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WEL COME TO CSIR-IIP
CSIR-Indian Institute of Petroleum
CSIR Leadership Conference
26-28 April, 2012 Chandigarh
CSIR-IIP
Highlights of achievements in
last 5 years
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Most Significant Achievements: 2007-12 CSIR-IIP
Technology Commercialized/ Transferred
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
•Pure Benzene •Gasoline:Sulphur <10ppm & Benzene <0.3%
CSIR-IIP Technology (Extractive Distillation)
CSIR-IIP Technology/Knowhow
Commercialization
NRL Dewaxing- Plant using CSIR-IIP Deoiling-Dewaxing Technology
Haldia SDU Revamp with IIP-EIL Know-how
Dewaxing-Deoiling Pilot Plant at CSIR-
IIP
Rs. 753.72 Cr Investment 50K TPA Paraffin wax 5K TPA µCrystalline Wax Technology by CSIR-IIP, PEDP by EIL with CSIR-IIP
Visbreaker Pilot Plant at CSIR-IIP
Internal-Soaker Technology for Visbreaking Unit at HPCL, Vizag
Solvent Extraction technique Energy Efficient Process Low cost Gr. II Lube Oil product
Plant capacity: 1.0 MMTPA CSIR-IIP Technology Engineering Package by EIL with CSIR-IIP
Fee received Rs135 Lakhs
Completion in July 2012 Test run in Aug. 2012
Production of Pure Benzene & US grade Gasoline from FCC Naptha
TIP in Progress Implementation in RIL, Jamnagar Installation, commissioning of Plant by RIL
CSIR-IIP Technology Commercialized CSIR-IIP Technology on Rerefining of used Lube Oil
Used oil Refined Product
Technolgy to M/s DeMenno Kerdoon, CA, USA
TIP & BDEP by CSIR-IIP Plant to start in early 2013 To be implemented in India
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
LPG SWEETENING CATALYST
CSIR-IIP Product Thoxcat ES Sweetening Catalyst
•Globally competitive. •Low cost •Less consumption •No further investment •Applicable in conventional & fibre-film sweetening processes
Catalyst Production Unit
Commercial Status: Used for LPG Sweetening in •FCC LPG Merox Unit of BPCL •LPG Merichem Unit of IOCL, Haldia •LPG Merox Unit of MRPL, Mangalore •LPG Merox Unit of BORL, Bina Trials runs with additives in •Sat LPG Merox Unit of RIL, Jamnagar in 2011 •Soon to be commercialized in RIL in 2012
•Patents: Foreign 06 Indian 03 •Publication: 03
Sweetening Unit
Licence Fee & 10% Royalty
CSIR-IIP Technology Commercialized
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
FCC
E X T R A C T I O N
LPG
GASOLINE
HCO
CLO
LCO
CLO
NMP
FEED
RAFFINATE
EXTRACT
CBFS / Mesophase Pitch
Upgradation of FCC Recycle Oil at HPCL
CSIR-IIP Pilot Unit
HPCL FCC Unit
FCC feedstock improvement Higher FCC product yield Co-production of premium quality CBFS
Rs.90.00 Cr/Annum Profit for Refinery
CSIR-IIP Technology Solvent Extraction Technique
CSIR-IIP Technology Commercialized
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Raw Materials: Neem, Ricebran, Karanja, Castor, Mahua, Linseed, Sugarcane etc.
