technologies on offer by indianoil technologies ltd

Technologies on offer by IndianOil Technologies Ltd.

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Needle Coke Technology

Needle Coke is a premium grade petroleum coke, used in manufacturing of graphite electrodes for the arc furnaces in the metallurgy industry. A good quality of needle coke is hard due to the dense mass formed with a structure of carbon threads or needles oriented in a single direction. Needle coke is highly crystalline and can provide the properties needed for manufacturing graphite electrode. It can withstand temperatures as high as 2800oC. The crystallinity affects the most important properties of the graphite electrodes, i.e., the co-efficient of thermal expansion (CTE) and electrical resistivity.

Needle coke is a specialty product, manufactured by few companies in the world. Being produced by very closely guarded technology, only few countries in the world own the technology to manufacture needle coke. Availability of delayed coker units (where petroleum coke is one of the products) in its refineries, and absence of any manufacturers in India, impelled IndianOil to work for the development of needle coke technology.

By developing this novel technology and producing needle coke in its Guwahati refinery, Indian Oil has become the pioneer in India in this technology. The merits of our technology was also tested in the coker unit of Bongaigaon Refinery & Petrochemicals Limited (BRPL) through plant trial runs.

Features

The technology is primarily focused on production of needle coke in any existing delayed coker unit using available feed streams without any costly pre-treatment. Formation of needle coke requires specific feedstocks, special coking and also special calcination conditions. If feedstocks are suitable for needle coke, process conditions for coking and calcination are selected to improve the properties and yield of the needle coke. Typical yield of needle coke is 16 -25 wt% of fresh feed.

With given feed streams conforming to needle coke formation, grassroots coker unit provides additional flexibility in terms of application of special coking conditions. This in turn leads to improvement in quality and /or yield of needle coke. Technical back up for special design of the grassroots coker unit for needle coke production can be provided. Needle coke properties are strongly dependent on the feedstock characteristics. Sulfur, metals and other impurities of the feed, unless separated, would be concentrated in the coke. Presence of these in the needle coke adversely affects its price even if all other properties are adequate for a premium grade coke. This makes the quality and price of this specialty product fully dependent on the properties of streams available in each refinery.



Typical Process Conditions

• Oilivorous can be effectively employed for disposal of oily sludges generated at • Oil refineries during crude oil storage • Marketing installations in product storage tanks • Pipeline installations • Oil exploration sites

Our Back up Strength

We are well equipped with state-of -the-art facilities for conducting studies on needle coke. While coker pilot plant is used to study the process parameters for characterization of coke, we have CTE measurement facility comprising calciner furnace, pulverizer, extruder, graphitization furnace, dilatometer, etc. We also have facility to measure the electrical resistivity of coke. Economics This technology uses the low value heavier petroleum streams without any pre-treatment. Also, no revamp or augmentation of the existing delayed coker unit is necessary. Since the needle coke feedstock blend is different from the usual coker feedstock, in case of capacity limitation, the utilization of the coker unit for the purpose of secondary conversion may get reduced. The technology addresses this point and ex-refinery distillate yield is maintained. Therefore, virtually, there is no additional cost for producing needle coke and the ex-refinery profitability will improve due to its higher price. Implementation Approach

• Integrated survey of the refinery configuration and identification of streams suitable for needle coke production.

• Examining the properties of the identified streams for exploring the preliminary feasibility for going ahead with the project.

• Comprehensive study on design of the existing hardware and the possible feed streams to finalize the feed blend and process conditions.

• Confirmation of feed blends and coke quality in delayed coker pilot plant run. • Establishing the feasibility of needle coke production in commercial scale.

INDMAX A Technology for Residue Upgradation & LPG / Light Olefins Maximization Refinery profit margins are shrinking due to rise in crude prices, stringent fuel specifications and increased competition. Value addition to the existing processes and adoption of innovative technologies has become essential for a refiner to stay ahead in the refining business. On the other hand, the demand of heavy ends e.g. furnace oil, LSHS (Low Sulphur Heavy Stock) is limited with annual growth of about 2% and many refineries are not fully equipped with modern residue up-gradation processes. We have developed a patented technology named



“INDMAX” to produce Liquefied Petroleum Gas (LPG) from heavy petroleum fractions to the extent of 40 to 65 wt% of feed. The LPG is highly olefinic (>70 wt% of LPG) rendering the INDMAX process as the best suitable technology for producing propylene and butylenes from heavy petroleum fractions including residue. Due to the very high olefinicity, the INDMAX LPG has significant petrochemical value. INDMAX INDMAX process is similar to Fluid Catalytic Cracking (FCC) technology except that the catalyst system and operating conditions are different. Major highlights of the process are:

• High LPG yield (40-65 wt% of fresh feed). • High propylene yield (17-25 wt% of fresh feed) and high butylene yield (20-28 wt% of

fresh feed). • Feed CCR ranging from 0.35 to 5.0 wt%; Type VGO, RCO and SR. • Use of specific proprietary catalyst with low coke make, to manage with a single stage

regenerator without any catalyst cooler. Catalyst for INDMAX

INDMAX employs a proprietary catalyst, which has three different functional components. The bottom-cracking component provides highly acidic sites for catalytic cracking of heavy feed molecules, which otherwise lead to coke and dry gas formation. The component responsible for upgrading naphtha range hydrocarbons is shape selective in nature, which allows selective cracking to light olefins without increasing the coke and dry gas make. The third component contains conventional ultra-stable Y zeolite, which shows synergistic effect with the other two components of the catalyst.

