(GHG) emissions. A critical step toward this goal is the classification and systematic monitoring of emissions. To facilitate effective tracking, emissions are categorised into three scopes: Scope 1, Scope 2, and Scope 3. Reporting of Scope 1 and 2 emissions is mandatory, whereas Scope 3 reporting remains voluntary and is the most challenging to quantify. Scope 1 emissions are direct emissions originating from sources owned or controlled by the company. These include stationary combustion (such as fuel used in heaters or boilers), mobile combustion (from company- owned vehicles), fugitive emissions (such as leaks of refrigerants or hydrocarbons), and process emissions (such as CO₂ released during chemical or industrial processes like cement production). Scope 2 emissions are indirect emissions resulting from the consumption of purchased electricity, steam, or heat, generated off-site and supplied to the facility. “ As emission regulations tighten to support national and global net- zero targets, and as refiners seek to maximise profitability by processing heavier crude slates, there is a growing need for advanced technologies that reduce coke formation ” Scope 3 emissions encompass all other indirect emissions not covered in Scope 2, occurring across the value chain. These include upstream and downstream activities such as purchased goods and services, transportation, fuel and energy-related activities, end-of- life treatment of sold products, and waste generated during operations. Fuel-grade petcoke is a high-sulphur byproduct, typically containing up to ~7 wt% sulphur. It is commonly used as an energy source in industries such as cement, steel, and power generation. However, the combustion of petcoke emits substantial amounts of pollutants, including COx, SOx, and NOx, contributing significantly to air quality degradation. In recognition of these environmental risks, the Hon’ble Supreme Court of India imposed restrictions on the
use of petcoke as fuel within the National Capital Region. As emission regulations tighten to support national and global net-zero targets, and as refiners seek to maximise profitability by processing heavier crude slates, there is a growing need for advanced technologies that reduce coke formation. Ind-Coker AT technology incorporates a two-stage thermal cracking mechanism – unlike the single-stage process in conventional DCUs – to efficiently process heavier residue feedstocks. This innovation achieves approximately 5 wt% lower coke yield compared to standard coking technologies. The reduction in coke production directly translates into a significant decrease in emissions: potential CO₂ reductions of ~7 million MMTPA and sulphur dioxide (SO₂) reductions of ~400 thousand tonnes per annum (kTPA) across India. This article presents the development of this technology through pilot-scale studies and its subsequent commercial demonstration in a 3 MMTPA unit, highlighting its strategic role in shaping the next generation of refinery configurations. Ind-Coker AT vs conventional coker technology In a conventional delayed coking process, residue feedstock is converted to light distillates and coke by thermal cracking. The process involves heating the residue feedstock to cracking temperatures inside a furnace and then routing it to coke drums to provide required residence time. The process methodology of this technology differs from that of the conventional coking process. It employs a novel pre-cracking process prior to severe thermal cracking for converting heavier residue to middle distillates and lower coke and fuel oil compared to the conventional delayed coking process. Initially, heavy residue feed is subjected to mild cracking in a ‘pre-cracker’ reactor, and the products of mild cracking reactions are separated in an intermediate separator column. Thereafter, the heavy bottom product fraction from the intermediate separator column is directed to a coking section, where it is subjected to coking in the coke drums. Products from the intermediate separator column and coke drums are drawn out from a common fractionator column.
Refining India
42
Powered by FlippingBook