Madan Kumar Kumaravelan
Chief Manager - R&D
Hindustan Petroleum Corporation Limited
India
K Madan Kumar has done Masters in Chemical Engineering at Indian Institute of Technology (IIT), Bombay in 2008. He joined HPCL in 2008. He has 3 years of refinery experience followed by 14+ years of R&D experience. He is leading a team of Process Design & Scale-Up group at HP Green R&D Centre, Bengaluru. India. He has vast experience in research areas pertaining to Fluidized catalytic cracking, Thermal cracking of Vacuum Residue, Absorption & Adsorption, Process intensified Rotating Packed bed, Used Cooking Oil pretreatment, CBG production from Biomass etc.
Participates in
TECHNICAL PROGRAMME | Energy Technologies
GHG Emissions (Scope 1&2) Abatement (CO2, Methane) - Detection; CO2 Capture; CCUS; DAC; Carbon Products
Forum 20 | Hall 5 Digital Poster Plaza 4
13
October
12:30
14:30
UTC+3
Since emergence of the need for carbon capture, solvent based CO2 absorption processes encompassing conventional trayed columns have been dominating. However, these CO2 absorption columns have major limitations of tall size (20 to 30 meters) and huge weight. Main reason for such huge height is due to poor gas-liquid mass transfer efficiency which is governed by gravity.
Hindustan Petroleum Corporation Limited (HPCL), India has developed a novel HiGAS technology for overcoming these limitations. With this breakthrough technology, height of absorption columns can be reduced significantly by 10 times. HiGAS technology uses a Rotating Packed Bed (RPB) made of high surface area packing elements and induces centrifugal forces that are over 100 times of gravity. This reduces the Height Equivalent to Theoretical Plates (HETP) by 50-100 times, resulting in multitude level intensification of mass transfer efficiency and small unit size. First-of-its-kind commercial HP-HiGAS unit has been successfully implemented in HPCL Refinery, India for refinery fuel gas sweetening. This 2.5 meters HIGAS unit designed for removal of acid gas from 4 wt% to 100 ppm has replaced the existing 23 meters absorption column having 28 trays thus resulting in a significant size reduction of 10 times.
HPCL is now setting-up a commercial scale carbon capture unit for producing blue hydrogen based on HP-HiGAS technology. This unit with 24 KTPA CO2 capture capacity is being set-up at the Hydrogen Generation Unit (HGU) in HPCL refinery at an investment of 2 million USD.
HP-HiGAS technology, backed by its significant benefits of low size / foot print, low capital cost and improved safety, is the next generation revolution in carbon capture technologies as it perfectly suits all the CO2 capture requirements. Tapping the huge potential of HiGAS technology worldwide for carbon capture, would create a dramatic impact across the globe.
Hindustan Petroleum Corporation Limited (HPCL), India has developed a novel HiGAS technology for overcoming these limitations. With this breakthrough technology, height of absorption columns can be reduced significantly by 10 times. HiGAS technology uses a Rotating Packed Bed (RPB) made of high surface area packing elements and induces centrifugal forces that are over 100 times of gravity. This reduces the Height Equivalent to Theoretical Plates (HETP) by 50-100 times, resulting in multitude level intensification of mass transfer efficiency and small unit size. First-of-its-kind commercial HP-HiGAS unit has been successfully implemented in HPCL Refinery, India for refinery fuel gas sweetening. This 2.5 meters HIGAS unit designed for removal of acid gas from 4 wt% to 100 ppm has replaced the existing 23 meters absorption column having 28 trays thus resulting in a significant size reduction of 10 times.
HPCL is now setting-up a commercial scale carbon capture unit for producing blue hydrogen based on HP-HiGAS technology. This unit with 24 KTPA CO2 capture capacity is being set-up at the Hydrogen Generation Unit (HGU) in HPCL refinery at an investment of 2 million USD.
HP-HiGAS technology, backed by its significant benefits of low size / foot print, low capital cost and improved safety, is the next generation revolution in carbon capture technologies as it perfectly suits all the CO2 capture requirements. Tapping the huge potential of HiGAS technology worldwide for carbon capture, would create a dramatic impact across the globe.