With the optimum catalyst formulation, very high catalytic conversion, LPG and light olefin yields are ensured, while making the lowest dry gas and coke yield.

INDMAX catalyst demonstrates an exceptionally high Vanadium tolerance (21000 ppm on Ecat), which is twice that of a conventional RFCC catalyst.

Features of INDMAX

• Yields higher LPG and light olefin due to the excellent dry gas and coke selectivity of the proprietary catalyst.

• Improved coke selectivity permits a very high cat/oil ratio (15-25), as compared to the other state of the art processes.

• Employs higher riser temperature (560ºC), and a relatively high dilution steam rate (15-20 wt% of feed) to get high catalytic conversion.

• The high steam rate in the riser allows to minimize the hydrocarbon partial pressure which, among other things, also helps in (a) lowering the rate of coke formation, (b) increasing the olefinicity of products by minimizing the hydrogen transfer reactions, and (c) increasing the heat demand in the riser.



• Significantly higher catalyst to oil ratio provides a very efficient heat transportation from the regenerator to the riser and produces a lower delta coke on catalyst.

• The lower delta coke results in a significantly lower regenerator temperature, which provides additional flexibility for resid processing in the new process. In fact, the heat circulation in the INDMAX reactor/ regenerator is so efficient that the unit can process up to 4 - 5 wt% CCR feedstock in a single stage total combustion regenerator without catalyst cooler.

Process Conditions & Yields The important process conditions and yields of INDMAX process are summarized below along with those of conventional FCC unit. INDMAX comparison with FCC Process FCC INDMAX Feed Properties Density, gm/cc 0.89 0.872 RCR, wt% 0.30 0.253 Product Yield, wt% (Fresh Feed) Dry Gas 2.9 6.1 LPG 12.1 50.4 Gasoline 31.2 19.4 Diesel 40.0 12.1 Bottom 8.3 5.5 Coke 5.5 6.4 Light Olefin Yield, wt% (Fresh Feed) Propylene 3.6 21.2 Iso-butylene 1.2 6.1 Total Butylene ---- 24.7 Typical Operating Conditions Reactor Top Temp, ºC 490-510 550-570 Regen Temp, ºC 650-730 670-700 Cat/ Oil Ratio 4-7 15-25 Reactor Pressure, Kg/cm2 ,abs 3.0-3.5 2.4-2.6 It is seen that INDMAX process gives very high LPG and light olefin yield with lower gas/ coke make. The cat/ oil ratio is also very high in the INDMAX. Potential customer of INDMAX

• Refineries with high demand of LPG and propylene/ butylenes with lower diesel requirement.

• Refineries integrated or planning to integrate with downstream petrochemicals for exploiting the higher yield of propylene/ butylenes.



• Refineries where residues, preferably with high hydrogen content and low CCR/metals and /or especially having hydrocracker bottom are available.

Our Back up Strength Backed by a strong R&D with state- of- the- art facilities for characterisation and performance evaluation of FCC catalysts and additives, IndianOil is well equipped to give precise solutions to our customers’ requirements. The Important facilities available with us are:

• Four Automated MAT units • Three FCC Pilot Plant • Two Steaming Units • Characterization equipments include ABD, PSD, SA, PV, TA/TGA, TPD, RGA, SDA,

PNA Octane analyzer etc. • Kinetic based FCC process simulation model FCCMOD. This model has been

extensively used to study the interaction among process variables in the INDMAX process. Among other things, FCCMOD has unique ability to predict commercial plant performance based on the micro reactor data generated for any new feed or catalyst.

Economic Feasibility Typical IRR amounts to about 17% without olefin recovery and 35% with olefin recovery. Implementation Approach

• Detailed analysis of different residue streams of the refinery and their availability. • Determination of the desired product slate i.e. LPG/Gasoline ratio. • Establishing the requirement with down stream integration i.e. whether the propylene/

butylenes separation to be included or not. • Performing a scoping study of the project. The scoping study will include the product

yield, quality estimates and equipment required for the entire unit. • Preparation of cost estimate for establishing the techno-economic feasibility of the

project. • Preparation of the project proposal and subsequent design package.

i - MAX FCC Catalyst Additive for boosting LPG Yield World over refinery margins are shrinking and there is increasing emphasis on profitability. To help refiners to meet this challenge, we have developed a ZSM-5 based FCC catalyst additive formulation “i-MAX” to boost the yield of Liquefied Petroleum Gas (LPG) in FCC units. In addition it also promotes an increase in gasoline octane number with decrease in bottom yield. ZSM-5 zeolite is the active component of LPG boosting additive formulations. ZSM-5 additives are widely used in refineries worldwide. Large numbers of such additives are available in the international market.



However, use of the commercial additives result in higher bottoms yield due to dilution effect and lower bottom conversion. Keeping in mind the limitations encountered with commercial additives, developmental work was taken up at IndianOil R&D Centre focusing on improved utilization of ZSM-5 zeolite for higher LPG yield and incorporation of matrix for up-gradation of bottoms. This research project culminated in the successful development of i-MAX additive. i-MAX Technology i-MAX technology developed by IndianOil R&D Centre

• Boosts LPG yield in FCC/ RFCC units (2.5-3.6-wt%) at a concentration of only 5-wt% on catalyst.

