Abstract: A process for preparation of catalyst to produce ultra-low sulfur diesel (ULSD) from high refractory sulfur feedstock. The catalyst composition comprises a modified alumina carrier, impregnated by metal of group VIB is in the range of 15-25% and metal of group VIIIB is in the range of 1-5% as oxides. The catalyst prepared in the present invention produces highly dispersed MoS2 active sites on the modified carrier. The catalyst produces ultra low sulfur diesel (ULSD) along with improved cetane, density reduction and endpoint reduction.

Abstract: The furnace of a delayed coking unit which is utilized for heating residue feeds to high temperatures can suffer from decrease in run length and fouling caused by caustic carryover from the upstream desalter unit. An antifoulant additive for preventing caustic induced fouling of thermal cracker furnace tubes is disclosed. The described antifoulant additive acts by converting the inorganic caustic compound such as NaOH to naphthenate salt of the metal as well as by reducing the fouling tendency of the whole feedstock, thereby making it ineffective in causing coking reaction. The additive finds application in thermal residue upgradation furnaces such as delayed coking unit, visbreaker, etc.

Abstract: The present invention discloses a process and an apparatus for conversion of waste plastic pyrolysis oil into value added products, wherein, the pyrolysis oil is produced from waste plastics by utilizing HCGO as a preheating stream. The process and apparatus as disclosed improves the conventional DCU process in terms of liquid, gaseous yields and reduction in coke yields and without disturbing the hardware of the conventional process along with energy efficient production of pyrolysis oil. The present process and apparatus include a delayed coking process and a system for the delayed coking process which involves the integration of delayed coking system with pyrolysis section and utilization of produced pyrolysis oil by co-processing it with residual heavy hydrocarbon feedstock.

Abstract: The present invention discloses an integrated process scheme for producing (i) high-octane gasoline blending stream (ii) high aromatic heavy naphtha stream which is a suitable feedstock for benzene, toluene, and xylene (BTX) production and (iii) high cetane ultra-low sulphur diesel (ULSD) stream suitable for blending in refinery diesel pool.

Abstract: The present invention provides a multistage single reactor system for hydroprocessing and a process of carrying out multistage hydroprocessing in the said reactor assembly consisting of, a fixed bed solid catalyst system, a feed injection system enabling axial flow of hydrogen saturated hydrocarbon feed, a hydrogen dispensing system inside the reactor enabling minimum required hydrogen flow in cross-flow pattern, also using multitudes of integrated separation and withdrawal limbs for continuous staging. The innovative reactor disclosed in the present invention enables continuous separation and withdrawal of gaseous products along the reactor length by means of combined horizontal reactor orientation and vertical separation limbs provided at the top of the horizontally oriented reactor. The advantage of the reactor assembly includes effective heat sink of exothermic reactions and lower severity of operation due to removal of inhibitory gaseous products.

Abstract: The present invention relates to a catalyst and a method for preparation of that catalyst for the selective hydrogenation of diolefins present in gasoline streams along with the shifting of lighter sulfur compounds in the feed stock to heavier sulfur compound by the reaction with olefinic compounds.

Abstract: The present invention provides a novel route for synthesis and production of linear alpha olefins (LAO) and central olefins from the feedstock comprising fatty acids, triglycerides and esters of fatty acids, and mixture thereof through controlled hydrogenolysis, hydrogenation and dehydration reactions simultaneously in a hydro processing reactor containing a catalyst system having dual site—a metallic site for hydrogenation/reduction reaction under hydrogen environment, and an acidic site for conversion of alcohol to olefin via E1 or E2 reaction mechanism.

Abstract: As part of an integrated oxidative alkane dehydrogenation and hydrogen generation process, carbon dioxide from Pressure Swing Adsorption (PSA) off gas stream of Hydrogen Generation Unit (HGU), and alkane from any known source are sent to oxidative dehydrogenation (ODH) unit for producing high value olefins, such as ethylene, propylene and butenes. Products formed from ODH reactor are separated and the stream comprising of hydrogen, carbon monoxide and methane are recycled to Shift reactor of HGU unit for enhanced production of hydrogen at PSA.

