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Highly Selective Fischer-TropschSynthesis for Production of Jet Fuel
from Syngas
Santosh K Gangwal
9th International Freiberg Conference on IGCC and XTL
Technologies
Closing the Carbon CycleBerlin, GermanyJune 3 – 8, 2018
Southern Research
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• Southern Research Institute is an Independent Non-profit Corporation.
• Energy-related process research (biomass, coal, solar, waste heat) with a $30+ million initial investment from SR in 2007
• Lab, bench and pilot scale technology development, 30,000 ft2 high bay pilot plant, complete lab facility for process development
• Develop cutting edge technology with support from Government (e.g. DOE), private industry and internal funding
• License technology at appropriate stage, JV, spin off
Southern Research Energy and Environment Division Technology Development Business Model
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SR Supports The Full Pathway to Energy Technology Commercialization
- Lab Prototyping
- Feasibility Study
- Initial Commercial Design
- Pilot Plant
- Test/Optimize
- Commercial Design
- Commercial Demo.
- 3rd Party Verification
- Final Design Tweaks
Proof of Concept
Proof of Technology
Viability
Proof of Commercial
Viability
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SR XTL Technology Concept
Southern Research
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TECHNOLOGY DEVELOPMENT TEAM
• Southern Research (Lead, ATR catalyst development, FT reactor design/testing, Olefin upgrading)
• Chevron (Co-zeolite hybrid FT catalyst supplier)
• IntraMicron (Thermally conductive reactor packing)
Southern Research
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SR XTL Technology Development Status
6/12/2018 Southern Research Engineering
• Technology development began in 2012 with an initial grant from DOE—process is currently at large bench scale
• Total funding to date from Government and Southern Research $ 7.0 million (not including Chevron contributions)
• Technology Components
• SR patent pending sulfur tolerant Ni reforming catalyst
• Chevron Co-zeolite hybrid FT catalyst—over 20 patents
• Intramicron patented microfiber entrapped catalyst (MFEC) packing for FT
• SR FT Reactor design and operational know-how
• SR FT patent-pending olefin upgrading process add-on (significantly increases jet fuel yield)
• SR currently in discussions for scale up to pilot plant with a couple of companies but is open to further collaborations
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Chevron Cobalt-Zeolite Hybrid Catalyst
Production of clear wax free liquids
Reference: Kibby C. L., Jothimurugesan K., Das T., Saxton; R. J., Burton, Jr. A. W., US Patent Application 20110144219 (2011)
• Highly selective: >70% hydrocarbon liquids
• 5x greater yield than traditional catalysts
• Eliminate production of undesirable wax
• CAPEX and OPEX reductions
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IntraMicron’s MicrofibrousEntrapped Catalysts (MFEC)
Cu-entrapped FT Catalyst
Particles
MFEC Allows
• Use of simpler fixed beds• Large diameters up to 2-6
inches• Very high activity catalyst
particles• Isothermal operation
Resulting in
• High productivity and selectivity
• Shorter and fewer tubes• Reduced cost
Images from http://www.intramicron.com
Southern Research
96/12/2018 Southern Research Engineering
SR 2 Inch and 4 Inch Diameter Fixed-Bed Reactors
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SR XTL Technology Concept
Southern Research
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Reformer and FT Test Program
6/12/2018 Southern Research Engineering
• Lab-scale catalyst development and testing with simulated syngas
• Field testing using actual syngas from Kellogg transport gasifier (TRIG) at the National Carbon Capture Center (NCCC)
126/12/2018 Southern Research
Reformer Installed in Cabinet for Operation in Class 1 Div. 2 Industrial Environment at NCCC
136/12/2018 Southern Research Engineering
Fischer-Tropsch Skid Installed at NCCC
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Reformer and FT Skids Installed at NCCC for Testing with Actual Syngas
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ATR Catalyst Field Testing• High conversion of methane in
the presence of 380 ppm H2S –tars and ammonia not detected in effluent
• Ability to control H2:CO ratio
• Strong effect of temperature on methane conversion
• No evidence of catalyst poisoning
6/12/2018 Southern Research
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Adjusting H2:CO Ratio
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FT Field Testing; 2 inch Diameter Reactor
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FT Field Testing; 4 inch Diameter Reactor
0%
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90%
100%
4/9/2017 12:00 4/10/2017 0:00 4/10/2017 12:00 4/11/2017 0:00 4/11/2017 12:00 4/12/2017 0:00 4/12/2017 12:00 4/13/2017 0:00 4/13/2017 12:00 4/14/2017 0:00
CO Conversion Liquid Selectivity
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FT Liquid Selectivity from 4 inch reactor Testing• ~75% selectivity to
liquid hydrocarbons
• ~86% of liquid hydrocarbons in jet fuel range
• Improved Economics!
Southern Research
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• ATR Catalyst Testing– Laboratory-scale reformer was successfully modified and tested with coal-derived syngas for 125
hours at NCCC
– Catalyst had high methane conversion in the presence of 380 ppm H2S with no apparent poisoning
– Experiments demonstrated ability to adjust H2:CO ratio by adjusting steam flow (WGS not needed)
• Selective FT Synthesis– 2 and 4 inch ID FT reactors were successfully tested with Chevron catalyst and IntraMicron MFEC
technology in SR reactor
– ~75% selectivity to liquid hydrocarbons
– ~86% of the liquid hydrocarbons in the jet fuel range after SR upgrading
• Positive results warrant scale up of both technologies. SR currently in discussions with a company but would welcome other collaborations
6/12/2018
Conclusions
Southern Research
6/12/2018 Southern Research 21