Summary of "LIVE - Day 3 - Hall B - 28th Energy Technology Meet"
Summary of “LIVE - Day 3 - Hall B - 28th Energy Technology Meet”
This session at the 28th Energy Technology Meet (ETM) focused on cutting-edge innovations, technological advancements, and indigenous developments in the energy and refining sectors. The emphasis was on catalysts, process technologies, and integration of new product lines aligned with sustainability and Atmanirbhar Bharat initiatives.
Key Technological Concepts and Product Features
1. Innovation in Catalysts and Scaling Lab to Field
- Catalysts are critical to refinery efficiency, sustainability, and energy reduction.
- Advances in heterogeneous catalysts, especially in resid hydrocracking, petrochemical catalysts, and steam cracking.
- Focus on ablating bed resid hydrocracking (EBRH) technology:
- High residue conversion rates (60-90%) with selective middle distillate production.
- Flexibility in feedstock handling, including high contaminant feeds.
- Catalyst innovations to maintain asphaltene stability and reduce fouling.
- Dual catalyst systems combining different catalyst platforms to optimize conversion and sediment control.
- Growth in global and Indian resid hydrocracking units, with new Indian units under commissioning.
2. Catalyst Innovations for Greener and More Efficient Refining (KGEN)
- Addressing growing diesel demand while complying with sustainability mandates (e.g., biofuel blending targets).
- Innovations to maximize severe feed processing, co-processing of vegetable oils, and extend catalyst cycle life.
- Customized reactor loading schemes for conventional and co-processing feedstocks.
- Real-life case studies showing increased cycle length, reduced temperature operation, and increased bio-feedstock co-processing without compromising unit stability.
3. Pathbreaking Catalyst for Polypropylene Production (Indian Oil)
- Development of indigenous Ziegler-Natta catalyst (N22) for polypropylene production.
- Unique magnesium precursor chemistry developed in India, controlling catalyst morphology at sub-nano scale.
- Catalyst scaled from lab to commercial scale with improved productivity and reduced fines.
- Supports India’s self-reliance by replacing imports and using locally available chemicals.
- Significant improvements in catalyst efficiency and polymer properties demonstrated in commercial trials.
4. Advanced Catalyst for Maximizing Propylene and Ethylene Yields in FCC Reactors (HPCL)
- Development of nano-sized ZSM-5 zeolite catalysts with truncated spherical morphology.
- Reduced diffusion path lengths leading to faster cracking, higher olefin yields, and lower coke formation.
- Enhanced external surface area and acidity tuning to maximize propylene and ethylene production.
- Commercial scale-up and validation with significant economic benefits projected for FCC units.
5. Regenerated Catalyst Pool Management (URAT)
- Emphasis on mindful, deliberate reuse of catalysts to reduce costs and CO₂ footprint (~60% reduction).
- Catalyst pool management involves segregating spent catalysts, regeneration, and maintaining inventory for flexible and crisis-ready loading.
- Benefits include cost savings, reduced metal price volatility, and support for Make in India initiatives.
6. Next Generation Acetylene Hydrogenation Catalyst for Steam Crackers (Sutkim)
- Development of selective hydrogenation catalysts for acetylene removal in ethylene streams.
- Addressing challenges of thermal runaway due to exothermic reactions and variable CO content.
- Catalysts with wider operating windows, higher selectivity (~98%), and longer life cycles (up to 3+ years).
- Front-end and tail-end hydrogenation technologies discussed with new catalysts reducing regeneration needs and improving safety.
Domestic New Product Innovation Session Highlights
1. Refinery and Active Pharma Intermediate Integration (MRPL)
- Development of indigenous isobutyl benzene process technology for pharma intermediates.
- Integration of refinery streams with pharma production to diversify portfolio and improve margins.
- Demo plant nearing completion with plans for scale-up; focus on high purity and impurity control.
- Future pipeline includes paracetamol, salicylic acid, and other pharmaceutical intermediates.
