IndianOil R&D... Forging New Frontiers
New Delhi 01-Jul-2011
Mr. R.S. Butola, Chairman, IndianOil
Depleting fossil fuels reserves, increasing energy needs and changing environment are the key drivers of innovation in the energy sector today. In this race to innovate the best technologies, reduction of carbon, water and waste footprint in various operations will be the guiding philosophy. Technology selection may increasingly be influenced by taxes on polluters, carbon audits & credits and governmental mandates for reduction of pollution. Currently deployed technologies that do not address the concern of global warming, will lose their relevance slowly and become obsolete in due course.
The technology-driven world of today requires constant innovations to make a corporate more competitive and efficient. In petroleum downstream sector, technological innovations are necessitated by the need to extract more out of the limited energy reserves and utilise new and unconventional energy sources. Global concerns over limited energy resources and increasing carbon emissions have accelerated the process of development and realignment of technological options having the least carbon footprint and more efficient usage of fuels. Increasing use of hydroprocessing for fuel quality improvement, desulphurisation and a shift towards cleaner fuels richer in hydrogen or to even neat hydrogen, and renewables will be required.
IndianOil R&D Centre
The Research and Development centre at Faridabad has been striving continuously to substantiate the IndianOil's vision of becoming the "Energy of India". To take care of the entire gamut of business operations of the corporation, which has the highest refining capacity, the largest pipeline & marketing network and diversified portfolios of E&P, Petrochemical and renewable energy, IndianOil's R&D Centre has chalked out ambitious strategies and plans. It is engaged in the research of low carbon technologies, products and processes in the areas of Refining Technology, Pipeline Transportation, Lubricant technology, Fuel additives, Petrochemical & Polymer, Biotechnology, Nanotechnology, Bio fuels. Hydrogen - Fuel cells, Gasification of coal/Petcoke/ Biomass, Solar Energy, Shale Oil and Gas Hydrates. Today, the Centre is credited to possess the brightest of minds conducting futuristic research using state-of-the-art analytical facilities and pilot plants.
Vibrant Research Areas Refining Technology
A scientist at work at IndianOil's
R&D Centre, Faridabad
From the very beginning, IndianOil's refineries adopted state-of-the-art technologies sourced from worldwide licensors and adapted these to the in-house requirements. However today, IndianOil has developed its own technologies, which compete with the best in the world and has placed the company on the global map of technology licensors. The Indmax technology for up gradation of residue to distillates, LPG and petrochemical feedstock is one of the hallmark technologies developed by IndianOil, which has brought laurels to the corporation. The technology has been licensed for use in the upcoming 15 million tonnes grassroots Paradip Refinery.
Work is underway to license it globally in collaboration with M/s ABB Lummus US. The other hallmark technologies are Needle Coke, DHDT for Diesel Hydro-treating, Light Naphtha isomerisation, INDALIN for conversion of low value olefinic naphtha.
IndianOil scientists have taken an initiative for development of less carbon-intensive technologies for deep desulphurisation of diesel and gasoline through adsorption route consuming less hydrogen. There are 20 different process simulation models which are used for troubleshooting, optimisation, process design, catalyst evaluation and technology development. FCC Model is licensed to M/s Intercat, US, earning substantial revenues. The technology basket also contains INDAdept Process which is an ideal process for meeting Bharat Stage-IV and V MS/HSD sulphur specifications. The food grade/polymer grade Hexane Technology unit is operational at Gujarat Refinery and the technology has been selected for the upcoming HMEL Refinery at Bhatinda.
Refining, over a period of time, has moved from physical separation to molecular transformation wherein catalysts play a critical role. A good amount of time and effort is going into development of catalysts for increasing LPG production, sulphur reduction in products, hydrogen reduction, etc. The breakthrough DHDS/DHDT catalyst developed by IndianOil is being successfully used in CPCL since 2009 meeting Bharat Stage IV specifications.
However, there are miles to go. The way forward in the area of refining technology is focused around superior resid cracking, Advanced Remaining Life Assessment Studies (RLA) & Non Destructive Testing (NDT), Corrosion & Reliability Research, Catalyst and Additives, Resid Hydrocracking, Alkylation and FT Synthesis.
Lubricant Technology Indian lube market ranks fifth in the world and is growing as compared to the developed world where it is either stagnant or falling due to advancement in performance. The challenges for industry in the area of lubricants include development of long drain and fill-for-life products, energy efficient lubricant formulations, lubricants compatible with alternative fuels and newer products to meet stringent environmental regulations.
SERVO Lubricants caters to the complete requirement of industry demands. With over 4000 product formulations, 800 commercial grades and 350 OEM approvals, sales of SERVO lubes contribute to ~8 % of IndianOil's profit. With strong R&D backup, SERVO holds 38 % of the lubes market and is the national lube business leader among 20 major players in the country. SERVO Marine oil proudly stands among the six globally approved technologies and fulfills 90 % of global marine OEM requirements.
