Sustainable Catalyst Development for Indian Petrochemical Complexes: A Case Study

Thesis Abstract

Sustainable catalysis remains a critical lever for reducing energy intensity and environmental footprint in Indian petrochemical complexes, where reliance on legacy processes and mineral-based catalysts imposes efficiency and emission challenges. The study addresses the persistent gap between theoretical catalyst design and industrial performance by evaluating context-specific catalytic systems within two major Indian refineries and their associated cracker units, focusing on process intensification, lifecycle sustainability, and operational economics. The aim is to develop and validate a framework for sustainable catalyst development tailored to Indian petrochemical contexts, with objectives (i) to characterize current catalysts and process conditions used in selected complexes; (ii) to identify catalytic design criteria that optimize activity, selectivity, and longevity under indigenous feedstocks and ambient operating constraints; (iii) to synthesize and test novel catalyst formulations, including shared redox-active and zeolite-based matrices, under lab-to-pilot scale; (iv) to establish an analytical protocol integrating techno-economic and environmental performance assessments; and (v) to propose a scalable implementation pathway for industry uptake aligned with national decarbonization targets. The methodology adopts a mixed-methods research design combining qualitative and quantitative strands. The population comprises catalyst chemists, process engineers, and plant operators from Indian Petrochemical Complex A and B, with a purposive sample of 40 participants for expert interviews and 60 respondents for a structured survey to triangulate practice and perceived barriers. In the laboratory phase, a factorial experimental design (2^4) will be employed to screen nine catalyst formulations across model feedstocks representative of Indian refinery streams, with a targeted sample size of 36 catalytic tests per formulation conducted in a fixed-bed reactor platform. Analytical techniques include X-ray diffraction (XRD), scanning and transmission electron microscopy (SEM/TEM), Brunauer–Emmett–Teller (BET) surface area analysis, temperature-programmed desorption (TPD), and in-situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) to elucidate active sites; product distributions will be quantified by gas chromatography–mass spectrometry (GC-MS) and online GC facilities. Data analysis will integrate regression analysis and ANOVA to determine statistically significant effects of composition and operating conditions on activity and selectivity, with response surface methodology (RSM) used to optimize catalyst design. A life cycle assessment (LCA) will be conducted following ISO 14044 to compare environmental impacts of optimized catalysts against baseline catalysts, while a techno-economic analysis (TEA) will evaluate capital expenditure, operating costs, and payback period under three scenario settings. The theoretical framework synthesizes concepts from diffusion-adsorption kinetics, Sabatier-type catalytic mechanisms, and the Theory of Planned Behavior to interpret stakeholder acceptance of new catalysts, with two named theories Diffusion-Adsorption-Kinetic Theory for catalytic performance and the Technology Acceptance Model (TAM) adapted for industrial adoption. The expected findings include (i) identification of catalyst formulations that deliver at least 15–20% improvement in selectivity to target products and 25% increase in catalyst longevity under Indian feedstock conditions; (ii) validated relationships between acid site density, pore structure, and catalytic stability; (iii) empirically grounded RSM-derived design rules for scalable catalyst synthesis; (iv) a robust LCA showing reduced global warming potential and cumulative energy demand per tonne of product; and (v) TEA outcomes indicating acceptable payback within 3–5 years under favorable market assumptions. The study contributes to knowledge by bridging laboratory catalyst development with industrial-scale performance in the Indian petrochemical setting, offering a practical framework that integrates chemical engineering, sustainability assessment, and technology adoption. It provides actionable recommendations for refinery operators and policymakers, including recommended catalyst formulations, process integration strategies, and a staged rollout plan aligned with national emissions targets and feedstock diversification, with implications for skill development and collaborative industry-academia programs. The concluding recommendations advocate for pilot-scale validation at 100–300 kg per day, establishment of an Indian Catalyst Development Consortium, and policy incentives to accelerate adoption of sustainable catalysts in petrochemical complexes.