the zeolite-based system with the indigenously developed IV-IZOMax CAT . A total of 23 tonnes of catalyst was manufactured in 12 lots of ~2 tonnes each, with each lot rigorously tested for performance and physicochemical properties in lab-scale microreactors. The overall catalyst requirement was less, reflecting the enhanced activity of IV-IZOMax CAT . The BGR ISOM unit processes light straight- run naphtha and light reformate, with hydrogen from the catalytic reforming unit (CRU) used as make-up hydrogen. The catalyst was loaded in May 2024, followed by feed cut-in during June 2024. The catalyst was successfully demonstrated, meeting all guaranteed parameters during the Performance Guarantee Test Run (PGTR). The performance of the catalyst during the PGTR is given in Table 3. Benefits of the IV-IZOMax CAT The superior activity of IV-IZOMax CAT enables operation at significantly lower reactor inlet temperatures (135°C to 242°C), improving isomerate yield from 91% to 97%. The economic benefit from deploying this catalyst technology, compared to the Pt-zeolite catalyst at the BGR ISOM unit, is about $4.5 million per annum. This is achieved through higher product yield and a reduction in reactor inlet temperature by ~107°C. Environmental impact IV-IZOMax CAT operates efficiently at lower reactor temperatures, leading to a ~2.5 KTA reduction in CO₂ emissions at the BGR ISOM unit. Lower temperatures also minimise byproduct formation from cracking reactions, enhancing overall conversion efficiency and reducing wastage from flaring. This combination of higher process efficiency and lower emissions demonstrates the catalyst’s contribution to sustainable and environmentally responsible refining. Enabling the future of gasoline IV-IZOMax CAT enables refiners to produce high-quality gasoline blending streams in a cost-effective and sustainable manner. With clear advantages over conventional Pt-zeolite catalysts, the technology has the potential to
Performance matrix of IV-IZOMax CAT at BGR
Parameter specification Isomerate RON
Guarantee
PGTR value 86.7 97.3
values
86 94
Isomerate yield, wt%
Benzene in isomerate, wt%
Max 0.1
Below detectable limit
Table 3
replace nearly 112 zeolite-based ISOM units worldwide, representing an estimated global catalyst market of ~3,000 MT. Conclusion The commercial application of IV-IZOMax CAT in the ISOM unit demonstrates the maturity and reliability of this isomerisation catalyst under real refinery operating conditions. The catalyst delivered stable long-term performance, high activity, and strong resistance to common feed contaminants, confirming its suitability for sustained commercial use. Its successful operation illustrates that high-performance platinum-based isomerisation catalysts can be developed and deployed beyond traditional supply hubs while achieving performance consistent with established global benchmarks. Overall, this deployment reflects the continuing evolution of refinery catalysis toward more efficient, resilient, and sustainable gasoline production pathways.
Vimal K Upadhyay upadhyayvk@indianoil.in Pushkar Varshney varshneyp@indianoil.in Dr Satyen K Das dassk5@indianoil.in Atul Ranjan ranjanatul@indianoil.in Kaushik Singha kaushik_singha@indianoil.in Dr Alok Sharma sharmaa@indianoil.in Dr Chaitanya Sampara csampara@viridischemicals.com
Refining India
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