Auto Fuel Quality Improvement
By Indian Refineries
Experience so far &
Preparedness to produce fuels
meeting BS-III/IV norms
N.K.Bansal,
Vijay Prakash
S Sarkar
IOCL
Contents
 Background for improvement
 Changing specs of Auto Fuels
 Quality up-gradation Projects for
BS-II/III norms
 Industry experience on quality
switchover
 Preparedness for meeting BSIII/IV norms
 Way forward -Future concern
Auto Fuels Quality
Improvement
Why? And When?
Emission Control In India- Background
1995 Directive issued for catalytic converter on passenger cars
in metros along with unleaded petrol.
Fuel specs revised/target specs for 2000 notified.
1996
Revised emission norms issued – met through minor
engine modifications
1998
Supreme court issued several directives for NCT/NCR
2000
Euro- II norms implemented in Delhi for cars.
2001
Bhure Lal committee submits report on clean fuels
Dr Mashelkar committee constituted to recommend Auto
Fuel policy for India
2002
Auto Fuel Policy report submitted by Dr. Mashelkar and
Road Map firmed up
Major Changes in Specification of
Gasoline
Parameter
BIS-2000
BS-II
BS-III
EU-IV Eq.
Sulphur ppm max.
1000/500
500
150
50
Benzene Vol% max.
5/3
3
1
1
Aromatics Vol% max.
-
-
42
35
Olefins
-
-
21(18#)
21(18#)
Vol% max.
RON
(#) Premium grade
88/93(#)
88/93(#)
91/95(#)
91/95(#)
Major Changes in Specification of
Diesel
Parameter
BIS-2000
BS-II
BS-III
EU-IV Eq.
Sulphur ppm max.
2500/500
500
350
50
Cetane No. *
48
48**
51**
51**
Cetane Index (CI)*
-
46**
46**
46**
Distillation 0C
at 95% max.
370
370
360
360
Polycyclic Aromatics
-
-
11
11
(Wt % max.)
* Lower by 3 nos. for Assam Crude
** Either Cetane No. or CI
Changing Specs. of Auto Fuels
Gasoline
•Lead Phase out
•Increasing trend of Octane
•Lower “S” in MS
•Lower Benzene
•Restrictions on Olefin & Aromatics
Changing Specs of Auto Fuels
HSD
•Increasing trend of Cetane
•Diesel getting lighter
•Lower “S” requirement
•Restrictions on
Polyaromatics
Fuel Quality Improvement Challenges
• Gasoline
-Reduction of Benzen
& aromatics
• Diesel
- Sulphur reduction
- Cetane increase
- Reduction of olefins
- Poly-aromatic control
- Reduction of sulphur
- End point & density
- Increase in octane
reduction
Timeline for Vehicular Emission Norms
& Fuel Quality
Entire country (Except for Metros and some selected
cities
Bharat Stage - II
1st April 2005
Bharat Stage - III
1st April 2010
Metros & Major cities (Bangalore, Hyderabad,
Ahmedabad, Pune, Surat, Kanpur and Agra) #
Bharat Stage - III
1st April 2005
Euro-IV Equivalent
1st April 2010
# Lucknow & Solapur also added subsequently.
MS Quality
Improvement to
BS-II/III
MS Blending Components in
Refineries
S No
Process Unit
MS Component
Characteristics
1
Catalytic
Reforming
Reformate
2
Fludised
Catalytic
Cracking
FCC Gasoline
High RON, Low
Sulphur, High
Benzene and
Aromatics
High RON, Low MON,
High Sulphur, High
Olefins
3
Crude
Distillation
Light naphtha
4
5
Hydrocracking Light /Heavy Naphtha
unit
Delayed Coker
Cracked Naphtha
& Visbreaking
Units
Low RON, Low
Sulphur
Low Sulphur, Low
RON
Low RON, High
Olefins, Diolefins,
high Sulphur
Refinery Efforts
for MS Quality Improvement
Lead Phase Out & RON improvement:
• Commissioning of new CRUs / Revamp of existing
CRUs at various Refineries
• Commissioning of new FCCUs / Revamp of existing
FCCUs at various Refineries
• Blending of Oxygenates
• Splitting of FCCU gasoline
Benzene Reduction :
• Cut adjustment in Naphtha splitter for CRU feed
• Reformate splitting into Light reformate (rich in
Benzene) & Heavy reformate (deficit in Benzene)
• Hydro-isomerisation of Light reformate
• Direct routing of Hy. Reformate to MS
• Reformulation of blends
Refinery Efforts
for MS Quality Improvement
Sulphur/Olefin Reduction
• Addition of Sulphur reduction additives in FCCU to
reduce FCC Gasoline Sulphur
• Reduction in FCCU feed sulphur by adjusting feed
mix
• Cut adjustment of FCC Gasoline
• Rerouting of streams like HCU Lt. Naphtha
• Withdrawal of VBN & Coker Naphtha
General
• Stream Sharing between Refineries and absorption of
Petrochemical Return Stream
HSD Quality
Improvement to
BS-II/III
HSD Blending Components in
Refineries
S No
Process Unit
HSD Component
Characteristics
1
Fludised Catalytic
Cracking
TCO
Low Cetane, High
Sulphur
2
Crude distillation
SRGO
Crude Specific
3
Hydro Cracking
Gas Oil
High Cetane, Low
Sulphur
4
Delayed Coking &
Visbreaking
Kero/Gas Oil
Low Cetane, High
Sulphur
Refinery Efforts
for HSD Quality Improvement
Sulphur Reduction
• Addition of 2nd Reactor in all DHDS Units to meet
0.05% `S’
• Revamp of existing DHDS/Change of Catalyst
• Adjustment in operating conditions of process units
Cetane Improvement
• Installation of DHDT Units
• Installation of Hydro-Cracker units