Abstract: The present invention relates to a sequential thermo-chemical treatment along with adsorption-based pre-treatment process for residual oils having a very high naphthenic acid content. First stage of the process is a thermal pre-treatment step which results into generation of hydrocarbon stream with a reduced naphthenic acid content due to high temperature. In second stage of pre-treatment, generated hydrocarbon stream from stage-1 is subjected to esterification reaction with alcohol, such as methanol, to further reduce the TAN of hydrocarbon stream. After recovery of alcohol from the reaction mixture, depending on TAN reduction required reaction mixture may be subjected to an adsorption stage, third stage pre-treatment, where an adsorbent mixture comprising of FCC spent catalyst is used to adsorb the TAN of feed hydrocarbon stream. The treated hydrocarbon stream is then co-processed with DCU feed stock for producing lighter hydrocarbons.

Abstract: The present invention is related to the isomerization process in which a light naphtha stream comprising of paraffinic (mono and single branched), naphthenic and aromatic hydrocarbons in the range of C5-C7 is contacted with the solid catalyst in multiple reaction zones and in presence of hydrogen to produce high octane gasoline predominantly comprising of paraffins (single and di-branched) and naphthenes. The process scheme comprises of more than one isomerization reaction section operating at different temperatures and other operating conditions. The catalyst employed in these reaction sections is a high coordination sulfated mixed metal oxide catalyst which contains at least one noble metal and sulfated zirconia in addition to the other components. The process of the present invention also comprises more than one fractionation section and recycling of a particular stream to the reaction zone for improving the isomerization of light naphtha.

Abstract: This invention relates to an additive capable of increasing the gasoline octane (by 2-3 units) with minimum loss of gasoline. More specifically, the present invention discloses a fluid catalytic cracking additive composition capable of enhancing gasoline octane, said composition comprising 5-50 wt. % zeolite component, 0-15 wt % alumina, 5-20 wt % colloidal silica, 10-60 wt % kaolin clay, 5-15 wt % phosphate, and 0.1 to 5.0 wt. % of bivalent metal selected from Group-IIA or Group-IB, wherein the zeolite component comprises of medium pore pentasil zeolite in an amount of 1 to 50 wt. % and said zeolite consists of one or more MFI topology zeolite having SiO2/Al2O3 mole ratio in the range of 10-280. The present invention also discloses a process for preparation of the additive.

Abstract: The furnace of a delayed coking unit which is utilized for heating residue feeds to high temperatures can suffer from decrease in run length and fouling caused by caustic carryover from the upstream desalter unit. An antifoulant additive for preventing caustic induced fouling of thermal cracker furnace tubes is disclosed. The described antifoulant additive acts by converting the inorganic caustic compound such as NaOH to naphthenate salt of the metal as well as by reducing the fouling tendency of the whole feedstock, thereby making it ineffective in causing coking reaction. The additive finds application in thermal residue upgradation furnaces such as delayed coking unit, visbreaker, etc.

Abstract: The present invention relates to an integrated process for increasing the research octane number (RON) of FCC gasoline with simultaneous reduction in benzene content. In this process, benzene rich gasoline fraction is reacted with light olefin rich gaseous streams like FCC off gas/dry gas, coker off gas to produce alkyl aromatics using FCC catalyst system containing ZSM-5 zeolite. The catalyst is continuously drawn from the FCC regenerator by suitably placing the alkylation reactor in communication with the FCC regenerator. The product stream of the alkylation reactor is routed to main fractionator for separation of off gas and benzene lean gasoline. This integrated process not only improves the octane number of gasoline but also lowers the gasoline benzene content. Further the integrated alkylation reactor system acts as a heat sink lowering the FCC regenerator temperature and enables the FCC unit to process high CCR feeds.

