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Microalgae’s role in sustainable biofuel production

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Strategies for cost-effective decarbonisation: Future-proofing Indian refineries Studies on methanol dehydration over beta zeolite catalyst Integrated web platform for accurate GHG emissions mapping Fueling success: SAF route to aviation sustainability Circular polymer through chemical recycling of waste plastics

Diksha Singh and Sreevidya RV Research & Development Centre, Engineers India Limited

Major fossil fuels such as coal, natural gas, and oil are depleting and emit high levels of CO₂ and nitrogen oxides when used for energy generation. The diminish- ing reserves of readily recoverable fuels, concern over global climate change, and increasing fuel prices demand the develop- ment and use of alternate fuels for energy independence and security of a country. Recently, there has been an increased shift towards using biomass-based energy to reduce carbon footprints. Bioenergy includes a suite of biomass-based energy sources, including biofuels such as bioeth- anol, biodiesel, biogas, Bio-CNG, and Bio- ATF. Currently, biofuels like bioethanol and biodiesel are partially replacing gasoline and diesel, respectively, in the transporta- tion sector. Biorefineries are also gaining momentum for converting biomass into value-added products such as biofuels, biochemicals, and bioenergy/biopower. For biorefineries to operate on a continuous basis, large- scale biomass production and harvest- ing are required. Growing dedicated crops specifically for biofuel production may reduce the land available for food crop production. Hence, sustainable practices must be followed for large-scale biomass production and harvesting. The various biomass feedstocks for bio- energy production are starch/sugar-based feedstocks such as corn, sweet potato, and cassava; oil seed-based feedstocks such as soybean, rapeseed, and coconut (first generation, 1G); ligno cellulose-based feedstocks such as rice and wheat straw (second generation, 2G); and algae-based feedstock such as micro and macroalgae. The major drawback of 1G fuel sources is that the production of raw materials com- petes with the food and fodder supply for land and requires a huge amount of water. 2G fuel technologies are cost intensive. This can be resolved by 3G fuels, specifi- cally biofuel produced from microalgae.

which produce 68.13 L/acre to 2,404 L/acre oil, microalgae has a 19,000 L/acre to 57,000 L/acre oil yield. Preliminary literature and laboratory studies have been carried out to iden- tify robust microalgae species for biofuel production. The study identified spirulina platensis for further focusing on its char- acterisation and analysing its lipid content and fatty acid profiling. The spirulina platensis used in this study was procured from one of the national repositories for microorganisms. The selected strains were cultivated in a Zarrouk nutrient medium suitable for their growth. Microalgal strains were cultivated in different capacities of Erlenmeyer flasks in a orbital shaking incubator and fermentor. The growth parameters pH and temper- ature were kept constant based on the requirement of the strain. The cultivated strains were then harvested by filtration/ centrifugation and dried. The cultivation of desired samples were then confirmed microscopically. Proximate analysis was carried out as per the ASTM standards (ASTM E-1755-E1757). Total solids were obtained in the range of 6.7- 12%, ash content was 12.98-45%, and moisture was achieved in the range of 70-90%. The calorific value obtained for the microalgae biomass was 2039.65 Cal/g. To analyse the fatty acid profile, the lipids were extracted from the biomass and GC-MS analysis was performed. In our study, a lipid content of 48.4% has been obtained. The composition of the fatty acids includes palmitic acid, erucic acid, stearic acid, oleic acid, and linoleic acid. The lipid accumulation in microalgae demonstrates the potential of spirulina platensis as an effective feedstock for biofuel production. The high value-added products obtained as byproducts during the cultivation of these microalgae can make biofuel production fea- sible. Microalgae are also involved in carbon sequestration. These biological advantages make microalgae a potential contributor to helping India achieve its net-zero target.

Enhanced reliability monitoring of SMRs using advanced data analytics 8

Formic acid production using heterogenised iridium catalyst through the ICCC process Mastering mega-scale refinery and petrochemical projects

Maximising MS production from the isomerisation unit within VLI constraints 15 Advancing carbon capture for mass deployment across industries 16 Enhancing refinery sustainability with EmulsionSENS in desalter operations 17 Hybrid (fresh and regenerated) catalyst loading reduces fill cost and carbon footprint 19 Novel approach for assessing integrity of FCC unit cold wall riser with finite element analysis 21 How to increase compressor reliability: Combine digital maintenance and AI-based monitoring 22 Role of spiral heat exchangers in refineries 25 Additised solvent closed-loop cleaning package 25 Key actions for precious metal catalysts 26 Scope 1 and 2 decarbonisation roadmap for an oil refinery 28 Earthquake Warning System 29 MellapakEvo and the evolution of structured packing 30