2. Indigenous Technology for Diaromatic Solvents (HPCL)
- Development and commissioning of dearomatized solvents production using existing refinery streams.
- Addressing health and environmental concerns by reducing aromatic content.
- Plant design includes fixed bed hydrogenation reactors with nickel and platinum catalysts.
- Expansion plans to increase capacity and product portfolio.
3. Manufacturing of Sulfur Bentonite (IOCL)
- Innovation in converting refinery sulfur byproduct into sulfur bentonite fertilizer.
- Product improves soil health, crop yield, and quality; reduces soil alkalinity.
- Indigenous engineering and cost-effective project execution with significant import substitution potential.
- Positive market outlook with rising demand globally and in India.
4. Indigenous Refining Catalyst Manufacturing (IOCL)
- Commissioning of a catalyst manufacturing unit producing FCC and hydroprocessing catalysts.
- Backward integration with domestic raw material suppliers.
- Customized catalyst solutions tailored for Indian refinery needs.
- Demonstrated scalability and commercial deployment in multiple refineries.
5. Diaromatized Solvent Production (BPCL Mumbai)
- Production of diaromatized solvents at Mumbai refinery using existing hydrofinishing reactors.
- Phase one completed with 20 ktpa capacity; phase two underway to scale up to 200 ktpa.
- Use of innovative divided wall column technology for energy efficiency.
- Products serve diverse sectors including aerosols, metalworking, cosmetics, and pharmaceuticals.
- Significant reduction in imports and environmental benefits.
Reviews, Guides, and Tutorials
- Several presentations included real-life case studies demonstrating technology deployment and operational benefits.
- Emphasis on scaling lab innovations to commercial scale with pilot/demo plant examples.
- Insights into catalyst design principles, challenges (e.g., fouling, sediment formation), and solutions.
- Guidance on catalyst pool management and lifecycle optimization.
- Discussion on integration of refinery operations with pharma and agrochemical sectors for diversification.
- Overview of market trends, demand projections, and government mandates shaping technology needs.
Main Speakers and Sources
- Dr. Alex Pulotil (ED R&D, IOCL) – Chairperson, catalyst innovations and session moderator.
- Mr. N. Chandra Shakhar (ED R&D, BPCL) – Chairperson, catalyst innovations.
- Mr. Sadhart Moanti (WR Grace) – Ablating bed resid hydrocracking catalyst technology.
- Ms. Mega Agarwal (KGEN) – Catalyst innovations for greener refining.
- Mr. Gurit Singh (IOCL) – Indigenous polypropylene catalyst development.
- Mr. Prammot Kumar (HPCL) – Nano ZSM-5 catalyst for FCC.
- Mr. Siddhart Sager (URAT) – Catalyst pool management and regeneration.
- Mr. Arvind Sutki (Sutkim) – Next-gen acetylene hydrogenation catalysts.
- Mr. Karthik R (MRPL) – Refinery-pharma integration and isobutyl benzene process.
- Mr. Sanjay Lakshman (HPCL) – Indigenous diaromatic solvents technology.
- Mr. Harprit Singh (IOCL) – Sulfur bentonite fertilizer manufacturing.
- Ms. Yamini Gupta (IOCL) – Indigenous refining catalyst manufacturing.
- Mr. Shubhham Gupta (BPCL) – Diaromatized solvent production at Mumbai refinery.
- Mr. Nanda Kumar (MRPL) – Chairperson, domestic new product innovation session.
- Mr. Amal Kumar Roy (Advisor, Ministry of Petroleum and Natural Gas) – Presented tokens of appreciation.
Conclusion
The session underscored India’s growing capabilities in energy technology innovation, catalyst development, and process integration, emphasizing self-reliance, sustainability, and economic growth. Presentations highlighted successful indigenous technologies, commercial deployments, and future-ready solutions addressing both market demand and environmental imperatives. Collaboration between public sector units, R&D centers, and industry partners showcased a vibrant ecosystem driving India’s energy transition and refining sector modernization.
End of Summary
Category
Technology
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