Seed Oil
Chemical Processing
Developed Product
Soluble Cutting Oil
Biodegradable Soluble Cutting Oil
CSIR-IIP Technology Licensed to M/s EBLIPL, Coimbatore
100 MTPA Plant Commissioned in Feb.2012 Meets BIS Specs (IS 1115) For Ferrous & Non-Ferrous Metal Cutting
Technology Fees: Rs. 8.00 Lakhs + 5% Royalty Patent: IN 244501
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Significant Achievements under Non-Plan Projects
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Waste Plastics to Fuel & Petrochemicals
SCREW FEEDER
PYROLYZER
FEED (PE/PP)
FRAC
TIO
NAT
OR
GASES (C1-C5)
GASOLINE / DIESEL / AROMATICS
CATALYTIC REACTOR
RESIDUE
Diesel (~850 ml)
+ LPG
Gasoline (~700 ml)
+ LPG
Petrochemicals (~ 500 mL) +LPG
1 Kg waste (PE+PP)
Environment friendly solution to waste plastics disposal
Augment the supply of fuel and petrochemicals
Generate employment
SALIENT FEATURES • Exclusive production of either gasoline or
diesel or aromatics alongwith LPG from polyolefinic wastes (e.g. HDPE, LDPE, PP etc)
• Liquid fuel meet Euro III specifications • Simple, pollution free and environmental
friendly process • Estimated payback period for a 30 TPD plant ~
3 years
Lab scale (2006-2008) Waste plastics to value added hydrocarbons
Bench scale (Oct 2009-Dec 2011) Waste plastics to gasoline/diesel/aromatics
5 TPD pilot plant to be set up by GAIL Project management consultancy by IIP
BENEFITS
• Gasoline obtained from waste plastics
Plastics consumption in India (2010): ~10 MMT Plastic wastes in India (2010)*: ~15,000 TPD *source -CPCB
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Demonstrated ULSD production at laboratory scale unit
Suitable for small scale standalone units/ refineries
Ready for Commercialization
Oxidant
Diesel fuel
OXIDATIVE DESULPHURIZATION OF DIESEL
ULSD Oxidation Extraction Adsorption
S< 10 ppmw Salient Features: • Mild operating conditions • less capital and operating • cost • No hydrogen, reduces GHG
emissions • Improves cetane index
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
SINTEF
Technology Development for Ultra Low Sulphur Diesel Production
Adsorbent Synthesis (SINTEF)
Process Flow Sheet Development (IIP)
Library Design (DOE)
Combi Testing
XRD
Data Analysis
Data Storage
Parallel Sample Isolation
MultiAutoclave (sample array)
Robotics
Adsorbent Screening (IIP)
16 16.2 16.4 16.6 16.8
17 17.2 17.4 17.6
mL
/ g
Volume of Diesel Treated per Gram Adsorbent up to 30 ppm
Sulphur BT Level
Adsorbents
A B
Ad-1001Adsorber
Ad-1002Adsorber
E-1008 A/B/C/DHDS FEED Effluent Exchanger
C-1002Reg Gas Recycle compressor
E-1009Reactor efflluentTrim cooler
E-1010AdsorberEffluent Trim cooler
F-1001/1002Furnace
AFC-1002ADS EffluentAir Condensor
D-1001/1002/1003Separator drum
P-1005Quench pump
D-1004Amine KO Pot
T-1002Amine Absorber
Swee
t pu
rge
gas
INDIAN INSTITUTE OF PETROLEUM
PROCESS FLOW DIAMGRAM FOR INTEGRATED HDS-ADSORPTION PROCESS FOR ULS DISEL PRODUCTION
Lean amine
Slip Streamto Claus unit
F-1001
C-1002
E-1010
Make-UpN2Air
Diesel feed (2000 ppm s)
DIESEL Feed(2000 ppm S)
Boiler feed water
AFC-1003
Rich amine
SourWater
T-1002
D-1001
E-1008 B
E-1008 A
E-1008 C
F-1002
P-1005
E-1009
1
AFC-1002
Desulphurised diesel
2
5
3
4
E-1008 D
AFC-1003 Regeneration gas Air Cooler
H2
40
320
P-1005Quench pump
15
16.8
332
17.8
18
6.4
14.4 E-1011
48
E-1011 Lean Amine Preheater
To flare
Pressure , kg/cm2,g
Temperature 0 C
E-1012
E-1012Reg.gas exchanger
•Developed vapor phase adsorptive desulphurisation process for diesel • S < 50 ppm •H2 requirement is 6 times lower •lower operating pressure •integration with existing hydrodesulphurisation •Adsorbent thermally regenerable
Indo-Norwegian Co-operation Programme