Figure 1 Microscopic image of Spirulina platensis and the coiled thread of cells

Microalgae are photosynthetic organ- isms that convert sunlight, water, and car- bon dioxide from macromolecules such as lipids [triacylglycerols (TAGs)] into sugars. These lipids TAGs are promising and stable for biofuel feedstock. Microalgae are mainly composed of car- bohydrates (11-56%), lipids, proteins (30- 80%), pigments, and vitamins. The content of lipids in microalgae is usually 30-70% of the cell dry weight and can be as high as 90% under stressful environmental conditions. Through various biochemicals, thermochemical, nano-catalytic transfor- mations, and genetic engineering, micro- algae can be used to produce biofuels, including biodiesel, bio-syngas, bio-oil, bioethanol, and bio-hydrogen. They also produce value-added byproducts like phy- cocyanin, β -carotene, antioxidant, and vitamins. The lipid component from micro- algae can be transesterified into biodiesel, and the left-over biomass, mainly com- posed of carbohydrate, can be fermented into bioethanol. The unique advantages of microalgae as a renewable and sustainable energy source include their high photosynthetic efficiency and ability to grow in non-arable land, saline water, and wastewater. When compared to crop feedstocks like palm, corn, soybean, sunflower, rapeseed, canola, and jatropha,

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Figure 2 Literature image of spirulina platensis

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refining india 2024

Strategies for cost-effective decarbonisation: Future-proofing Indian refineries

Raju Chopra TOPSOE

approach does not help refiners decarbon- ise their existing assets, which can only be achieved through co-processing, revamping existing units to process bio-feedstocks, or implementing carbon capture technologies. Exploring Production of Green Products Refineries can also explore diversification into green hydrogen, produced using elec- trolysis powered by renewable energy. This zero-emissions hydrogen can be used in various refining processes, replacing con- ventional hydrogen produced from fossil fuels. Most refiners have already planned to install small-scale green hydrogen pro- duction units. As touched upon above, SAF is cru- cial for decarbonising the aviation sec- tor. Producing eSAF involves capturing CO₂ from biogenic sources, such as bio- mass, and converting it into aviation fuel. The SAF market is primed for significant growth. In 2023, SAF volumes doubled to more than 600 million litres (0.5 Mt), and in 2024 production is expected to triple to 1.875 billion litres (1.5 Mt). This is still only 0.53% of aviation’s fuel need, and 6% of renewable fuel capacity. The HEFA route for SAF production is seen as the cheap- est and most readily available route, with alcohol-to-jet another attractive option given the future availability of ethanol. One of the important pathways to grow produc- tion of SAF over the short-to-medium time- line will be eSAF, with production expected to ramp up over the next decade to meet global demand. Methanol is a versatile chemical and fuel, and producing it from biogas, using renew- able fuel, can add to the decarbonisation journey. Converting biogas to methanol involves capturing methane emissions and transforming them into a valuable prod- uct. This not only reduces greenhouse gas emissions but also creates a renewable fuel source. Conclusion Indian refineries face the dual challenge of maintaining economic viability while reduc- ing their environmental impact. By optimis- ing current operations, diversifying into decarbonisation, and exploring the pro- duction of green products, refineries can achieve substantial emission reductions and contribute to India’s net-zero goals. These strategies offer practical, cost- effective solutions that not only help in mitigating climate change but also future- proof refineries in an evolving energy land- scape. As the industry moves forward, Topsoe’s combination of proven technol- ogy, high-performing catalyst library, and decades of experience in the refinery busi- ness and green- and low-carbon solutions can ensure Indian refineries embrace the correct pathways to future-proof their unique operations.

In the face of global climate change and increasing environmental regulations, Indian refineries must adopt innovative strategies to reduce carbon emissions and ensure long-term sustainability. As India strives towards net-zero emissions, refineries have a crucial role to play in this transition. This article explores three main strategies that Indian refineries can con- sider optimisation of current operations, including emission-sensitive petrochemi- cal expansion, diversification into decar- bonisation opportunities, and exploration into the production of green fuels. These approaches offer practical, cost-effective solutions that can help refineries navigate in what is frequently a tight investment environment while minimising business risks and ensuring sustainable growth in this fast-growing world. In July 2023, India’s oil refining capac- ity reached 253.92 million metric tons per annum (MMTPA), making it the second- largest refiner in Asia. Through the private sector-led growth, there was a refinery capacity addition of almost 90 million met- ric tons in 2022. These numbers under- score the growth and significance of India’s refining industry. However, they also mean that cost-effective and simple methods of decarbonisation can have a significant impact on the environment and can point the way towards future-proofed and eco- nomically profitable operations. Optimisation in current operations Energy efficiency is a fundamental aspect of reducing carbon emissions and is often a low-hanging fruit for Indian refineries. Refineries can adopt various schemes to enhance energy efficiency, such as imple- menting heat recovery systems that can significantly reduce energy consumption. By capturing and reusing waste heat from processes, refineries can lower their energy requirements and emissions. Reducing fuel usage and process losses can lead to sub- stantial energy savings. This involves opti- mising combustion processes, improving insulation, and minimising flaring. Transitioning from steam to electric driv- ers for pumps and compressors and/or the addition of power recovery turbines and usage of electric heaters are prime exam- ples of how refineries can enhance effi- ciency and reduce emissions. Electric drivers are often more efficient and have lower maintenance costs, so benefits in terms of emission reductions and reduced costs are achievable. Usage of advanced process controls for major equipment, such as furnaces, reactors, columns, large pumps, and compressors, can also deliver benefits. Catalysts play a vital role in refining pro- cesses, and using the latest generation cat- alysts can optimise operations. Advanced catalysts can improve hydrogen utilisa- tion, which is crucial for desulphurisation and other processes. Optimising hydro-