• Increases gasoline yield. • Decreases bottom yield by 0.7-1.5-wt%. • Increases octane number of gasoline.

The results of plant trial of an Indian FCC unit showed that with i-MAX additive, an improvement on LPG yield is achieved by bottom up gradation. The advantages of i-MAX are due to improved dispersion of ZSM-5 zeolite and judicious mix of matrix composition at the stage of formulation. Also the good attrition strength of the additive is due to better binding technique developed at IndianOil R&D Centre. Performance of i-MAX The i-MAX additive has gone through rigorous testing at lab scale, pilot plant scale and commercial plant trial. At all levels of testing, it has successfully demonstrated its performance. Lab Performance : At constant conversion & 5 wt% i-MAX Conc. :

• Dry gas – No change • LPG yield- Increases • Propylene yield-Increases • Coke- Decreases • At constant coke, CLO yield- Decreases • Selectivity of propylene is 27-35 wt% of LPG • Selectivity C4 olefins is 31-36 wt% of LPG



Commercial Plant Performance

LPG Increases by 2.5 – 3.6 wt% Gasoline Increase in Gasoline yield Bottom Decreases by 0.7 – 1.5 wt% Coke No Change

Potential customer of i-MAX

• Any refinery with existing FCCU/ RFCCU with high LPG demand. • Refineries integrated or planning to integrate FCCU with downstream petrochemicals

for exploiting the higher yield of propylene/ butylenes. Our back up strength IndianOil R&D Centre is well equipped with state of the art testing facilities for FCC catalyst and additives. These facilities are used for evaluation of physical properties and performance of



fresh and equilibrium FCC catalyst and additives. Having a well-furnished catalyst development laboratory with spray dryers, crystallizer, mixing vessels, we have developed and demonstrated many formulations of FCC catalysts and additives. We also have facilities for developing NaY zeolite, ZSM-5 zeolite at lab scale and pilot plant scale. In addition, IndianOil has also developed a kinetics based FCC process simulation model (FCCMOD) which is used for performance prediction of FCC catalyst and additives based on micro reactor data generated for any new feed or catalyst. This proprietary process simulator has also been used for predicting plant performance of i-MAX additives. INDE Treat and INDE Sweet H2 S / Mercaptan Removal and Sweetening Process Technologies Today's refiners have to cope with relentless pressure on profitability due to high operational costs and increasing environmental demands. The Continuous Film Contactor (CFC) is a novel mass transfer device, developed jointly by IOC R&D and EIL, offers a solution for effective removal of undesirable compounds at lower costs. The lighter petroleum fractions and products contain many unwanted components such as sulfur compounds and naphthenic acids, which need to be removed due to their foul odour and corrosion tendency. CFC is the heart of INDE Treat and INDE Sweet technologies and it can remove:

• H2S from LPG, Naphtha & Gasoline • Mercaptans from LPG, Naphtha, Gasoline & ATF/ Kero • Naphthenic Acids from Diesel • Acid Gases from Natural Gas, Fuel Gas • Regenerate Spent Caustic, if required

CFC Technology

• This novel contactor is non-dispersive as contacting occurs between two laminar films of the phases involved. This contacting is achieved by specially treated thin wire bundles over which the two phases flow.

• The distributors involved in distributing the two liquid phases are critical. A novel and patented two-stage distributor distributes the aqueous caustic phase on the thin wire bundles and organic phase between the interstitial spaces.

• The liquids coming out of the contactor are collected in a vessel, which separates the two phases, by gravity into lower aqueous and upper organic phases.

Salient Features of CFC are

• Non - Dispersive contacting • Enormous surface area • High mass transfer efficiency • Based on caustic/ amine • Efficient removal of contaminants • Small size • No aqueous phase entrainment • Low caustic /amine consumption



• Low cost • Can be easily retrofitted in existing mixer -settler units • This patented process technology is way ahead of the existing technologies in many

ways: • Low energy consumption due to mixing at low-pressure drop. • Efficient contacting. • Efficient separation of hydrocarbon and aqueous streams (no caustic carryover). • Higher hydrocarbon to caustic ratio so smaller caustic circulation is required. • Less settling time, hence smaller settler.

Our Back up Strength In today's competitive world, survival demands excellence. Excellence in turn requires more precise knowledge and evaluation. Backed by strong R&D, we are ready to provide solutions, which suit our customer's needs and constraints. Our strengths include;

• Pilot plant data for optimized design / performance • Grassroots design capability • Existing unit revamp capability • Caustic Regeneration facility, if required • Process technology • Commercial experience

Implementation Approach

• Detailed analysis of different product streams to be treated from refineries. • Determination of the desired product quality. • Establishing the requirement of treating along with integration with existing facilities. • Determination of whether spent caustic regeneration is required. • Generating the data for treating and caustic regeneration in pilot plant, if required and

establishing operating conditions for the particular application. • Preparation of cost estimate for establishing the techno-economic feasibility of the

project. • Preparation of the project proposal and subsequent design package.

OiliVorous-S Technology for Disposal of Oily Sludge-Bioremediation Oily Sludge: The Problem Oily sludge, generated by oil refining industry, is notified as hazardous waste and its management and safe disposal pose major challenge for refiners. The sludge comprises hydrocarbons, soil, sand, metals and water etc., which get accumulated over time in storage tanks and pose several environmental and operational problems for grassroots refineries.



