KOCHI 87,000 (B) TOLUENE(T) (IIP-EIL) 20,000 (T) NOCIL, MUMBAI 90,000 (B) 110,000(T) 2. FOOD GRADE HEXANE BPCL, MUMBAI 25,000 (IIP-EIL) CPCL, CHENNAI 25,000 HPCL, MUMBAI 50,000 3. BIMETALLIC REFORMING CPCL, CHENNAI 90,000 CATALYST (IIP-IPCL) 6.2 (Cat.) IPCL,VADODARA 110,000 6.8 (Cat.) 4. CONVERSION OF LIGHT GAIL, N. DELHI 8,000 NAPHTHA TO LPG AND HIGH OCTANE GASOLINE 5.LOBS THROUGH NMP IOC, BARAUNI 400,000 EXTN. (IIP-EIL) IOC, HALDIA 350,000 Contd …

  10. Technologies Licensed PROCESSES TECHNOLOGY UNIT LICENSED CAPACITY TPA 6. DELAYED COKING BRPL,BONGAIGAON 500,000 (IIP-EIL) NRL, NUMALIGARH 306,000 7. 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, PANIPAT 450,000 HPCL, VIZAG 1,000,000 8. 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 LAWRIE 300 PHENOL (IIP) LTD, CHENNAI Contd … * Revamp

  11. Technologies Licensed PROCESSES TECHNOLOGY UNIT LICENSED CAPACITY TPA 11. Na/Ca SULPHONATE, NAL, HYDERABAD 1100 E P ADDITIVE (IIP) 12. SULFOLANE (IIP) CHPL, AHMEDABAD 300 13. HOT ROLLING OIL (IIP) LIL, MUMBAI 1,000 14. DEOILING/DEWAXING DORF KETAL CHEMICALS 30 - 40 ADDITIVE FOR INDIA LTD. LUBRICATING OIL 15. PROPANE DEASPHALTING HPCL, MUMBAI 50,000# (IIP-EIL) CPCL, CHENNAI 50,000# 16. LUBE OIL REREFINING (IIP) 65 FIRMS 20,000 17. 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 ------ 19. CONVERSION OF VEGETABLE ARMACO CONSULT. -------- OIL FEED STOCK TO ESTERS PVT. LTD., MUMBAI USING SOLID HETEROGENEOUS CATALYST Contd … # Bright Stocks

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

  13. 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

  14. FINANCIAL RESOURCE BASECSIR Grants

  15. Ongoing Sponsored R&D Projects

  16. Extra Budgetary Resources (Figures Rs. in Lakhs)

  17. Knowledge Generation (2000−2009) • Patents Filed 168 • Indian 76 • Foreign 92 • Patents Granted 107 • Indian 96 • Foreign 21

  18. Extramural R&D (2000−2009) • Doctoral Theses 39 • M. Tech. Theses 50 • Short term projects 2424 of Engineering & Science Students - Sponsored from Industry 1755 - Vocational Trainees 212 from academic institutions

  19. Advanced Separation Processes • Liquid Liquid Extraction • Adsorptive Separation • Absorption Aromatic Recovery Unit BPCL, Mumbai

  20. Commercialized Light Aromatic Extraction Technologies

  21. RE-EXTRACTION TECHNOLOGY A Low Cost Revamp Option for SO2 Based Kerosene Treating Unit, Mainly in Eastern Sector Some Recent Contributions 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

  22. 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 Lab-scale Adsorption Unit for Gasoline Desulphurization Process tested in bench scale. Technology Information Package ready

  23. Renewables • Bio fuels • Bio lubricants • Additives

  24. 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

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

  26. 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 • Additive for furnace oil for better combustion • Additive for cracked naphtha for stability THE ABOVE TECHNOLOGIES ARE PROTECTED BY INDIAN / FOREIGN PATENT APPLICATIONS

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

  28. SWEETENING FLUID CATALYTIC CRACKING NOVEL MATERIAL Catalysts & Catalysis LIGHT STOCK PROCESSING REFORMING GAS PROCESSING

  29. FEED H2 C Y L I N D E R FOR GASOLINE PRODUCTION eg. at CPCL FOR BTX PRODUCTION eg. at IPCL BURRETE REACTOR FURNACE WATER IN CONDENSER PUMP WATER OUT HIGH PRESSURE SEPRATOR WET GAS METER LOW PRESSURE SEPRATOR DISSOLVED GASES LIQUID PRODUCT INDIGENOUS IPR 2001 CATALYST HAS BEEN IN COMMERCIAL OPERATION SINCE 1991 IPR 2001 Reforming Catalyst

  30. Sweetening Sweetening is a process of extraction/conversion of mercaptans Catalyst production technology has been transferred to Lona Industries Ltd, Mumbai 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. 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. • 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 • Better Activity in LPG sweetening depicted by lesser regeneration/conversion time • Better performance than commercial catalyst at high sulfur level in the feed

  31. NTGG PROCESS Converts Light Naphtha To LPG and High Octane Gasoline Some Recent Contributions • 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 Highlights…

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

  33. Petrochemicals & Speciality Chemicals • Hydrocarbon oxidation • Value addition to petroleum products • Specialty additives

  34. 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

  35. Petroleum Product Applications • Mass emission studies • Tribology • Industrial & domestic combustion

  36. Crude Oil & Products Evaluation • Crude assay • Petroleum products testing • Fuel Testing Laboratory

  37. 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

  38. 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

  39. 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

  40. 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

  41. 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

  42. 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…

  43. Support to Government Agencies for Major Policy Decisions • 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

  44. 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

  45. 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

  46. THANK YOU

  47. 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

  48. Objectives • 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.

  49. R & D Approach Development of Core Technologies Development of Enabling Technologies Development of Supporting Technologies

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