TECHNICAL PROGRAMME | Energy Fuels and Molecules
Alternative Fuels - E fuels, Biofuels and SAF
Forum 15 | Hall 10 - SAUDI ENERGY Technical Programme 3
13
October
14:15
15:30
UTC+3
The aviation sector is under increasing pressure to reduce carbon emissions, with the International Air Transport Association (IATA) committing to cut emissions to 50% of 2005 levels by 2050. Sustainable Aviation Fuel (SAF) has emerged as a key solution, offering a near drop-in replacement for conventional Jet A-1 fuel. However, large-scale SAF production faces challenges due to high capital investment and complex multi-step processing in conventional pathways like Hydro processed Esters and Fatty Acids (HEFA).
To address these challenges, Hindustan Petroleum Corporation Limited has developed HP- Triglycerides to Jet fuels (HP-TriJet), an innovative single-step hydroprocessing technology that converts Used Cooking Oil (UCO) into Sustainable Aviation Fuel (SAF) and Green Diesel. Unlike conventional processes that require separate hydrotreating, hydrocracking, and isomerization stages, HP-TriJet seamlessly integrates depropanation, deoxygenation, hydrocracking, and isomerization within a single reactor system, utilizing a proprietary catalyst and optimized process conditions for efficient fuel production
Key features of HP-TriJet include:
India’s Food Safety and Standards Authority (FSSAI) estimates that 3 MMT of UCO can be recovered annually, providing a significant domestic feedstock source for SAF production. In alignment with global decarbonization goals, HPCL has completed the Basic and Front-End Engineering Design for a 7.4 KTPA HP-TriJet plant. With project implementation in progress, HP-TriJet is emerging as a cost-effective and scalable solution for advancing low-carbon aviation and transportation fuels
This game-changing technology provides a sustainable, economically viable, and industrially scalable solution for reducing fossil fuel dependency in the aviation and transport sectors.
To address these challenges, Hindustan Petroleum Corporation Limited has developed HP- Triglycerides to Jet fuels (HP-TriJet), an innovative single-step hydroprocessing technology that converts Used Cooking Oil (UCO) into Sustainable Aviation Fuel (SAF) and Green Diesel. Unlike conventional processes that require separate hydrotreating, hydrocracking, and isomerization stages, HP-TriJet seamlessly integrates depropanation, deoxygenation, hydrocracking, and isomerization within a single reactor system, utilizing a proprietary catalyst and optimized process conditions for efficient fuel production
Key features of HP-TriJet include:
- Flexible product yields: Capable of producing up to 35% SAF (meeting Jet A-1 specifications) or 80% Green Diesel (compliant with EN 15940:2016 Class A standards) based on operating conditions.
- Lower capital and operating costs: A single-step process eliminates the need for multiple reactors and reduces hydrogen consumption, improving economic feasibility.
- Scalability and refinery integration: Enables co-processing with conventional feedstocks, allowing refineries to transition towards renewable fuel production without major infrastructure modifications.
India’s Food Safety and Standards Authority (FSSAI) estimates that 3 MMT of UCO can be recovered annually, providing a significant domestic feedstock source for SAF production. In alignment with global decarbonization goals, HPCL has completed the Basic and Front-End Engineering Design for a 7.4 KTPA HP-TriJet plant. With project implementation in progress, HP-TriJet is emerging as a cost-effective and scalable solution for advancing low-carbon aviation and transportation fuels
This game-changing technology provides a sustainable, economically viable, and industrially scalable solution for reducing fossil fuel dependency in the aviation and transport sectors.