As a conservative estimate, a refining capacity of about 100MMTPA generates about 20000 metric tons of oily sludge per year and its disposal in environmentally sound and cost effective manner is a must. The conventional option of oily sludge treatment in refineries includes subjecting the sludge to melting pits and/ or hot oil circulation in tanks and the de-oiled sludge is mostly land filled or put in secured pits. This approach is costly and does not provide an environmentally effective solution to such a perennial problem. Bioremediation The Remedy Biological agents, usually bacteria and fungi, can be utilized to reduce/eliminate oily sludge. These microbes either eat up the contaminants (mostly organic compounds), or assimilate them (heavy metals) and lead to efficient cleanup of the contaminated site. This intervention - bioremediation - has been in use since 1970's and has acquired global acceptance. OiliVorous –S OiliVorous -S Technology is a joint development of IndianOil R&D and TERI The Product OiliVorous-S is a blend of five specific microbes selected to biodegrade a wide range of hydrocarbon contaminants of oily sludges. The large-scale production of these microbes is done under stringent conditions of quality check and final blend of microbes is adsorbed on a naturally occurring biodegradable carrier matrix to facilitate its dispersion during use and ease in transportation. Product Attributes OiliVorous -S

• Consists of "Natural Bacterial Isolates and Not Genetically Modified" • Safer to handle, no disease causing organisms • Has excellent capability to degrade wide range of hydrocarbon contaminants including

organosulfur compounds • No environmental side effects

Application Areas OiliVorous-S Can be effectively employed for disposal of oily sludges generated at

• Oil refineries during crude oil storage • Marketing installations in product storage tanks • Pipeline installations • Oil exploration sites



IOC(R&D) Capabilities and Services OiliVorous -S Technology Service for bioremediation of oily sludges is offered jointly by IOC(R&D) and TERI. IndianOil R&D Centre has state-of-the-art facilities and expertise for analytical and biological evaluations needed for management of bioremediation programs at client's locations. OiliVorous-S is the registered trademark of IOC (R&D) and TERI Material Engineering Services Introduction We have developed a full range of services in the area of material failure analysis, remaining life assessment and fitness for service assessment to suit the needs of diverse clients. We apply both classical engineering methods and advanced technologies towards a goal of providing our customer better and most cost effective solutions. Our full ranges of services are: Material Failure Analysis

• High temperature failure • Metallurgical degradation failure • Corrosion/environmental assisted cracking failure • Fatigue failure

Remaining Life Assessment

• Component specific for critical equipment • Component specific methodology development

Fitness for Purpose Analysis

• Fracture mechanics application • Engineering critical assessment

Onsite Condition Monitoring/Fire Damage Assessment

• Field hardness testing and replication • Metallurgical degradation studies • Positive material identification • Conventional non - destructive testing • Field inspection of critical equipment



Tailor made Training Programs

• Material failure analysis • Remaining life assessment • Metallurgy for non-metallurgist • Software on remaining life assessment • Material selection

Equipment Our laboratories are fully equipped with advanced mechanical, metallurgical corrosion testing related equipment. Special facilities available include

• Scanning Electron Microscope with EDAX attachment • State of the art Optical Microscope with image analysis system • Servo-Hydraulic Universal Test Machines • Direct Reading Spark Emission Spectrometer • Corrosion Inhibitor Testing Facilities etc. • Portable kits Include: A) Metallography Kit B) Hardness Tester C) Alloy Analyzer D)

High Temperature Thickness Measurement Meter Software /Data We have developed software for predicting remaining life and assessing mechanical integrity on offered service basis. These include

• RLA / FFP software for pressure vessel life prediction • RELIF- Boiler component life prediction • CLIP- Creep life prediction • RLAHT- Heater tube life prediction

We have generated several databases required for both life assessment and condition monitoring activity.

• Virgin microstructure data of refinery components • Degraded microstructure data, high temperature mechanical property and creep

property data of service exposed components • Fracture mechanics based mechanical property data

Technical Manpower Our technical manpower hold advanced academic degrees in a score of engineering disciplines of metallurgy and mechanical engineering. Our staff with ISNT / ASNT certification in conventional NDT techniques and with essential hands-on experience have the capability to deliver integrated and cost-effective solutions. They have the ability to handle any situation and will remain in support until you see the benefits.



We have set benchmarks in several areas of expertise including predictive failure analysis, remaining life assessment etc. Our mission is to provide accurate failure diagnostics, reliable recommendation and complete testing service. Brief Description Material Failure Analysis: Conduct root cause analysis of failure on a wide variety of equipment and structures using state of art metallurgical laboratory. In this activity, we determine how and why equipment or a component failed thorough systematic investigations involving laboratory tests as well as review of operational history. Implementable recommendations are given for avoiding the recurrence of failures. On-site Condition Monitoring: The study involves generation of present material health of the equipment through in-situ metallography, hardness survey, down time & online thickness survey, alloy analysis and conventional NDT. Such studies are often undertaken for high temperature components (Operating above 400 C) such as furnace tubes, critical pipings, reactors, vessels etc. A periodic generation of data on the material health of the equipment can help in a) Increasing in plant efficiency & productivity by avoiding of premature failures, b) Predictive maintenance and replacement planning and c) Safer operation Remaining Life Assessment & Fitness For Purpose Evaluation : The activity involves qualitative / quantitative prediction of remaining useful service life of equipment that have either surpassed their design life or have undergone mal-operation during their normal service. Depending on the criticality of operation studies are conducted to varying levels that may or may not involve lab. studies on cut samples. The study varies from a simple on-site review of history & data card of the equipment to laboratory accelerated simulation studies on cut samples ex. ASRT, IGSCC etc. The deliverables are :

• Decisions to run, repair, replace the equipment • Setting up of equipment inspection intervals • Remaining useful life of the equipment under given operating conditions

Fire Damage Assessment Assists plant management in restoration of fire affected plant in shortest possible time for static equipment and pipings

• Quick assessment of the extent of damage • Identification of component requiring replacement • Certification of component that can be reused • Supervision during restoration



Who should approach us?

