systems, Indian Oil Corporation Ltd and Viridis Chemicals Pvt Ltd jointly developed IV- IZOMax CAT , a platinum-supported on mixed-metal oxides catalyst. This catalyst combines good tolerance toward feed contaminants with higher activity. An important advantage of this catalyst type is that it does not require continuous chloride dosing, which simplifies operation, reduces corrosion issues, and improves overall process reliability. As a result, this catalyst is considered a promising option for more efficient, sustainable isomerisation operations. Despite the critical role of isomerisation catalysts in modern refineries, many operators worldwide continue to rely on a limited number of global catalyst technology providers. Developing advanced catalyst systems within regional ecosystems is therefore of growing strategic interest, offering potential advantages in cost optimisation, supply chain resilience, and long-term technology stewardship. In this context, IV-IZOMax CAT demonstrates that high-performance isomerisation catalysts can be designed, manufactured, and commercially deployed outside traditional supply hubs, achieving performance aligned with internationally established benchmarks and advancing global capabilities in refinery catalysis. Light naphtha isomerisation is a catalytic refining process that enhances gasoline quality by increasing the octane number of light straight-run naphtha without increasing aromatics. The process primarily involves the rearrangement of normal paraffins (C₅- C₆ hydrocarbons) into their corresponding branched-chain isomers, which possess significantly higher octane values, as per the Process chemistry of light naphtha isomerisation reaction pathway shown in Figure 2 . Isomerisation reactions occur over a bifunctional catalyst, where the metal function facilitates hydrogenation-dehydrogenation reactions. Meanwhile, the acidic function imparted by the mixed-metal oxide matrix promotes skeletal rearrangement of hydrocarbon molecules. Operating in the presence of hydrogen, the process ensures catalyst stability and suppresses coke formation.
Ben
CH
MCP
Ben CH MCP nC iC nC 3MP 2MP
Benzene Cyclohexane Methy Cyclo-Pentane
n-Pentane Isopentane n-Hexane
nC6
2MP
23DMB
3-Methyl Pentane 2-Methy Pentane
GAS
3MP
22DMB
23DMB 22DMB nC iC
2,3 Dimethyl Butane 2,2 Cimethyl Butane n-Heptane Iso para ns of C components Methyl Cyclo-Hexane
iC7
nC7
nC5
MCH
iC5
MCH
In addition to paraffin isomerisation, trace olefins and aromatics in the feed are hydrogenated, helping control olefinic and benzene content in the gasoline pool. The result is a high-octane, clean gasoline blending component that supports compliance with stringent fuel quality and environmental regulations. Journey from development, lab-scale experimentation to commercialisation The catalyst development programme commenced at the laboratory scale, where several formulations were synthesised in small quantities and systematically evaluated in the laboratory-scale microreactor. Based on laboratory screening, the most effective formulation was selected and subsequently scaled up in two batches of 50 kg each. Platinum loading was carried out on representative samples, and their performance was evaluated using different light naphtha feeds, followed by extended pilot plant trials. The scaled-up catalyst consistently demonstrated performance and stability comparable to laboratory results, confirming its robustness and scalability. Commercial feasibility study To demonstrate commercial viability, the catalyst was evaluated through extended pilot plant operation for more than 1,000 hours under representative process conditions, using actual refinery feed from the Bongaigaon Refinery (BGR). In parallel, contaminant tolerance studies were performed by systematically exposing the catalyst to Figure 2 Components conversion chemistry in light naphtha isomerisation
Refining India
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