TECHNICAL PROGRAMME | Energy Technologies
Powering Mobility: The Energy Transition and the Future of Transportation
Forum 24 | Hall 5 Digital Poster Plaza 4
15
October
12:00
14:00
UTC+3
In the ever-evolving landscape of energy storage, the requirement for sustainable alternatives to conventional lithium-ion batteries (LIBs) has gained unprecedented urgency. Against the backdrop of depleting lithium reserves and growing trade constraints, this research explores a pivotal advancement in sodium-ion battery (SIB) technology—a cost-effective, environmentally conscious solution poised to redefine energy storage and contribute significantly to the global shift toward net-zero emissions [1]. As a future transportation initiative, this work elucidates the development of high-voltage, fast charging-cathode materials for SIBs, emphasizing their potential to propel indigenous energy storage technology globally, while fostering the requirement to accommodate stationery energy storage applications.
SIBs, with abundant sodium resources available worldwide, is currently growing as a competitor for lithium-ion technology. Our research spotlights large scale (kg batch) synthesis of sodium vanadium based fluorophosphates (NVPFX), a high-voltage (3.8 V average) cathode material synthesized through an environmentally neutral, single step annealing less process. This uniquely engineered material has remarkable energy density, reaching an impressive 350+ Wh/kg in half-cell configuration, a performance that positions them as formidable contenders to LIBs. This high energy density unlocks the doors to a myriad of efficient applications across industries, while contributing to the reduction of greenhouse gas emissions. A pivotal performance metric in the energy storage arena, cycling stability, stands testament to the robustness of NVPFX-based SIBs. With over 3000 cycles achieved and a capacity retention rate exceeding 85%, these batteries are primed for real-world applications, promising longevity and reliability. Moreover, these SIBs exhibit an exceptional charge capability while preserving deliverable capacity, rendering them ideal candidates for rapid-charging scenarios. This characteristic enhances user convenience and practicality in diverse applications while aligning with net-zero emissions targets.
A further significant achievement in this research is the incorporation of carbon nanotubes (CNTs) into NVPFX, further amplifying its rate capability retention during swift charging and discharging. The CNT were developed via a carbon neutral synthesis technique which further contributing to the reduction of carbon footprint and hastening the transition to a net-zero emissions future. Even under the compulsion of a 6-minute rapid charge, these SIBs deliver a commendable capacity (80% of practical capacity). In short, this innovative development of high-voltage cathode materials for SIBs not only solves issues with lithium-ion batteries but also powers future of transportation via affordable sodium-ion battery technology.
Sodium-ion batteries: present and future, Chem. Soc. Rev., 2017,46, 3529-3614
SIBs, with abundant sodium resources available worldwide, is currently growing as a competitor for lithium-ion technology. Our research spotlights large scale (kg batch) synthesis of sodium vanadium based fluorophosphates (NVPFX), a high-voltage (3.8 V average) cathode material synthesized through an environmentally neutral, single step annealing less process. This uniquely engineered material has remarkable energy density, reaching an impressive 350+ Wh/kg in half-cell configuration, a performance that positions them as formidable contenders to LIBs. This high energy density unlocks the doors to a myriad of efficient applications across industries, while contributing to the reduction of greenhouse gas emissions. A pivotal performance metric in the energy storage arena, cycling stability, stands testament to the robustness of NVPFX-based SIBs. With over 3000 cycles achieved and a capacity retention rate exceeding 85%, these batteries are primed for real-world applications, promising longevity and reliability. Moreover, these SIBs exhibit an exceptional charge capability while preserving deliverable capacity, rendering them ideal candidates for rapid-charging scenarios. This characteristic enhances user convenience and practicality in diverse applications while aligning with net-zero emissions targets.
A further significant achievement in this research is the incorporation of carbon nanotubes (CNTs) into NVPFX, further amplifying its rate capability retention during swift charging and discharging. The CNT were developed via a carbon neutral synthesis technique which further contributing to the reduction of carbon footprint and hastening the transition to a net-zero emissions future. Even under the compulsion of a 6-minute rapid charge, these SIBs deliver a commendable capacity (80% of practical capacity). In short, this innovative development of high-voltage cathode materials for SIBs not only solves issues with lithium-ion batteries but also powers future of transportation via affordable sodium-ion battery technology.
Sodium-ion batteries: present and future, Chem. Soc. Rev., 2017,46, 3529-3614