• Refining Industry • Petrochemical industry • Oil & gas industry

Our Esteemed Customers We have already rendered services in Material Failure Analysis, Remaining Life Assessment and Condition Monitoring activity to Indian Oil Corporation, Kuwait National Oil, Corporation. Chennai petroleum Corporation Limited (CPCL), Bharat Petroleum Corporation Limited (BPCL), Mangalore Refinery and Petrochemical Limited (MRPL) Numaligarh Refinery (NRL), Engineers India Limited (EIL), Indian Petrochemical Limited (IPCL), Bongaigaon Refining and Petrochemical limited (BRPL) and National Thermal Power Corporation (NTPC). Servo - DS®

Novel Stabilizer for Distillate fuels Trade Name SERVO-DS®

Product Description Servo-DS is an effective diesel fuel stabilizer with synergistic combination of patented chemistry backed by IndianOil R&D technology and established as a high performance stabilizer for improving the stability of fuel having cracked streams from FCCU's, Cokers, Vis-breakers and Pyrolysis processes. The antioxidant property of Servo-DS also provides maximum sludge and sediment control and good colour stability. Features

• Patented synergistic formulation • Free flowing liquid - easy to handle • Completely soluble in distillate fuels. • Excellent sediment control • Excellent oxidation inhibitor of distillate fuels • Efficiently controls filter choking • Good high temperature stability • Water insoluble under normal handling conditions.

Performance Excellent performance in:

• ASTM D-2274 • ASTM D-4625



• UOP-413 • Du Pont F-21-61 •

Applications

• Servo-DS imparts better HSD stability. • Servo-DS may be directly applied into the run down line from the production unit by

means of a proportioning pump. • Servo-DS can also be added to storage tanks, tank cars and pipeline or blending tanks.

Recommended Dosage Treat rate of Servo-DS will vary with the nature and severity of application. The dose rate depends on the desired level of oxidation stability and composition of the fuel. Typical Properties Form Liquid Colour Colourless to Straw Yellow Specific Gravity, @ 15.6ºC 0.87 - 0.89 Flash Point 45ºC (Abel) Viscosity @ 40ºC 1.5 - 2.2 cSt Blending Servo-DS is readily soluble in HSD and other distillate streams at relatively low temperatures. Users may also prepare stock blends by dissolving Servo-DS in any of the diesel blending stream for accurate and low treat level of the product. Benefits

• Backed by IndianOil R&D technology • Follow up and trouble shooting thru' expert technical support. • In-plant optimisation of Servo-DS improves shelf life of fuel both during storage and in

use. • Optimal use of Servo-DS minimizes the treat cost.



Handling

• Keep away from heat, sparks and open flames. • Keep container closed after use. • Use the product with adequate ventilation. • Observe the warning labels on product container. • Other normal precautions for chemicals apply.

Health Information

• Avoid breathing vapours and contact with skin, eyes and clothing. • Wash thoroughly after handling. • In case of eye contact, immediately flush with plenty of water for at least 15 minutes. • Flush skin with water • Call a physician.

Packaging Servo-DS is available in 190 kg MS drums. INNOVA-LI Diesel Fuel Lubricity Improver The Need

• The sulfur level in diesel is being brought down due to environmental reasons • Lowering of sulfur by hydroprocessing leads to removal of certain polar compounds

from diesel which are associated with deterioration of lubricity of diesel • Equipment can be designed for low fuel lubricity, but sufficient lubricity is required for

existing equipment • Lower fuel lubricity can cause failure in injection pumps

The Solution

• The lubricity improver Innova-LI developed by IndianOil is a convenient way to restore lubricity in ultra low sulfur diesel.

The Test

1. High Frequency Reciprocating Rig Test (HFRR)

Wear scar diameter (WSD) at Temp.60 C, Time 75 min, 2N Load, Amp.1mm, Freq. 50Hz. is the measure of lubricity performance of the lubricity additive in low sulfur diesel fuel



2. Performance Requirements of Lubricity Additive Innova-LI {No Harm Test} Antagonism with Engine Oil

Wear scar diameter (WSD) at Temp.60 C, Time 75 min, 2N Load, Amp.1mm, Freq. 50Hz. is the measure of lubricity performance of the lubricity additive in low sulfur diesel fuel

(Method A) Fuel additive +engine oil (TBN 10-12) + fuel blended in ratio of 1:2:20 and kept at 50 C for 4Hrs. (Method B) Fuel additive + engine oil blended in ratio 1:1v/v and kept at 90 C for 72hrs. A portion of mixture then dissolved in fuel in ratio of 1:25v/v. Checked the visual appearance of sample, filtration rate and amount of sediments by filtering 100 ml portion of mixture through 0.8-micron filter paper.

