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Fuels production

More environnementally-friendly fuels - For conversion, IFP Energies nouvelles seeks to address three major challenges: conversion of increasingly heavy crudes, compliance with ever more stringent standards and reduction of CO2 emissions related to conversion processes.

Conversion: increasingly efficient

Demand for heavy fuels is falling whereas their proportion in world oil supplies is increasing. It is therefore necessary to develop increasingly efficient conversion technologies. Petroleum with a high technological content (extra-heavy crudes, deep offshore, tar sands, oil shale, etc.), which will play a growing role in extending oil and gas reserves , will also require specific technologies.

For the conversion of residues and heavy crudes into fuels and combustibles, IFP Energies nouvelles is continuing to develop hydroconversion processes and catalysts. It is working on the development of a new range of catalysts associated with the Hyvahl^TMfixed-bed residue hydrodesulfurization process.

In addition, since the refining industry generates significant amounts of CO₂ (especially heavy conversion processes), IFP Energies nouvelles is examining the possibility of integrating CO₂ capture and storage processes in refineries.

Growth in gas oil demand

The other significant market trend is the growth in gas oil demand, while gasoline demand is dropping. This phenomenon - for the time being primarily in Europe - is now tending to spread internationally. As a result of this, there is a need to further adapt refining facilities. To this end, IFP Energies nouvelles is working to improve the flexibility of the FCC (Fluid Catalytic Cracking) process. This involves focusing on either maximization of propylene or the production of middle distillates. The FlexEne solution, brought to market in 2010, fits squarely with this approach. Research is also concentrating on the development of hydrocracking catalysts with greater selectivity for middle distillates.

In order to meet this increasing demand for middle distillates, IFP Energies nouvelles is also developing a process for the oligomerization of FCC light cuts towards kerosene and gas oil pools.

Stricter specifications

The tightening-up of standards and regulations related to fuels is continuing and being extended on a global level: widespread application of the European specification limiting the sulfur content of gasolines and gas oils to 10 ppm, reduction of the olefin and benzene content of gasolines, reduction in the polyaromatic content of gas oils, etc.

Where gasoline production is concerned, IFP Energies nouvelles is working on the development of catalysts, along with hydrotreatment processes (for desulfurization) and paraffin isomerization processes (to increase the octane number). For the hydrotreatment of catalytic cracking gasolines, a new range of catalysts was taken to market in 2010 for the Prime-G+™ desulfurization process, developed by IFP Energies nouvelles and Axens.

For the production of gas oils and kerosenes, IFP Energies nouvelles is working on the improvement of catalysts and hydrodesulfurization processes. The main focus is on increasing the activity and stability of catalysts in order to reduce the running costs of refineries. For example, a new nickel and molybdenum-based catalyst, intended for the deep hydrogenation of gas oils, was brought to market in 2010.