Novel low carbon emitting technologies for production of ultra low Sulphur Diesel
IIP
High through put combinotarial screening leading to novel sulphur selective adsorbents
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
CSIR-IIP Technology for Removal of SO2 from Flue Gas Streams
CSIR-IIP Process on Absorption
Pilot Plant by EIL with CSIR-IIP Knowhow •Generation of large databank
on solvents for SO2 removal • Development of thermally and chemically stable solvents
• 100 % slip over CO2
• MOU signed between CSIR – IIP, EIL and NRL • BDEP by CSIR-IIP & EIL • Commercialization at Numaligarh Refinery
Limited (NRL) & IOCL, Guwahati • Capacity: ~5000 Nm3/hr flue gas
Pilot Plant at EIL, New Delhi
CSIR-IIP Plant
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
CSIR-IIP Technology for gas removal by Absorption Process
CSIR-IIP Pilot Plant
Ready for Commercialization Jubilant Organosys Ltd Capacity : 6000 Nm3 per hr biogas
•Indigenous catalyst developed • Novel promoter •Much superior performance compare to commercial catalyst
CSIR-IIP Screening Unit
CO2 Removal
Ready for Commercialization
Chambal Fertilizer Ltd. Capacity : 450 MTPD of CO2 production
Large solvent databank solvents with improved characteristics Reduction in solvent regeneration energy requirement
H2S Removal
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Significant Achievements under XI FYP Projects
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Green jet fuel can match properties of petroleum derived Jet fuel. Increased demand for green jet due to CO2 legislation, energy security.
Light Gases Deoxygenation/Isomerization Diesel
Deoxygenation/Selective Cracking/Isomerization
Light Gases
Naphtha
Biomass Derived oil
Bio-Jet Fuel
Diesel Acid Gas Removal
Vegetable Oil
Reactor
Separator
H20
CO2
+ Gas OilMake up Hydrogen
Propane &Light Ends
Naptha or Jet
Diesel Product Capacity: 100 kg feed/day.
15 Liters of Bio-Jet Fuel supplied to Industrial Partners HPCL & IOCL
The Bio-Jet Fuel Meets all the Major Specifications for Aviation Fuel.
CSIR-IIP Pilot Plant
Publication: 15 (HIF:9.446, LIF: 2.791, AvIF: 4.56)
Patents: 3 Collaboration with Pratt & Whitney, Canada CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
BIOETHANOL PRODUCTION FROM CELLULOSE AND STARCHY BIOMASS USING THERMOPHILIC MICROORGANISMS
1 Tonne SCB yields 206 L dry ethanol (from hexose stream) 22.5 kg yeast biomass (pentose sugar stream) 22.5 kg furfural (catalytic conversion of pentose
sugar stream) Recovery of ethanol by solvent extraction; reduces
the energy requirement Whole genome sequencing of thermophilic yeast
ethanologen Kluyveromyces sp. IIPE453 (collaborative work with CSIR-IGIB and TCGA))
fermentation at 500C
85 - 90% recovery of total sugar
dil. acid pretreatment followed by enzymatic saccharification
saccharification by novel amylase at elevated temperature
96% recovery of ethanol from fermentation broth by
solvent extraction
Thermophilic yeast Kluyveromyces sp.
IIPE453
MoU with Praj Matrix for Technology Development in Pilot plant & commercialization Patents: Foreign-5, Indian-2 Publication: 8 PhD: 3
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
For CO2/CH4 feed mixture CH4 purity exceeds 95 mol% CH4 Recovery > 85%
Adsorption Technology Development for CO2 Recovery from Biomass Pyrolysis / Gasification Off Gas
CSIR-IIP V S Processes
Gases H2, CO2, CO,
CH4, C2H4
Commercialisation Prospects Small scale Food/Agro Industries
•Highly selective adsorbent developed , superior to conventional adsorbents •Satisfactory Adsorbent performance with ternary feed mixtures
Designed a PVSA cycle with high performance in simple configuration
CSIR-IIP SINTEF Joint Project Collaboration with NTPC Tie-up with Monash Univ.
