Research And Development

English
Image: 

academic and research institutions

HP GREEN R&D CENTRE (HPGRDC), BENGALURU

HPCL has set-up its prestigious ‘HP Green R&D Centre’ at Bengaluru, India in 2016 with an objective to develop innovative & path breaking technologies and products. The Centre has been set-up in eastern fringes of Bengaluru, the garden city of India, and is located 15 km from ITPL / Whitefield. HP Green R&D Centre is being built in phases in a campus of 104 acres. The Phase–I of the R&D centre has laboratories in the areas of FCC / RFCC, Hydroprocessing, Catalysis, Bioprocesses, Crude Evaluation & Fuels Research, Analytical, Process Modeling & Simulation and Nano Technology which are built with state-of-the-art research facilities / equipment. The R&D centre is recognized by the Department of Scientific and Industrial Research (DSIR) and has collaborations with research institutes in India and abroad. Currently, HPCL R&D has a dedicated team of about 77 officers (scientific & support) and 84 fixed term associates (scientific).

  1. HPGRDC – ACHIEVEMENTS

    HPCL R&D Centre has made major technical accomplishments in terms of developing & commercializing novel technologies and products in refineries which led to significant cost advantages and efficiency improvements in HPCL.

    New Technologies & Products Demonstrated 19
    Indian Patents Filed 115
    International Patents Filed 143
    Patents Granted (Indian, US, Europe, Japan) 54
    International Publications 42
  2. HPGRDC – NEW TECHNOLOGIES

    • HP – HiGAS Technology:HPCL developed new generation ‘HP-HiGAS’ technology for gas absorption / separation application. The technology is based on ‘Process Intensification’ and intensifies mass transfer through rotating packed bed having high centrifugal process. The first of its kind commercial unit was commissioned at HPCL Visakh Refinery for the process of H2S removal from fuel gas. The existing conventional trayed column (23 mts.) was replaced with 2.5 mts. HiGAS unit achieving size reduction by 10 times. This technology has significant potential for H2S, CO2 absorption from refinery fuel gases and natural gas offshore treatment.View BrochurePDF File Opens in a new window
    • Hydrogen PSA Technology:Pressure Swing Adsorption (PSA) is extensively used for purification of Hydrogen from mixture of gases. The technology is offered by very few foreign licensors worldwide and all technical aspects are closely guarded. HPCL developed and commercialized H2PSA technology, and the first unit with 36,000 Nm3/hr capacity was commissioned at HPCL Visakh Refinery producing 99.5% H2 from the CCR off-gas feed. Also, adsorbent replacement was successfully done in existing PSA units. HPCL plans to set-up new H2 PSA units in future and offer for technology licensing.View BrochurePDF File Opens in a new window
    • SprayMax FCC Feed Nozzle:Feed Nozzle is a critical hardware component of a FCC unit, which atomizes liquid feed into finer droplets. This helps in enhancing desired vapour phase reaction. These nozzles are supplied by technology licensors only. HPCL developed “SprayMax” nozzles for FCC unit & successfully commercialized at HPCL Mumbai & Visakh Refineries. Concept to commercialization of “SprayMax” nozzles has gone through various stages viz. design conceptualization, Air-water testing with prototype nozzle & CFD study. Advantages are conversion increase by 1-2 wt%, improved MoC, suit to site design with minimum hardware modification & short lead time for delivery.View BrochurePDF File Opens in a new window
    • Cat Visbreaking Technology:HPCL has developed Cat-Visbreaking process for increasing the distillate yield in Visbreaker unit while maintaining stability of fuel oil. Usage of HPCL developed VisCat Catalyst helps in increasing conversion in Visbreaking unit and thereby reduces the fuel oil production. This has been successfully demonstrated at HPCL Visakh Refinery Visbreaker unit. VisCat is a liquid catalyst and easy to implement in existing Visbreaker units with very short payback.View BrochurePDF File Opens in a new window
    • [HP]2 FCC TECHNOLOGY:FCC units typically produces 3-5wt% propylene, however, there has been continuous growth for propylene in the market. HPCL R&D has developed an in-house high propylene FCC technology i.e., [HP]2 FCC Technology which produces over 20wt% propylene based on its proprietary catalyst, process and R-R section hardware. The proprietary catalyst system of [HP]2 FCC is tailor made with higher selectivity towards light olefins viz. propylene. The [HP]2 catalyst trials were successfully conducted at HPCL’s Mumbai and Visakh refineries FCC units by taking 10 to 15% inventory changeover. Further technology scale-up / demonstration is underway at HPCL.View BrochurePDF File Opens in a new window
    • HP – TSA Technology:Temperature Swing Adsorption (TSA) technology is used in refineries for various applications such as process gas drying, product drying and air drying. This technology is majorly licensed by foreign suppliers. HPCL R&D has developed in-house HP-TSA technology for purification of air by removal of carbon di-oxide and moisture. The treated air is further processed to produce Cryogenic Nitrogen. This technology has been demonstrated at HPCL Visakh Refinery CNU by the way of cost effective adsorbent system replacement.
    • HP-CoSol Process:HPCL R&D has developed a highly selective HP CoSol process for lube oil yield improvement in Solvent Extraction units. This process uses mixed solvent system comprising of co-solvents along with N-Methylpyrrolidone (NMP) and was implemented at HPCL Mumbai refinery with optimum dosage of mixed solvents. The commercial plant trials resulted significant lube oil yield improvements for 500 N distillate and De-Asphalted Oil (DAO) operation respectively. The process is highly selective towards removal of Polycyclic Aromatic hydrocarbons (PAH). The PAH reduction was observed to be 2-3 wt% compared to base case in the lube raffinate, which will be useful as blending stock in production of low PAH rubber process oil.View BrochurePDF File Opens in a new window
  3. HPGRDC – NEW PRODUCTS