APPEARANCE FILTRATION TIME (sec.)

SEDIMENTS (g)

METHOD 'A' Clear, transparent 40 0.0024 METHOD 'B' Clear, transparent 42 0.0020 The Performer INNOVA-LI A Diesel Fuel Lubricity Improver

• Excellent lubricity performance (HFRR) • Good No Harm performance7



• Biodegradable source • Good storage stability • Recommended dosage 60-100 ppm depending on lubricity of base diesel fuel

Typical Properties

S No. Specifications Value 1. Appearance Liquid 2. Color Amber colored 3. Boiling Range >200ºC 4. Acid value 180-195 5. Odour Faint odour 6. Density at 20ºC 0.90-0.92

Available Forms / Packaging Available in rail tank wagon, road tank wagon HDPE/ steel drums of about 193 Kg net Handling and Storage

• Keep away from heat, spark and open flames. • Keep container closed after use. • Use product with adequate ventilation. • Observe warning label on product container • The recommended additive storage temperature is >20ºC

Health Information

• Avoid breathing vapours and contact with skin, eyes and clothing. • Wash hands thoroughly after handling. • In case of eye contact, immediately flush with plenty of water for at least 15 minutes. • Flush skin with water • Call a physician

SERVO®-AO Novel Antioxidant for Gasoline Trade Name SERVQ®'-AO Product Description SERVO®-AO is a synergistic combination of patented aminophenolic chemistry backed by IndianOil R&O technology and established as a high performance antioxidant for



preserving various types of modern gasoline blends, including thermally and catalytically cracked components from FCCUs, Cokers, Vis-breakers and Pyrolysis processes. Features Patented in India & USA

• Free flowing liquid -easy to handle • Excellent gum control • Provides excellent oxidation stability and maximum storage life for all types of gasoline

streams • Performance Excellent performance in :

• ASTM 0-873(Modified) • ASTM 0-525 • ASTM 0-381

Applications SERVO®-AO is injected directly into the gasoline streams Recommended Dosage Treat rate will vary with the nature and severity of application. The dosage rate depends on the desired level of oxidation stability and composition of the fuel. Typical Properties Physical State Liquid Appearance Dark Red Sp. Gr @15.6°C 0.90 -0.92 K. V. @38°C, cSt 25 -30 Flash Point,°C min 50 Blending :SERVO®-AO is readily soluble in gasoline and distillate streams at relatively low temperatures. Users may also prepare stock blends by dissolving SERVO®-AO in aromatic rich stream for accurate and low treat level of the product Benefits :

• Follow up and trouble shooting through expert technical support. • In-plant optimisation of SERVO®-AO shall improve shelf life of fuel both during storage

and in use • Optimal use of SERVO®-AO shall minimize the treat cost • Backed by IndianOil R&D technology • Packaging SERVO®-AO is available in 190 kg MS drums

Technological Services in Hydroprocessing What we offer

• Optimisation of hydroprocessing units through pilot plant experimentation and application of mathematical models



• Maximization of yield of desirable product slates • Performance improvement through: • optimisation of operating conditions I • Maximum utilisation of existing catalyst system

• Troubleshooting of hydroprocessing units

• Improvement of product properties • Assistance in solving abnormal behaviour in the units

• Assistance in selection of new catalyst system and / or process technology through pilot plant evaluation, physico-chemical characterisation, modeling and simulation etc.

• Catalyst remaining life assessment and unit performance monitoring studies • Detailed characterisation of feed and product streams • Quality check-up of procured catalysts • Micro-Reactor Unit • Catalyst loading/unloading, reactor start up and shut down procedures • Process feasibility • Pilot plant design and assistance in installation and commissioning

The Tools State-'of-the-art pilot plants of different scales and configurations operated by expert manpower having rich experience in handling high pressure and Hydroprocessing Pilot Plant temperature sophisticated applications in hydrogen environment. Catalyst Characterization Facilities

• Adsorption and Chemisorption Units • Atomic Emission Spectrometer • Mechanical Properties Evaluation Units • Temperature Programmed Desorption/Reduction • X-ray Diffractometer • Scanning Electron Microscope (SEM) • Thermal Analysis Unit (TGA, DSC, DTA) • Electron Spectroscopy for Chemical Analysis (ESCA) • CHNS & CS Analyser • Diffuse Reflectance-UV VIS • Microcalorimeter

Feed / Product Characterization Facilities

• Sulfur and Nitrogen Analyzer • SIMDIS and HTSIMDIS Units • Refinery gas analyser • GC-Sulfur Chemiluminiscence Detector • GC-MS



• High Performance Liquid Chromatography Unit • NMR spectrometer • X-ray Fluorescence (XRF) • Inductively Coupled Argon Plasma Unit • Other Measurements (Pour point, density, moisture, TAN, TBN, Mercaptans, RON etc.)