Now the focus in lubricant technology area will be towards modernization of Engine Test Facilities for lube testing. Attention is also accorded to developing eco-friendly industrial lubes, rubber process oils, radiation resistant lubricants, Bharat Stage V/VI compliant and fuel efficient engine oils, Synthetic Aviation Lubricants, component based gas engine oils, MARPOL compliant marine oils and Poly urea greases. IndianOil also aims to strengthen research in advanced tribology.
PipelinesJointly with the Bhaba Atomic Research Centre, IndianOil R&D developed the first indigenous magnetic flux leakage based (MFL) intelligent pigs (IPIG) for pipeline inspection making IndianOil the only company east of Suez to own this technology. IPIG (Instrumented Pipeline Inspection Gauge) / CPIG prototypes of 12", 14" and 24" were developed and tested in over 2,000km pipelines. The IPIGs in these segments are now ready for commercialisation and process of identification of suitable partners for commercialisation has been initiated.
Fuels 
Hydrogen pump
The Fuels Group at IndianOil's R&D Centre has developed many fuel additives which have earned revenues on account of import substitution. Some of the important products include Multifunctional Additives (MFA) for gasoline and diesel, lubricity improver, diesel stabiliser, corrosion inhibitor, antioxidants and friction modifiers.
Several new projects are on the anvil in the coming years. These include Lubricity Improver for Naphtha in Gas Turbines. Friction Modifier for Gasoline MFA, Friction Modified Diesel MFA for improved mileage, Combustion improver for Furnace Oil, Additive package for branded FO, Nano-additives as fuel combustion improver, Drag Reducers, etc
Bio Technology 
Indmax Unit - Guwahati Refinery
The bio-remediation technology developed by IndianOil's R&D Centre has been deployed at our refineries and marketing installations for oily sludge disposal. The Corporation plans to set up an Advanced Bio-energy research facility in collaboration with the Deptt of Biotechnology. The main focus will be on second generation biofuels and technology development & deployment. IndianOil is also targeting Capability building in the areas of Genetic Engineering, Microbiology & Enzymology.
Alternative Energy Several ambitious projects in the sphere of solar energy, utilisation of Shale Oil, Gas Hydrates, and reforming of Natural Gas to H-CNG, CO to Ethanol, Algal Biofuels and Gasification of coal/petcoke/biomass have been embarked upon. Considering the inherent problem of trans-esterification process and biodiesel, a process for processing non-edible vegetable oil through hydro-processing has been developed and shall be tried for commercialisation. In addition, work is underway on promoting technologies for second generation biofuels, which may be produced from a variety of feedstock including waste material such as ethanol from lignocellulosic fermentation, Algae based bio-fuels, Biomass to Liquid (BTL) via pyrolysis and gasification.
Research at R&D Centre in the area of solar energy is also gearing up. Evaluation of solar photovoltaic technologies, technology selection, focus on solar, thermal, hybrid system based on gasification unit, solar thin film & dye sensitised systems and development of solar appliances are some of the key areas of research in the coming years.
Hydrogen is projected as the fuel of the future. There is need to work around a cluster of technologies for production of Hydrogen from renewable sources. This will enable developing countries such as India to shift to the next generation strategies in building sustainable energy system of the future. IndianOil has done extensive work to study the effect of H-CNG blend on the environment. India's first H-CNG dispensing station was set up at our R&D Centre. A less severe, single step compact reforming process has been developed for production of H-CNG for direct dispensing into vehicles thus eliminating the need for separate production of hydrogen, its storage and blending. A demonstration unit at pilot plant scale for this technology is being set up at our R&D Centre.
Petrochemicals & Polymers The Petrochemicals and Polymers group is at a nascent stage at our R&D Centre. It provides continuous technical support to the Naphtha Cracker and Business Development Group.
Some of the challenging tasks earmarked by this team of IndianOil scientists include Bench-marking of commercial grades, optimisation of additives for cost reduction, development of Catalyst Evaluation capabilities, etc.
Human Capital Focus on the energy sector is likely to drive a huge demand for skilled and trained technical personnel. In fact, there is an undeniable gap between science and citizens. A challenge for Indian energy companies especially IndianOil will therefore be, to prepare the next generation of technologists. IndianOil has taken an initiative for technological skill development by regular Industry-Academia partnerships and providing opportunities for post-doctoral research to identify and induct right research talent and encourage scientists / engineers for pursuing doctoral studies in India and abroad.
The challenges are plenty, competition is tougher, but opportunities are endless. IndianOil's R&D team is steadfast on its march to develop low carbon technologies to fulfill the vision of IndianOil to become the energy of India! Opening new frontiers in fossil energy is vital for the company and the country.