    • HP FurnOKare:Furnace tube scaling is a commonly encountered problem in refineries, which over a period of time becomes thick deposits. This reduces the heat transfer efficiency of the tubes & the skin temperature increases to the maximum design temperature. To address this, HPCL developed in-house chemical formulation for online cleaning of furnace tubes for removal of scales without shutting down the unit. The product was successfully demonstrated and implemented at about 25 furnaces of HPCL Mumbai & Visakh Refineries along with MRPL, OMPCL and IOCL-Mathura.View BrochurePDF File Opens in a new window
    • HP BioActiva:HPCL R&D developed a new bio-additive for the treatment of refinery effluent. The newly developed product consists of adapted microbial consortia along with essential nutrients for boosting the microbial activity. The addition of HP-BioActiva reinvigorates the biological system resulting in reduced levels of BOD, COD, and phenolics. The newly developed bio-additive has been successfully implemented at both HPCL refineries & HMEL Bhatinda which has shown sustained activity even under shock loads of chlorides, sulphurous compounds and ammonia.View BrochurePDF File Opens in a new window
    • HP DUCER:Fixed bed reactors in refineries are highly prone to plugging issues which lead to increase in pressure drop across the reactors and reduced feed throughput. HPCL’s HPDUCER, provides a solution to the issue of solid deposits in hydroprocessing reactors. The product was successfully demonstrated in DHDS reactors of HPCL Visakh Refinery. Major advantages are its cost effectiveness, longevity and efficiency, which results in reduction in total consumption of the chemical.View BrochurePDF File Opens in a new window
    • HP-RAZOR:Oxy-acetylene remains the preferred choice for metal-cutting applications even though it is expensive and difficult to store and handle. The main drawback of other oxy-fuels (such as LPG, natural gas, etc.) is the considerably lower flame temperatures. As a part of its “Make in India” initiative, HPCL has developed a novel LPG additive, HP-IPCA which not only improves flame temperature but also considerably reduces both LPG and oxygen consumption. The additized LPG, HP-RAZOR is significantly cheaper than acetylene and was successfully demonstrated for various metal-cutting applications in RINL, Vishakhapatnam.View BrochurePDF File Opens in a new window
    • HP-CORRMIT:Corrosion is one of the major problems in pipeline transportation, which leads to leakage of gases, fuels and often to major accidents. To mitigate this problem, Corrosion Inhibitors (CI) are injected into pipelines at very low dosage level (ppm) that protects the internal surface of pipeline by forming a protective layer. HPGRDC developed a new family of novel, highly efficient corrosion inhibitors, HP-CORRMIT, for fuels such as liquefied petroleum gas (LPG), Gasoline, Diesel, etc. HP-CORRMIT has successfully being implemented at HPCL’s MHMSPL (LPG pipeline) over 1 year.View BrochurePDF File Opens in a new window
    • HP-DLA:Sulphur compounds are natural carriers of lubricity in diesel. However, to meet growing environmental concerns, stringent restrictions are being applied on diesel sulphur levels (50 ppm in BS IV/ Euro IV to 10 ppm in BS VI/Euro VI). As a result, inherent lubricity of diesel is adversely affected which is typically compensated by addition of external additives. HPCL has indigenously developed a new family of additive, HP-DLA. The additive is cost-effective and showed significantly improved activity over conventional additives. HP-DLA has been successfully implemented in HPCL, Visakh & Mumbai refineries. The additive has significant future potential as a gradual move to lower sulphur levels would increase consumption of lubricity additive.View BrochurePDF File Opens in a new window