Refineries in India have a crucial role to play in the transition to net zero

gen usage reduces the need for addi- tional hydrogen production, thus lowering emissions. Modern catalysts can operate efficiently at lower pressures and temper- atures, reducing energy consumption. New catalysts allow refineries to process a wider range of opportunity crudes, including those with higher impurities, without compromis- ing efficiency or increasing emissions. The third straightforward tool available when it comes to operational optimisation and emission reductions is the upgrading of refinery hardware. Enhancing reactor inter- nals can improve mass transfer and reaction rates, leading to higher efficiency. Installing high-efficiency column trays, packings, and special types of heat exchangers can recover additional heat from high-tempera- ture streams and special types of reboilers, further improving energy efficiency. As one of the only countries expected to experience refinery growth in the coming years – driven in a large part by petrochem- ical diversification – Indian refineries will need to be a focus on using technologies to ensure that emissions are minimised. Diversification of operations As the demand for sustainable aviation fuel (SAF) continues to rise, refineries are seek- ing ways to transition into renewable refin- eries. While this transformation typically requires significant financial investment and time, co-processing offers a simpler, cost-effective alternative. By introducing renewable feedstocks directly into exist- ing diesel hydrotreaters, refineries can pro- duce a combination of renewable and fossil diesel, reducing CO₂ emissions from fossil- based feedstocks. The cost of converting a conventional refinery into an SAF/hydrotreated vegeta- ble oil (HVO) facility through co-processing can vary significantly depending on sev- eral factors. These factors include excess hydrogen availability, current refinery infrastructure, logistics for acquiring and storing renewable fuels, refinery layout, and utilisation rate. In some cases, by lev-

eraging existing infrastructure and making minor modifications, refineries can start producing SAF quickly and efficiently. For example, a conventional refinery with a kerosene hydrotreater unit operat- ing at moderate pressure, sufficient cata- lyst volume, and excess hydrogen supply, may require only a change of catalysts (hydrodeoxygenation and dewaxing cata- lysts) for co-processing up to 5% volume. In this scenario, the production of SAF can be achieved with minor Capex (capital expend- iture) investment and no revamp or minor revamp of the kerosene hydrotreater. Additionally, utilising biogas as a feed- stock in hydrogen production can reduce the carbon footprint of hydrogen production in plants. Biogas is a renewable resource, and its use in hydrogen production can help lower overall emissions. Finally, the implementation of carbon reduction technologies, such as carbon capture and storage (CCS), can be a method for refineries aiming to lower their carbon footprint. CCS technology captures carbon dioxide (CO₂) emissions from industrial pro- cesses and stores them underground, pre- venting their release into the atmosphere. Refineries can integrate CCS to signifi- cantly cut their carbon emissions. It is also worth noting that India currently has ethanol blending and biodiesel blending policies in place to decarbonise its fuel mix, but refiners need new ethanol production plants to meet these targets. However, this Indian refineries face the dual challenge of maintaining economic viability while reducing their environmental impact

Contact: rach@topsoe.com

refining india 2024

Studies on methanol dehydration over beta zeolite catalyst

Arundhathi Racha, Chanchal Samanta, Mahesh W Kasture, Rakesh Vankayala and Chiranjeevi Thota Bharat Petroleum Corporation Ltd, Corporate R&D centre

• Methanol synthesis: Synthesis gas (syngas), composed mainly of carbon mon- oxide (CO) and hydrogen (H₂), is produced from feedstocks such as natural gas or coal. The syngas is then converted into methanol through catalytic reactions. • Dehydration of methanol: The pro- duced methanol is subsequently dehy- drated to form DME. This step is typically conducted over solid acid catalysts, such as zeolites, which facilitate the removal of water and promote the formation of DME. The overall reactions can be summarised as follows:

Production of fuels and chemicals with a lower carbon footprint is emerging to reduce the environmental impact of petroleum-derived fuels and chemicals. Dimethyl ether (DME) stands out as a via- ble option because of its favourable com- bustion characteristics, emitting lower levels of nitrogen oxides (NOx) and par- ticulate matter (PM) compared to conven- tional fossil fuels. For instance, DME can be blended with liquefied petroleum gas (LPG) or used directly in diesel engines, making it an attractive alternative in both transportation and domestic applications. DME has the potential to reduce emis- sions by up to 85% compared to fossil fuels.¹ DME can be produced from dehydration of renewable methanol, which in turn can be produced from biomass or hydrogena- tion of captured CO₂.² , ³ However, metha- nol dehydration is not straightforward, and depending on the catalyst system, metha- nol conversion can lead to the production of different kinds of products, such as ole- fins, gasoline, aromatics or DME. Some alternative on-purpose production routes, such as methanol-to-gasoline (MTG), methanol-to-olefins (MTO), and metha- nol-to-aromatics (MTA), are commercially developed and under various stages of development.⁴ Selective production of DME from meth- anol necessitates the selection of active and selective catalysts that would be non- selective towards undesired side reactions. With this objective, at Bharat Petroleum (BPCL) R&D studies have been conducted to identify a suitable catalyst system for selective conversion to methanol to DME. In India, the urgency to enhance energy security is paramount, given its heavy reli- ance on imported fossil fuels. The Indian government is actively promoting the pro- duction of methanol and DME from domes- tic resources, such as coal and biomass, to reduce import dependency and foster self-reliance. This initiative aligns with India’s com- mitment to the Paris Agreement and its goal of achieving carbon neutrality by 2070.⁵ The Methanol Economy Research Programme (MERP) highlights the poten- tial of methanol and DME to mitigate rising import costs and improve energy security, as they can be produced from locally avail- able resources, including high-ash coal and captured CO₂ from industrial processes. The production of DME and light hydro- carbons (olefins) from methanol is crucial for several reasons. Firstly, these com- pounds can be synthesised from renew- able feedstocks, contributing to a circular economy and promoting sustainable devel- opment. Secondly, the ability to convert methanol into DME and light hydrocarbons provides flexibility in meeting the diverse needs of the petrochemical industry, which is essential for economic growth. For exam-