Patents:Foreign-1, Indian-3 Publications: 6 (Av IF=2.52) PhD: 2
CSIR-IIP’s Developed PVSA System
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Biodegradable Lubricants
Raw Materials: Neem, Ricebran, Karanja, Mahua, Castor, Linseed, Sugarcane etc.
• Soluble Cutting Oil
• Transformer Oil
• Gear Oil
• Lithium Grease
• Hydraulic Oil
• 2 T Oil
Ecofriendly Additives • Extreme Pressure gear oil additives from
hyderogenated phospho-sulfurized cardanol • Additive Pack for Soluble Cutting Oil, 2T Oil, Gear Oil,
Hydraulic Oil, Lithium Grease and Transformer Oil
Key Significances: • Provides better Lubricity, Reduces break down period. • Completely biodegradable from agro-products. • Safe to use, no health hazards, no disposal problem • From Renewable source • High flash point, less volatile, food grade & non toxic • Compatible with mineral oil
Chemical Processing
Developed Product
End uses
Technology licensed Patents, Foreign:17 Indian: 2 Papers: 6
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
19
Modified alkyd resin development for value addition to Glycerol
The know how for production of modified alkyd resins using glycerol for various specialty end uses.
WSD: 0.78mm; Coefficient of friction: 0.02, Weld load:215kg
4 Ball Rig Test; Load:200kg
SEM of Ball after test
ATRP (initiator, methyl-2 chloropropionate; Ligand, N,N,N,N,N pentamethyl di-ethylene tri-amine; metal halide, copper chloride) in ratios 100:1:1:2
Glycerolmonomaleate
15 min., Stirring, N2 flushing (1:1 mole ratio)
Glycerol + Maleic acid
CoPolymers Am MMA
>30 polymers, optimized reaction
Coating (alkali,acid proof) Additive (aqu.& oil)
Product & process developed Ready for commercialization Dorf-Ketal
ATRP
•Publication: 06 •Patent: Indian 01 Foreign: 01
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
20
Important Chemical Intermediates from Glycerol
1,2 &1,3 propane diols
Under optimized condition, Product
Conversion > 85%
Product purity > 90% with pure
glycerol 80 % with
glycerol from biodiesel process
Cu-metal supported
catalysts found to be most
suitable
Butyl Ethers
99% conversion of glycerol with selectivity to
di- and tri-ethers greater than 95% was
obtained.
Commercial prospects:
Potential oxygenates to
diesel and biodiesel
reformulation.
Engine testing for emissions
2764/DEL/2011 dated
22.09.2011
0
1
10%GTBE/Diesel Diesel PM in
mg/
km
Compartive PM Emission
0
5
10
0 1 2 3 CO
in P
PM
Power KW
Comparative CO Emission
5%GTBE/Ga… Gasoline
GLYCEROL
40
50
60
Diesel 2.5% GTBE/Diesel 5% GTBE/Diesel Cet
ane
No
Cetane No Trends While Blending
GTBE
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Engine Performance Studies
Evaluation of bio-fuels developed under the project for their suitability in advanced technology vehicles for desired performance and for meeting Indian mass emission norms
SEM Image of particulate from 10%bio-diesel/diesel Blend
Parameters Total Number Count/cc
Geometric Mean Diameter (nm)
Count Mean Diameter (nm)
Bio-Diesel
2.09E+08 42.87 60.99
Diesel 2.33E+08 57 69.88
Particulate size distribution measurements for Biofuels
Preliminary stability studies of Ethanol /Diesel Blends using Butanol as a Co- solvent
Optimization of Spray Characteristics of Butanol /Gasoline Blend (B10)
Evaluation of GTBE as Fuel Additive Preliminary stability studies of Ethanol /Diesel
Blends using Butanol as a Co-solvent Effect of biodiesel addition in diesel on nano size
particle distribution in the engine exhaust