    • HP – THERMOPRO:Fouling of refinery process equipment is a common problem resulting in severe economic penalties. Solutions to these issues are currently offered by few foreign vendors and they are process specific. HPCL R&D has developed a novel & cost effective Antifoulant i.e., HP-THERMOPRO to mitigate fouling in heat exchangers. The formulation prevents the reactions contributing to fouling thus leading to superior performance over commercial benchmarks. The product was successfully demonstrated in crude-side & SR-side preheat exchangers at HPCL Visakh refinery. Main advantage is that it is a single formulation which is effective for all types of crudes and heat exchanger circuits.View BrochurePDF File Opens in a new window
    • HP – NEUTMAX:Corrosion in the overhead system of crude distillation units is a severe problem which is caused by HCl produced by hydrolysis of chloride salts in crude oil. To mitigate this corrosion, neutralizing amines are dosed at overhead section of the crude unit. HPCL R&D has developed a novel & cost effective neutralizing amine i.e., HP – NEUTMAX keeping in view the neutralizing ability, solubility of the salts and corrosion rate. The product was successfully demonstrated at the CDUs of HPCL Visakh refinery with better performance at lower dosages (about 25% reduction) compared to commercial products.
    • HP – BIOREMEDIA:HP – BIOREMEDIA is a microbial bio-additive developed by HPCL R&D for enhanced degradation of hydrocarbons in sludge. The newly developed product mainly consists of microbial consortia with significant hydrocarbon conversion capabilities that are stabilized by immobilizing on an organic carrier material. Preliminary field trials at Visakh Refinery indicated that the addition of HP-BIOREMEDIA to hydrocarbon sludge with ~3-5 % oil content resulted in their near-complete within 90 days.
    • HP-TRAE Process:HPCL R&D has developed an improved process of HP-TRAE for producing the environment friendly rubber process oils. TRAE-Treated Residue Aromatic extract is one of the aromatic type rubber process oil used in tyre industry. HP-TRAE process is highly selective towards Polycyclic aromatics (PCA) extraction from lube oils. Commercial trials were carried out at Mumbai refinery for the production TRAE grade rubber process oil. HP TRAE process reduces the Poly cyclic aromatic compounds (PCA) by 0.7-0.8 wt% compared to conventional process which results in reduction of overall production cost of rubber process oil. This process also yields 2-3 wt% of more raffinate yields compared to conventional process.
    • PoWer 99:There is growing demand for Motor Spirit with high octane rating especially in sports & luxury cars where the fuel needs to withstand high compression ratios. In view of this, HPCL developed and launched high octane motor spirit, poWer 99 in India, which has an octane rating of 99, highest ever in the country. Besides reduced knocking and, poWer 99 also gives better fuel efficiency and produce lesser emissions. The product has been successfully launched in more than 13 cities such as Bengaluru, Vishakhapatnam, New Delhi, Mumbai, Pune, Hyderabad.
    • HP – SAN:HP-SAN is an optimized quick hand rub / sanitizer formulation which is improvised to have a feel good factor through effective moisturization, colour and fragrance for skin well-being. The efficacy and residual activity is tested to be better than commercial formulations in killing surface bacteria. The scaled up formulation has been distributed to various HPCL personnel (R&D, Marketing, LPG ROs etc.), securities, at COMCO outlets and Bengaluru police.View BrochurePDF File Opens in a new window
  4. TECHNICAL SERVICES

    HPCL R&D has the state of the art facilities for catering research based services to various refining processes like Hydrotreating, FCC, Reforming, Isomerisation and other processes. The centre is equipped with various pilot plants, micro-reactors, analytical equipment and process models which are extensively used during selection of fresh catalyst supplied by the vendors prior to usage in commercial FCC, Diesel hydrotreating, Naphtha hydrotreating units. Also, HPCL R&D has been providing various services to refineries such as crude assay evaluations, sulphur speciation of refinery streams, catalyst TOS studies, etc.