The Indian government has

Methanol (MeOH)

ple, ethylene, propylene, and butylene are key components in the manufacture of plastics and synthetic rubber. The Indian government has initiated projects to establish methanol and DME production facilities, recognising their potential to support domestic energy needs and reduce reliance on imports. The National Coal Gasification Mission aims to gasify substantial amounts of coal by 2030, facilitating the production of syngas, which can be converted into meth- anol and subsequently into DME and light hydrocarbons. initiated projects to establish methanol and DME production facilities, recognising their potential to support domestic energy needs and reduce reliance on imports

Indirect synthesis

CO H

Dimethyl ether (DME)

Syngas

Direct synthesis

Figure 1 Dimethyl ether production route

This strategic approach not only addresses energy security but also con- tributes to pollution reduction, as DME combustion results in lower emissions com- pared to traditional fossil fuels.

2CH₃OH → CH₃OCH₃ + H₂O

v Direct route: In this method, DME is synthesised directly from syngas in a sin- gle reactor, which simplifies the process and can enhance efficiency. This approach allows for the simultaneous production of methanol and DME, potentially reducing capital and operational costs compared to the indirect method. The direct synthe- sis of DME from syngas is an area of active research, particularly for improving yield and reaction conditions.

Production routes for DME and light hydrocarbons

The production of DME and light hydrocar- bons (C₂ to C₄) can be achieved through various routes, primarily categorised into direct and indirect methods ( Figure 1 ). These processes utilise different feed- stocks, including natural gas, coal, bio- mass, and organic waste, to produce these valuable compounds. Main production routes for DME  Indirect route: This is the conven- tional method for DME production, which involves two main steps:

Main production routes for light hydrocarbon production

There are two main routes for producing light hydrocarbons (C₂ to C₄) from metha- nol ( Figure 2 ):  Methanol to olefins (MTO) process: • Methanol is first synthesised from syn- gas (CO + H₂), which can be derived from natural gas, coal, biomass, or other carbo- naceous feedstocks. • The methanol is then converted to light hydrocarbons (ethylene, propylene) over zeolite catalysts like SAPO-34 or ZSM-5 at elevated temperatures (400-500°C). • The light olefins can be further pro- cessed into gasoline-range hydrocarbons or other valuable chemicals. v Methanol dehydration to DME fol- lowed by DME conversion: • Methanol is dehydrated to DME over solid acid catalysts like zeolites or alumina at 250-400°C. • The DME is then converted to light ole- fins and paraffins in a second reactor using the same zeolite catalysts as in the MTO process. • The light hydrocarbons can be separated and further processed as needed. Key considerations in these processes include: • Catalyst design and optimisation to tune product selectivity towards desired light hydrocarbons. • Efficient heat integration and process configuration to improve energy efficiency and economics. • Effective separation and purification of the light hydrocarbon products.

DTO or MTO ?

Light olens Ethylene & Propylene

DME

SAPO-34 Catalyst

Methanol

Figure 2 Light hydrocarbon production route

Tubular reactor

Temperature controller

Catalyst bed

Electric furnace

Nitrogen

Pump

Gaseous product

Methanol

Liquid product

Figure 3 Experimental setup for DME and light hydrocarbon production

refining india 2024

exhibited catalytic activity over a tempera- ture range of 280-450°C, with DME emerg- ing as the predominant product across all tested temperatures. Notably, the catalyst achieved a maximum selectivity for DME of 47.9% at 300°C, along with a methanol turnover frequency (TOFMeOH) of 741.9 h −1 , indicating a highly efficient conversion process under optimal conditions. As the reaction temperature increased, an enhanced fraction of strong acid sites on the zeolite, promoted higher hydrocar- bon formation through the olefin-based cycle. The reaction environment signifi- cantly influenced the crystallinity, porosity, and acidity of the beta zeolite; amorphous carbon deposition was observed, leading to a partial loss of crystallinity. Additionally, a pore-broadening phe- nomenon occurred at elevated tempera- tures, reflecting structural changes within the zeolite framework. Regeneration cycle tests confirmed stable catalytic activity throughout a 280-hour time-on-stream period, underscoring its robustness and

effectiveness for continuous operation in methanol dehydration reactions.