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Glimpses of CSIR-IIP Achievements(2007-2012)
No. of Technology Developed,Commercialized/Licenced: 12 No. of Paper Published: 180
No. of Patents; Foreign: 48 (filed & sealed) Indian: 31
Awards/ Recognizations:
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
Leader Ship and Excellence Award - OCEANTEX 2008 (Outstanding Achievement Award for R&D and Innovation) CSIR Technology Award-2009 Gold Medal from FICCI in DST-Lockheed Martin India Innovation Growth Programme on 20th May, 2010
CSIR Technology Awards – 2011 for “Business Development & Technology Marketing”
OceanTEX 2012 Leadership and Excellence Awards for the category of Outstanding Achievement in Research and Development
CSIR Leadership Conference, Chandigarh, 26-28 April, 2012
A long journey ahead
Thank You
Patents
Licensee
Catalyst Specifications
LPG SWEETENING CATALYST
Commercial Status
Catalyst Production Unit
Salient Features
Sweetening Unit
Product Name : Thoxcat ES Form : Liquid solution Color : Dark blue Odor : Odorless Specific Gravity @ 15/15 oC :1.06 ±0.02 Active ingredient, kg/bottle : 0.5(in 4.7 litres)
•Thoxcat ES catalyst is globally competitive. •Economical due to its low cost •Consumption is less for similar conversion •No investment will be needed for any plant modification •Applicable in conventional as well as fibre-film sweetening processes
The catalyst has been successfully tested in following units: •FCC LPG Merox Unit of BPCL •LPG Merox Unit of RIL, Jamnagar •LPG Merichem Unit of IOCL, Haldia •LPG Merox Unit of MRPL, Mangalore This had shown better performance than other catalyst being used earlier by them. BPCL Bharat Petroleum corporation Ltd (BPCL), Mumbai; Hindustan Petroleum Corporation Ltd(HPCL), Mumbai and Visakhapatnam, Chennai Petroleum Corporation Ltd (CPCL), Chennai and BORL, Bina are using this catalyst for LPG sweetening.
Granted : Total –9; USA – 2, UK – 2, France - 2, India – 3; Published : Germany – 2.
License for production and sale of this catalyst Thoxcat ES has been given to M/S Lona Industries Limited, Alta Bhavan, 532 Senapati Bapat Marg, P.O. Box No. 17006, Dadar, Mumbai-400028.
Catalyst Production Unit
CSIR-IIP Product Thoxcat ES Sweetening Catalyst
Licenced to M/s Lona Industries Ltd, Mumbai
LPG SWEETENING CATALYST
Trials runs with additives in •LPG Merox Unit of RIL, Jamnagar in 2011 •To be commercialized in RIL in 2012
Sweetening Unit
Licenced Fee & 10% Royalty
CSIR-IIP Technology Commercialized
•Globally competitive. •Low cost •Less consumption •No further investment •Applicable in conventional & fibre-film processes
Commercial Status: Used for LPG Sweetening in •FCC LPG Merox Unit of BPCL •LPG Merichem Unit of IOCL, Haldia •LPG Merox Unit of MRPL, •LPG Merox Unit of BORL, Bina
FCC
E X T R A C T I O N
LPG GASOLINE
HCO CLO
LCO
CLO
NMP
FEED
RAFFINATE
EXTRACT
CBFS / Mesophase Pitch
•Patents: Foreign 06 Indian 03 •Publication: 03
Haldia SDU Revamp with IIP-EIL Know-how
Dewaxing-Deoiling Pilot Plant at CSIR-IIP
Production of Paraffin & Microcrystalline Waxes
CSIR-IIP Deoiling-Dewaxing
Technology
Numaligarh Refinery
(NRL) Wax Deoiling
Unit 50,000 TPA Paraffin Wax
5,000 TPA µCrystalline Wax
Rs. 753.72 Cr Investment
Technology Development & Basic Design Data generated by CSIR-IIP
PEDP by EIL with Technical support by CSIR-IIP
Licence Fee Rs. 2.16 Cr. & PEDP Fee Rs. 2.70 Cr
Plant going on-stream by Dec. 2013