Process Models IOC R&D has developed various proprietary process models for hydrocracking, DHDS, Catalytic Reforming, etc. based on process chemistry and kinetics. These mathematical models are complementary to pilot plants. These are used for interpretation of pilot plant data and scale-up applications as well as for estimation of kinetic and deactivation parameters for different catalyst systems. Services Rendered In the Recent Past

• Troubleshooting of hydrocracker unit for obtaining design conversion at design throughput

• Optimization of hydrocracker units for maximization of middle distillates • Studies for maximization of LPG through application of novel catalyst system • Troubleshooting of DHDS unit • Selection of hydrocracker catalyst system for existing as well as grassroots refinery • Selection of DHDS catalyst system • Catalyst health assessment and performance monitoring for several hydrocracker units

Instrumental Pig (IPIG) Introduction Instrumented Pig is a device for inline inspection of buried pipelines to monitor their health and assess the risk associated with their operation. Currently, only very few companies like PI I, Rosen etc. provide these inspection services to pipeline operations world-wide. How It Works

• Instrumented Pig travels with the propelling force of the fluid being pumped through the pipeline. While traveling inside the pipeline the on board data recording systems record the defect data, sensed by the sensors touching the internal surface of pipe wall.

• After data analysis, the data on external and internal defects are reported with a fairly good accuracy with respect to defects sizing and location for a long distance pipeline.

• On the basis of this data the pipeline operator can take appropriate corrective measures depending upon the severity of the defects.



Principle of Operation

• Instrumented Pig works on the principle of Magnetic Flux Leakage (MFL) and detects the mechanical defects by sensing the change in flux near the pipe wall under the influence of applied magnetic field.

• The change in magnetic flux signal depends on the extent and type of metal loss, changes in material and its magnetic properties.

12"IPIG

• IndianOil and BARC have jointly developed 121/ size instrumented Pig based on MFL principle.

• Instrumented Pig has been extensively evaluated in Wet Test Loop specially designed and developed for testing of such tools under actual pipeline simulated conditions, at IndianOil R&D Centre.

• The developed Instrumented Pig has also been tested in one of our field pipeline.

Wet Test Loop The Wet Test Loop is a 12-inch diameter, 120m long pipe loop having various pipe fittings such as MOV's, bends, tee's etc. It also has pipe spools having internal as well as external defects of various dimensions. The test loop has the flexibility of once through and continuous operation and can be operated at various flow rates. Extensive Field Trials in M-A Section of BKPL Several field trials have been carried out, in 162 Km- long Mughalsarai-Allahabad section of BKPL. The performance of 12"IPIG with respect to mechanical negotiations, defect data capturing and analysis of defect sizes in terms of their size & location are commendable. The IPIG is commercially available to inspect 12" size aging pipelines. IPIG developed jointly by IOC & BARC Engine and Tribotesting This specialized and state-of-the-art facility has been the backbone of A&D Centre since inception. The facilitiss are broadly classified into three areas:

• Engine testing • Tribological evaluations • Metal working fluid testing

Engine Testing Laboratory offers expertise in the following fields

• Lube and fuel evaluation



• Development of in-house test methods and engine optimization

Lube and fuel evaluation: Different types of engines representing the whole segment of Indian automotive industry like TATA, Leyland, Maruti etc. and also international standard test engines to carry out various tests like Petter AV 1, MWM, CAC L 38, JASO etc. are installed. As the test benches are computer controlled, the whole test can be programmed for automatic data acquisition and control. Performance level of oils up to ILSAC GF 3 can be tested. Exhaust emission measuring facility using palletized test benches have been created so that different types of engines can be evaluated with ease. Diesel engines and gasoline engines up to 160 KW capacity can be tested. Development of in-house test methods and engine optimization: Specific lube related engine problems have been addressed in the past using indigenous test methods. These have become valuable tools for lube oil development, as these tests are much cheaper than internationally specified tests. Customised homologation and endurance tests can also be carried out for engine component optimization and durability using the state-of-the-art facilities. Tribological Evaluations Tribotesting on simulated rig test benches are used for the evaluation of lubricants over a wide range of test conditions such as load, speed, temperature and type of material. These are evaluated with respect to their friction, wear, scuffing, pitting and fatigue characteristics. Most of these rig tests have been standardized that are related to the performance of lubricants in specific applications and are included in many national and international specifications. The greatest worth of these tests is in terms of their use as a screening tool giving directional indication of what can be expected when a lubricant is applied in service in a specific application. These test rigs can also be used for quality control of the lubricant and to diagnose any field problem. In the recent past a ten stand bearing fatigue test rig has been developed which only a few companies in the world have access. This rig is capable of studying the effect of lubricating oil additives on fatigue life of rolling element bearings. The fatigue failure is detected by a precision SPM system. Design, development and fabrication of special purpose custom made tribological test rigs at competitive cost can be taken up by the laboratory. Metal Working Fluid Testing Metal working fluid testing offers its expertise in the evaluation of the following:

• Metal cutting oils



• Metal forming oils • Quenching oils • Automotives coolant and gear oil

Consultancy Services Engine and Tribotesting facilities created over the years have provided a rich experience and this has given us the confidence and capability to take up consultancy jobs for imparting training and setting up of such facilities. Maximisation of LPG yield in FCC unit IndianOil's Research and Development Centre widely recognized as a centre of excellence in petroleum technology has developed considerable expertise in enhancing the LPG yield by process optimization, catalyst selection and revamp of FCC units. Being a pioneer in the world to evaluate the ZSM-5 additive for distillate mode FCC units and subsequent plant trials in many Indian FCC units, IndianOil has valuable knowledge to share with our customers to maximize LPG yield. Significant improvement in the yield of LPG and propylene is possible by adding ZSM-5 additive in the system even at low concentration (0.5%). Scoping studies conducted by IndianOil R&D Centre at Indian FCC units indicated an increase in the yield of LPG from 10-20% to 25-25 wt % of feed and propylene from 4.5 wt% to 12 wt % of feed. LPG Maximization in FCC/RFCC can be achieved by:

• Adapting a suitable catalyst additive • Selecting a base catalyst that helps higher LPG yield • Optimizing the unit severity by de-bottlenecking the unit limitations for enhancing the

catalyst circulation • Adopting appropriate measures to minimize dry gas formation and to generate cushion

in the unit • Optimize process condition

Our Back, up Strength Backed by a strong R&D with state of the art facilities for characterisation and performance evaluation of FCC catalysts and additives, IndianOil R&D Centre is well equipped to give precise solutions to our customers' requirements. The important facilities available with us are:

• Automated MAT Units • FCC Pilot Plants • Steaming Units • Characterization equipment include ABD, PSD, SA, PV, TNTGA, TPD, RGA, SDA, PNA

Octane Analyzer etc. • Kinetics based FCC Process Simulation Model FCCMOD.

This model is used for performance prediction of FCC catalyst and additives, based on micro reactor data generated for new feed or catalyst. This simulator is very useful in performing



various scoping studies for increasing the LPG yield. The model is also useful for verifying the design adequacy of the major equipment in the unit. Benefits

• Maximization of LPG yield without any major revamp in the RFCC unit • Maximization of LPG with wet gas compressor capacity augmentation. A typical- study

for a 0.7 MMTPA RFCC unit shows that LPG yield can be increased from current level of 10-20 wt% to 25 -35 wt% of feed.

• IndianOi1 provides necessary technology for major revamp of FCC units with additional throughput increase along with the maximization of LPG or to fulfill other common objective of a normal revamp.

Implementation Approach

• Performing microreactor studies with FCC feed streams and catalyst plus ZSM-5 additive at different concentration levels. Use of FCC simulator will be made to predict the plant performance at different ZSM-5 concentrations.

• Conducting scoping study of the project including the optimization of process parameters and catalyst selection. Design adequacy of the reactor regenerator section, fractionator and gas concentration section will also be verified.

• Performing optimization studies for generating additional cushion in wet gas compressor and air blower.

• Preparing a revamp proposal including the cost estimate for establishing techno-economic feasibility of the project.

• Preparing design packages and project execution.

Novel Models / Simulators for Refinery Processess FCC-MOD Features and Capabilities

• A rigorous model based on four lumps cracking reaction kinetics and first principles • Consists of models for all sections of FCC process • Model has been validated extensively with industrial plant data • Model capable of predicting the plant performance for wider range of feed quality and

operating regimes • Model can be used for various applications such as

• Optimization of commercial plant performance for new catalyst/additive evaluation

• Day to day monitoring of FCC unit • Minor hardware revamp study

• Real time applications



• Throughput maximization in one of IndianOil FCC unit keeping conversion constant

• New catalysts selection on regular basis for Indian Oil FCC units • Hardware revamp study for non IndianOil FCC units

HC-MOD Features and Capabilities

• Rigorous hydrocracking kinetic model based on continuum theory of lumping approach • Configured for once through and recycle HCU • User friendly GUI • Estimation of effect of all critical feed properties, changing operating conditions, etc. on

yield patterns and Reactor's CAT • Preliminary profitability calculations • Preliminary deactivation module

Applications

• Simulation studies for process optimization, i.e. selection of optimum operating parameters for maximization of desirable product slates

• Commercial hydrocracker units troubleshooting • Effect of changing feed mix or feed properties on the operation of commercial unit • Data generation for tuning of LP model • Catalysts' health and remaining life assessment • Day to day performance monitoring of unit • Improving the conversion in commercial hydrocracker unit • Licensor failed to solve problem of negligible conversion in 2nd stage of a two stage

recycle hydrocracker unit which the above model could solve

REF-MOD Features and Capabilities

• Rigorous and simplified reformer models are available for SR and CCR type reformer units

• Plant performance optimization, monitoring and trouble shooting • Realistic octane number prediction • Accurate prediction of benzene in reformate • Catalyst activity and life prediction for specific cycle • Decision making tool for overall unit profitability

Application

• Installed in three IndianOil refineries • Benzene management studies for three IndianOil refineries • MS-2000 prediction for IndianOil refinery



VIS-MOD Features and Capabilities

• A rigorous model based on five lumps kinetics validated extensively with industrial plant data

• VIS-MOD is capable of predicting:

• Conversion and product yields • Viscosity cutting ratio • Temperature and pressure profiles in furnace coils • Distribution of feed sulfur in products • Important product properties • Blend properties of fuel oil with given cutterstocks

• VIS-MOD can be used for various applications such as

• Daily plant monitoring • Optimization of plant conversion without affecting VB tar stability • Selection of plant severity with change in feedstock

DHDS-MOD Features and Capabilities

• Prediction of total sulfur and the concentration of individual sulfur compounds for given feed quality, feed blend ratio and plant operating conditions

• Estimation of chemical hydrogen consumption • Reactors Temperature

• Bed-wise inlet and outlet temperatures • Delta T across bed

• In-house developed correlation based pressure drop prediction for reactor beds matches with commercial plant

• Realistic prediction of cetane number and Diesel yield • Estimation of Reactor Exit gas composition • Installed at one IndianOil refinery

technologies on offer by indianoil technologies ltd

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