These routes allow the production of val- uable light hydrocarbons from methanol, which itself can be derived from abundant and renewable feedstocks like natural gas, coal, and biomass. Integrating methanol aromatisation with light hydrocarbon aro- matisation can further increase the yield of BTX aromatics (benzene, toluene, xylenes) from the light hydrocarbons. By converting methanol to DME and to light hydrocarbons, the methanol econ- omy concept can be expanded to pro- duce a wider range of chemicals and fuels beyond just methanol itself. This flexibility is important for adapting to changing mar- ket demands and optimising the overall process economics. Major players like Linde AG, SABIC, and Methanex Corporation are leveraging advanced technologies and catalysts. BPCL’s Corporate Research & Develop- ment Centre has developed beta zeolite catalysts using a hydrothermal crystallisa- tion method for the production of DME and light hydrocarbons from methanol.⁶

By converting methanol to DME and to light

References 1 Styring P, Sanderson P W, Gell I, Skorikova G, Sánchez-Martínez C, Garcia-Garcia G, Sluijter S N, Frontiers in Sustainabilit y, https://doi.org/DOI 10.3389/frsus.2022.1057190. 2 Kriprasertkul W, Witoon T, Kim-Lohsoontorn P , Intl J. of Hydrogen Energy, 2022, 47, 33,338-33,351. 3 https://backend.orbit.dtu.dk/ws/portalfiles/ portal/6276908/prod11322045433376. R1107,_EFP06_(report)_RIS%C3%98_ april_2011%5B1%5D.pdf. 4 www.etipbioenergy.eu/images/AllBiofuel Factsheets2016.pdf. 5 www.tifac.org.in/index.php/reports-publi- cations/recent-publications/2-uncategorised/ 1063-methanol-and-dme-production-survey- and-roadmap 6 Chaudhary P, Arundhathi R, Kasture M W, Samanta, Vankayala R, Thota C, R. Soc. Open Sci. 10: 230,524. https://doi.org/10.1098/ rsos.230524 Contact: rachaarundhathi@bharatpetroleum.in

The beta zeolite molecular sieve with a SiO₂/Al₂O₃ molar ratio of 28.5 was synthe- sised using the hydrothermal crystallisa- tion method and subsequently examined for its performance in methanol dehydra- tion reactions. This micro-mesoporous beta zeolite hydrocarbons, the methanol economy concept can be expanded to produce a wider range of chemicals and fuel

Integrated web platform for accurate GHG emissions mapping

Rajasekhar M, Rajeev Nayan and Saikat Bhowal Engineers India Ltd. R&D Complex

To limit global warming to 1.5°C as per the Paris Agreement, emissions need to be cut by roughly 50% by 2030 and reach net zero by the middle of the 21st century. At COP26, India announced its commitment to achieving net-zero emissions by 2070. Many Indian companies have outlined their plans to achieve this target. A crucial initial step is the accurate measurement of CO₂e emissions across various industries. The lack of precise measurement can necessitate frequent adjustments to emission reduction tar- gets. Furthermore, discrepancies in defin- ing scope boundaries among organisations lead to significant variations in reported greenhouse gas (GHG) emissions. Many organisations follow different meth- odologies for defining their scope bounda- ries, which leads to a significant mismatch in GHG emissions compared to their peers. Using different methodologies to calcu- late emissions in different plants within the same organisation also leads to anomalies. Presently, there is no web-based plat- form specially designed for the compre- hensive calculation of Scope 1 and 2 emissions, including detailed process emis- sions that are specific to Indian industries such as upstream oil and gas, refineries, and petrochemicals. EngCO2 चित्रण TM is a digital web-based plat- form for CO₂e emissions calculation specific to Indian refineries and Indian needs devel- oped by EIL. Its uniqueness is as follows: • Comprehensive emissions calculation: Detailed Scope 1 and 2 emissions calcula- tion for various industries in unified platform.

Many organisations

follow different methodologies for defining their scope boundaries, which leads to a significant mismatch in GHG emissions compared to their peers • Live emission reporting: Integration with SCADA/DCS systems for live emis- sions data, including daily and monthly averages. EngCO2 चित्रण has been successfully deployed online, serving organisations in accurately estimating CO₂e emissions. Its application extends to configuration stud- ies for grassroots projects, enabling early- stage assessment of emissions for design optimisations. This platform is positioned to accelerate India’s journey towards achieving its net- zero targets, providing a crucial tool for industry stakeholders to effectively man- age emissions complexities.

EngCO2 चित्रण features an intuitive dashboard

Highlights major contributors to emissions, enabling targeted reduction strategies. • Collaborative input: Support for multiple users, facilitating input from various stake- holders across locations. • Progress tracking: Provides year- wise emission trends to monitor progress towards net-zero targets. • Enterprise-grade security: Ensures robust data management security standards. • Regulatory compliance: Generates reports that are compliant with Securities and Exchange Board of India (SEBI) reg- ulations for Business Responsibility and Sustainability Reporting (BRSR) annual reporting.