Abstract: The present invention relates to a method of making of hydrocarbon soluble metal composition comprising of one or more metals of group VIB of the periodic table, wherein the metal having 4+ oxidation state predominantly forms highly active metal sulfide catalyst for hydro-conversion of heavy oil feedstocks in liquid phase. More particularly, present invention relates to a hydrocarbon soluble metal composition comprising of reaction products of a metal source, a lipophilic phenolic acid, a surfactant and an organophosphorus compound. The present invention also provides a one-pot process for preparation of the hydrocarbon soluble metal composition comprising reacting a metal source, a lipophilic phenolic acid, a surfactant, an organophosphorus compound and water to obtain a reaction product and drying the reaction product to obtain the hydrocarbon soluble metal composition.

Abstract: The present invention relates to a process for converting the waste plastics along with the petroleum feedstock in a Catalytic Cracking Unit, in particular a Fluid Catalytic Cracking Unit employed in petroleum refineries. The invention also provides a method and hardware system to enable waste plastic to fuel conversion along with hydrocarbon catalytic cracking. The invented process aims to convert any type of waste plastic including polystyrene, polypropylene, polyethylene, metal containing Polyethylene-Polypropylene multilayer plastics & other metal containing plastics along with the petroleum derived feedstock such as vacuum gas oil, reduced crude oil, vacuum residue etc. in catalytic cracking unit.

Abstract: The present invention relates to a process for converting the waste plastic along with the petroleum residue feedstock in a Delayed Coker unit employed in refineries. The invented process aims to convert any type of waste plastic including polystyrene, polypropylene, polyethylene etc. including metal additized multilayer plastics along with the petroleum residue material from crude oil refining such as reduced crude oil, vacuum residue etc. Value added light distillate products like motor spirit, LPG, middle distillates etc. are produced upon co-conversion in the invented process and is recovered and treated along with the products of thermal cracking of hydrocarbon residues. The residual metals in the metal additized plastics upon co-conversion in the invented process will be deposited in the solid petroleum coke.

Abstract: An apparatus and a method for washing hydrocarbon product vapor are disclosed. The apparatus comprises housing, a first wash zone at a predefined cross-section of the housing for receiving the hydrocarbon product vapor, a plurality of injection units located within the first wash zone at predetermined intervals of the length of the housing for receiving wash oil. The injection units inject oil droplets formed from the received wash oil to contact the vapor and obtain a primary washed hydrocarbon vapor within the first wash zone. Further, a second wash zone is located above and in fluid communication with the first wash zone for receiving the primary washed hydrocarbon vapor. One or more spray headers receive wash oil and spray oil droplets formed from the received wash oil to contact with the primary washed hydrocarbon vapor, thereby forming a secondary washed hydrocarbon vapor.

Abstract: This invention relates to production of low sulfur MARPOL compliant bunker fuel oil and distillates using high sulfur residue, low sulfur residue and/or blend of high and low sulfur residue feed stock. The invention also describes a method for production of a cutterstock stream having a lower paraffin and higher aromatic content than a feed stream using a paraffin separation section and its blending to produce bunker fuel.

Abstract: The present invention discloses an integrated process scheme for producing (i) high-octane gasoline blending stream (ii) high aromatic heavy naphtha stream which is a suitable feedstock for benzene, toluene, and xylene (BTX) production and (iii) high cetane ultra-low sulphur diesel (ULSD) stream suitable for blending in refinery diesel pool.

Abstract: The present invention provides a novel route for synthesis and production of linear alpha olefins (LAO) and central olefins from the feedstock comprising fatty acids, triglycerides and esters of fatty acids, and mixture thereof through controlled hydrogenolysis, hydrogenation and dehydration reactions simultaneously in a hydro processing reactor containing a catalyst system having dual site—a metallic site for hydrogenation/reduction reaction under hydrogen environment, and an acidic site for conversion of alcohol to olefin via E1 or E2 reaction mechanism.