Refinery Efforts
for HSD Quality Improvement
Recovery
•Adjustment of operating conditions
•Routing of HCU Kero to HSD pool
General
•Stream Sharing between Refineries
•Adjustment in Cetane Improver dosing
•Reformulation of blends
Experience on switch
over from BS-2000 to
BS-II/III
Financial Impact
Huge
capital investments
Increase
Lower
in production cost
compensation to Refineries
Refinery Experience
General
Preparation of switchover plan
Close
monitoring of Projects
Operational
changes by careful planning and
effective utilisation of LP models and Simulation
Packages
Procurement
of
testing
equipment
and
their
calibration
Review
of Offsite facilities including stream routing,
storage and dispatch facilities
level planning for dilution of tank holdup –
about 3 months from Refinery to sale points
Micro
Refinery Experience
Preparation of switchover plan
Handling
of slop generated
Firming
up of manufacturing specs for products for
pipeline transfer of products
Firming-up
the Pumping sequence for pipeline
transfer
Pipeline
Inter-phase absorption plan
Refinery Experience
Contingency Measures in place
•Procurement of chemicals
Cetane
improver,
MTBE,
“S”
reducing additives viz. LGS- 150
•Stream sharing possibilities among refineries
Path Forward- Auto Fuels
(BS-III/IV)
•Existing system inadequate for meeting:
“S”,
“S”
RON, Aromatics and Olefins for MS
and Cetane index for HSD
•New technologies, revamps of existing units
and augmentation of facilities
Technological Options
(MS Quality Improvement )
Hydroprocessing :
•For Sulphur reduction.
•For Benzene Saturation
•For Olefin reduction
Isomerisation
•For Octane Improvement
Reforming
•For Octane Improvement.
Technological Options
(HSD Quality Improvement )
Hydroprocessing :
• Hydrotreating for Sulphur reduction &
Cetane Improvement
• Hydrocracking for HSD maximisation with
• Sulphur reduction /Cetane Improvement
MS (BS-III/ IV)
Octane & Aromatic



Revamp of Reformer at BRPL, Panipat, CPCL.
New Reformer at Gujarat, NRL, HPC(M), HPC(V), Essar &
KRL
Reformate Splitting at Gujarat, Barauni, Digboi, Panipat
NRL, HPC(M), HPC(V), MRPL followed by
 Bensat/Isomerisation of Light Reformate.
 Hy. Reformate directly to MS Blend.
Sulphur & Olefin reduction

Splitting of FCC Gasoline at Barauni, Gujarat, Panipat,
HPC(V), HPC(M) followed by
 Merox treatment of Light FCC Gasoline.
 Isomerisation of Middle Cut having Benzene.
 Hydrotreatment of Heavy FCC Gasoline
HSD (BS-III/IV)
Sulphur Reduction & Cetane Improvement
• Addl. Reactor in existing DHDT at Barauni.
• New DHDT at Gujarat, BRPL,CPCL, MRPL, BPC-M &
NRL.
• Capacity Expansion of Hydro Cracker at Panipat &
NRL and new Hydro Cracker at Haldia.
• VGO Hydrotreatment at Gujarat, BPC-Mumbai & KRL.
• Replacement of catalyst by new highly active catalyst
at MRPL
• Revamp of existing DHDS units
MS / HSD (BS-III/ IV)
Augmentation of Offsite facilities for :
• Stream routing including online blending
• Storage for intermediate streams and finished
products
• Dispatch facilities
• Handling of
interphase
Slop
generated
from
pipeline
Financial Impact
BS-II/III Production
•Investment over Rs.15,000 Crore
•Increase in production cost by approx.Rs.1.00 per
litre
BS-III/IV Production
•Investment over Rs.22,000 Crore
• Increase in production cost by approx.Rs.1.50 per
litre
Preparedness for BS-III/IV Facilities
• All efforts being made for commissioning
of facilities by Q3 of 2009-10.
• No cushion available for any slippage
• Lessons learnt during BS-II/III
• Implementation being taken care of.
• Contingency plans to be made at industry
• Level to take care of slippages.
Future Concern
• Increasing Fuel & Loss
• High capital investment, Increasing
refining cost, Shrinking operating margins
• Non-commensurate compensation for
Increase in cost of production
• Impact of T-95 recovery at 360 Deg C for
HSD – Disposal of Heavy ends.
• Inter-phase absorption during pipeline
pumping
• Space limitation in refineries for new
facilities
Future Concern
Increase
in complexity of refinery operations and
safety concerns
Shrinkage
in flexibility of operations w.r.t. crude mix,
processing capacity, product slate.
Non-availability
of any one component affects
product availability (viz FCCU gasoline, Reformate,
Isomerate)
Increasing
demand of skilled manpower
operating plants with advanced technology
Robust
need
for
design and Reliability of P&U operations : A
Future Concern
• Very high dependency of Refinery operations on
availability of quality upgradation facilities (Outage
of HGU / DHDS affects overall refinery operations)
• Technology and capacity augmentation keeping in
view long term quality requirements – Provision for
future add-on
Requirement
beyond 2010
LIMIT ?