• Utilisation of in-house process data: Leveraging EIL’s proprietary data and expertise in processing CO₂e emissions. • User-friendly interface : Intuitive inter- face with flexible input options and advanced dashboard. • Scenario analysis: Capability for ‘what- if’ scenarios, assessing emissions reduc- tions through fuel switching and process optimisation. • Mitigation of double accounting: Built-in measures to prevent double accounting of emissions. • Adherence to global standards: Aligns with global protocols, standards, and Indian regulatory requirements. • Emissions hotspot identification :

Contact: sekharraja@eil.co.in

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refining india 2024

Fueling success: SAF route to aviation sustainability

Leigh Abrams Honeywell UOP

Honeywell’s (FT) Unicracking™ technology converts FT liq- uids and waxes from agricultural, munic- ipal, and forestry waste, in addition to biogas and CO2 combined with H2 to FT Synthetic Paraffinic Kerosene (FT-SPK), which is a form of ASTM D7666-approved SAF. Fischer-Tropsch Honeywell UOP was recently awarded by DG Fuels with the largest announced FT-hydrocracker unit in the world to date, producing 13,000 BPD of SAF. The plant has an expected start-up in 2028 and will be located in Louisiana, USA. This also marks the first joint project with Johnson Matthey and BP’s co-developed Fischer Tropsch (FT) CANS™ technology, serving as a foundation for future joint FT+ hydroc- racking projects. For refiners, FT-Unicracking provides an excellent opportunity for repurposing exist- ing assets to take advantage of the SAF/ fossil kerosene spread. Hydroprocessing units can cost-effectively be revamped to 100% FT-Unicracking units or con- verted via a staged investment by first co- processing, followed by eventual 100% FT-Unicracking. One of the key benefits of FT liquids and waxes compared to other renewable/lower carbon intensity feedstocks is that these feeds are highly paraffinic and do not con- tain contaminants like chlorides, sulphur, nitrogen, and high amounts of oxygenates and metals. This is a technology pathway with a high Technology Readiness Level, in combination with a high carbon efficiency and a low, zero or even carbon-negative SAF product, resulting in a high bankabil- ity score. References 1 www.ourworldindata.org/co2-emissions- from-aviation 2 www.europarl.europa.eu/news/de/press-room/ 20230424IPR82023/fit-for-55-parliament-and- council-reach-deal-on-greener-aviation-fuels 3 www.icao.int/environmental-protection/ CORSIA/Documents/CORSIA%20States%20 for%20Chapter%203%20State%20Pairs_4Ed_ rev_web.pdf 4 www.icao.int/environmental-protection/ CORSIA/Pages/CORSIA-Eligible-Fuels.aspx 5 www.icao.int/environmental-protection/pages/ SAF.aspx 6 www.theicct.org/ira-unlock-green-hydrogen- jan23 7 www.moei.gov.ae/assets/download/ 9b4bf8a9/UAE_National_SAF_Roadmap.pdf.aspx 8 www.biofuelsdigest.com/bdigest/2023/09/16/ sustainable-aviation-fuel-challenges-of-scale

Aviation accounts for 1.9% of overall greenhouse gas (GHG) emissions, making it an important pain point for policymakers and consumers alike in the drive towards decarbonisation.¹ Climate action is becom- ing more codified by governmental initia- tives and regulations. For example, the European Council released its ReFuelEU Aviation rules as part of the ‘Fit for 55’ package, aiming to increase the sustainable fuels share at EU airports from a minimum of 2% in 2025 to 70% by 2050, with an additional sub-target for eSAF of 1.2% by 2030 and 35% by 2050.² The Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA), which is part of the United Nations’ International Civil Aviation Organization (ICAO), stipulates SAF as one of its eligi- ble measures.³ , ⁴ Following technical analy- sis of lower-carbon aviation fuels, ICAO has stated that “SAF has the greatest potential to reduce CO₂ emissions from International Aviation”.⁵ Investment targets The US’s Inflation Reduction Act (IRA) reduces the cost of clean hydrogen pro- duction by almost half and contributes to almost $369 billion dollars being made available to address energy security.⁶ Echoing the EU’s ‘Fit for 55’ package, the UAE’s Minister of Energy and Infrastructure has set a target of producing 700 mil- lion litres of SAF annually by 2030, and sees positive incentives as a critical tactic for achieving that growth.⁷ Meanwhile, in 2021, the Biden Administration announced its Sustainable Aviation Fuel Grand Challenge for the US aviation fuel supply sector to produce at least three billion gal- lons of SAF per year by 2030 and 35 billion gallons of SAF per year by 2050.⁸ Renewable jet fuel The Ecofining™ process for renewable jet fuel is based on refinery hydroprocessing technology. The process produces a bio- synthetic paraffinic kerosene (bio-SPK) or renewable diesel, which is then blended with standard jet fuel for use in flight. With incentives available today in the US, even marginal improvements in distillate yield provide a substantial economic benefit.

Renewable Naphtha

Ecofining ™ & UOP Renewable Jet Fuel Process

Inedible

Sustainable Aviation Fuel (SAF) Renewable Diesel (RD)

UOP Distillate Unionfining™ Process

Partial SAF Partial RD

Vegetable oils

Animal fats

Greases

Algal oil

Partial renewable LPG Partial renewable gasoline

UOP FCC Coprocessing

Petroleum

VGO Inedible FOGs

Partial RD

RFO for Heating/Power

Envergent RTP® (Pyrolysis)

Biomass

Renewable Naphtha RD and renewable Marine SAF

Hydrotreating/ Upgrading

Gasication

Fis c her - Tropsch + UOP FT-Unicracking™

SAF eSAF (when green H used)

Fis c her - Tropsch + UOP FT-Unicracking™

UOP Ethanol to Jet Process

Ethanol

SAF

Figure 1 Route to SAF production

called e-fuels, combining renewably manu- factured green hydrogen with CO₂ to pro- duce eMethanol. As a highly integrated design that can process flexible feedstocks using commercially proven processes, the technology results in high-yield eSAF pro- duction while reducing GHG emissions by 88% compared to conventional jet fuel.¹¹ Since 2011, millions of gallons of SAF have been produced using Honeywell UOP technology that meets ASTM D7566 spec- ifications. This includes the fuel used for the world’s first transatlantic flight powered entirely by SAF.¹² SAF can be produced from a variety of sustainable feedstocks, includ- ing vegetable oils, animal fats, non-food- based fats, second-generation feedstocks such as camelina, jatropha and algae, and low-carbon- intensity alcohols. GHG reduction by 70% When blended up to 50% with petroleum- based jet fuel, SAF offers significant advan- tages over traditional fuel, such as with its higher energy density in flight allows air- craft to fly farther on less fuel. That means it offers a drop-in replacement fuel that requires no changes to aircraft technology or fuel infrastructure.¹³

At a 10,000 BPD feed rate, for exam- ple, a 1 wt% yield advantage is worth approximately $6 million in profits annually. Moreover, our experience with many types of sustainable feedstocks means we can guarantee catalyst cycle lengths based on actual operating data. The value of avoid- ing a five-day shutdown for catalyst reload is worth approximately $8 million in revenue for a 10,000 BPD unit.⁹ Single-stage Ecofining technology, ena- bling renewable diesel production, is ideal for refinery retrofits. A retrofit initiative typ- ically costs 50-70% less than a greenfield project and can be completed in an aver- age of 12-18 months, setting the stage for a straightforward expansion to two-stage processing for renewable jet fuel, which can be implemented later.¹⁰ With these types of assets, the Honeywell UOP ethanol-to- jet (ETJ) technology has been developed for ethanol producers looking for diversification to satisfy the needs of the aviation market. Low-carbon SAF eFining™ technology is a methanol-to-jet fuel (MTJ) processing technology that can convert eMethanol to eSAF reliably and at scale. eSAF belongs to a class of fuels

9 www.uop.honeywell.com/en/industry- solutions/renewable-fuels/ecofining 10 www.pmt.honeywell.com/learnmore/ ecofining/ebook

11 www.honeywell.com/us/en/press/2023/05/ honeywell-introduces-uop-efining-technolo- gy-for-new-class-of-sustainable-aviation-fuel 12 www.worldenergy.net/gulfstream 13 www.uop.honeywell.com/en/industry- solutions/renewable-fuels/honeywell- sustainable-aviation-fuel Contact: Daniela.Delgado@Honeywell.com

refining india 2024 t consignment of circular polypropylene (CircuRepol (R) ) has 3 from RIL Jamnagar refinery complex. The Circular Polymer y units through chemical recycling of waste plastics using in- ology. Circular polymer through chemical recycling of waste plastics

Biswajit Shown, Shekhar Bissa, Paras Shah, Nirav Parsania and Naina Jivrajani Reliance Jamnagar Refinery and Petrochemical Complex

assets, is helping to create a circular econ- omy. The Jamnagar refinery has become the first in India to receive the prestigious ISCC PLUS certificate for producing circu- lar polymers through chemical recycling to reduce plastic waste. This initiative aims to reduce plastic waste, marking a significant step towards a greener future. To meet the sustainability target, the first consignment of circular polypropylene (CircuRepol ® ) was launched on 28 December 2023 from the RIL Jamnagar refinery. The circular polymer is being produced in exist- ing refinery units through chemical recycling of waste plastics using in-house waste plas- tic conversion technology.

Reliance Industries Limited (RIL) has dem- onstrated its commitment to sustainability by producing International Sustainability & Carbon Certification (ISCC) PLUS-certified circular polymer from waste plastics at its Jamnagar refinery. RIL’s technology for converting waste plastics to pyrolysis oil, along with innovative methods for pro- ducing circular polymer utilising existing

Contact: biswajit.shown@ril.com

Launch ceremony of first consignment of circular polypropylene

Enhanced reliability monitoring of SMRs using advanced data analytics ony of 1 st Consignment of Circular Polypropylene

Sukant Dev, Rohit Kumar, Vikas Sharma, AND Kaushalendra Kumar IOCL Mathura Refinery India

ing-based hydrogen generation units at its Mathura Refinery (MR). The unit was facing operational bottlenecks and reli- ability issues. The capacity of the unit was restricted due to tube skin temper- atures (TSTs) crossing the design limit above 70% plant load. Also, due to non- uniform firing, the furnace operation was imbalanced. Further, there were incidents of flame impingement on the tube, which resulted in reduced life and poor reliability of the catalyst tubes. To ensure tube reliability and opera- tional safety, a TST measurement is car- ried out. Unlike other furnaces, the TST measurement of the reformer tube is done manually using non-contact type infrared pyrometers due to the severe operating environment for the skin thermocouples of function. When using IR pyrometers for indirect temperature measurement, fac- tors such as emissivity, sight path effects, and reflected radiation can contribute to errors in temperature measurement. IR pyrometers capture all the radiation falling on their lens, including radiation emitted by the tube, radiation reflected by the tube surface, radiation reflected by the refractory walls, radiation due to the flames, and they display everything as the tube temperature. This means that the actual tube temper- ature would be 900°C, but the pyrometer

Figure 1 Data visualisation of the REFORM Tool

Background and Problem Statement Hydrogen, also termed the ‘Champagne Fuel for the energy transition’, is one of the most important and costly utilities in refineries and petrochemicals. It is uti- lised for processes such as hydrocracking, hydrodesulphurisation, and hydrotreating of petroleum intermediates. Most refiners employ steam methane reforming (SMR)

ane reforming is a highly energy-intensive process. For this, the reformer furnace is operated in the 900-1,000°C range. To endure such severe operation condi- tions, the tube metallurgy is made of spe- cial alloys with excellent creep strength, fatigue strength, oxidation resistance, and structural stability. IOCL operates steam methane reform-

for hydrogen production, with the reformer furnace being the central component of the process. A typical steam methane reformer is a fired furnace with rows of tubes containing catalyst through which feed is passed. The feed is a mixture of steam and methane, which converts to hydrogen in the pres- ence of a catalyst and heat. Steam meth-

refining india 2024

shows a temperature higher than 900°C. Proprietary technology for real-time ther- mal imaging of catalyst tubes is available in the industry; however, it might not meet the cost economics of Capex and plant outage for installation for all refiners. Intelligent use of Tube Skin Temperature Data and Advanced Analytics  Background temperature correction model IOCL MR has developed a furnace-spe- cific model for background correction and obtaining true temperatures. The back- ground correction model is specific to the constructional geometry of the furnace, has built-in formulae, algorithms, and procedures to generate corrected tube temperatures. Field trials at varying plant loads were carried out to verify and improve the accu- racy of the model. It was discovered that the actual tube temperatures, after back- ground correction, were 25-40° lower than the uncorrected temperatures. Additionally, to validate the accuracy of the model, gold cup pyrometry was used as a benchmark. The results of the gold cup pyrometry confirmed an error in the uncorrected TST of 30-40°C, thereby affirming the accuracy of the background correction model. With a TST margin of 25-40°C estab- lished, the plant capacity was safely increased, and TST was no longer limiting up to 84% plant capacity. v Data visualisation (heat map, burner management, and optimisation) In the subsequent development, TST data was used to develop an advanced data visualisation tool. The thermal map of the reformer furnace was generated using the TST readings captured by the pyrometer. With the thermal map, operators were able to see the exact visual profile of the furnace. They could identify areas of local- ised overfiring, tubes that were exceeding their design limits, burners causing flame impingement, and other crucial informa- tion that was previously not visible. Based upon the thermal map, the operators made adjustments to the burners and carried out optimisation. With regular furnace optimisation, local- ised overfiring was eliminated, and we could achieve up to 90% production capacity. w Advanced reliability monitoring (uti- lisation of TST for near real-time creep assessment and fitness for service evaluation) Utilising the tube skin temperature, stress-strain values from the Larson-Miller Parameter (LMP) curve provided by the tube manufacturer and following the pro- cedures laid down in API 579, which is the API code for Fitness for Service (FFS), the creep damage and fitness for service evaluations for each tube are performed in near real time. The entire evaluation is automated within the tool. So, the temperature of each tube is uti- lised to assess the daily health and reliabil- ity condition of each tube of the reformer, enhancing the reliability monitoring. All three functions of background tem- perature correction, data visualisation, and reliability monitoring have been encapsu- lated in an in-house developed tool known as REFORM (Reformer Optimisation and Reliability Monitoring) Tool.

Thermal map of Reformer

Date: 04.10.2023, H gen (%): 74%, Max tube skin temp: 941 ˚C Before Optimisation

Date: 06.10.2023, H gen (%): 74%, Max tube skin temp: 920 ˚C After Optimisation

Figure 2 Optimisation of burner firing with aid of data visualisation

FFS Level 1 Assessment

Accumulated Creep Damage

Figure 3 Creep assessment and fitness for service evaluation using daily TST data

TST values are recorded directly using the REFORM Tool loaded on an Intrinsically Safe Tablet. Background correction takes place automatically to provide accurate tube temperatures. A thermal map is gen- erated instantaneously, and the optimisa- tion process is carried out if required. The data is transferred to server, and reports are available on a dashboard hosted on the local intranet for operators of the next shift or anyone to view. Benefits The intelligent use of TST data and data analytics has resulted in the removal of bottlenecks in throughput (achieving 90% plant capacity utilisation without exceed- ing tube skin limits) with respect to tube skin temperature, more effective reformer furnace management (control of flame impingement and more optimised and balanced thermal profile of the furnace), and enhanced reliability monitoring (bet- ter understanding of the impact of every- day TST on tube reliability and enhanced tube life).

Background correction

Burner management

Heat map

TST DATA

Reliability monitoring

Optimisation

Data analytics

Creep assessment

Fitness for service

Figure 4 Comprehensive use of TST data

Thermal map of reformer

Optimisation map

Accumulated creep damage

API 579-1ASME FFS-1 Fitness for service evaluation

FFS Level 1 assessment

DATA MODULE

Tube skin temperature

Background correction

Optimisation Thermal map

Reliability monitoring

Creep assessment

Fitness for service

Burner management

Data analytics

Figure 5 Reformer optimisation and reliability monitoring tool in use at IOCL

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