fischer-tropsch synthesis in a microchannel reactor: the...
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Microchannel Fischer-Tropsch
Overview
IntroductionToday’s FT TechnologiesProcess Intensification ApproachesMicrochannel Fischer-Tropsch
Commercialising >20 yrs’ research at universityChemistry Department
Largest Chemistry Department in Western World and company founded by Head of Inorganic Chemistry
Well capitalised
Developing and commercialising catalysts for production of clean fuels
Based near Oxford, UK
Commercialising 15 yrs’research originating in US DoE National Laboratory (PNNL)
Founded by Battelle − world’s largest independent science & technology organisation ($4bn R&D p.a. / 20,000 staff / 130 locations)
Over $160m invested in technology to date, primarily by commercial partners
Global leader − largest microchannel process technology IP portfolio in world
Acquired by Oxford Catalysts in Nov-08
Based near Columbus, Ohio, USA
Oxford Catalysts Ltd. Velocys, Inc.
Critical mass: over 90 employeesPublicly traded (LSE: OCG)
Conventional FT Technology
FT Technology Today – Fixed BedKey Reactor Stats:– Weight: 1,200
tonnes– Capacity: 5,800
bpd– Diameter: 7m– Height: 20m– Reactor tubes: 29,000– Tube length: 12m– Tube diameter: 2.5cmFixed bed FT Reactors are
massive
FT Technology Today – Slurry Bed
--
Vapor ZoneVapor Zone
Slurry Bubble
(small catalyst
particles)
Vapor product
Liquid product
Catalyst/Wax
Separator
CatalystReturn
Syngas
Boiler Feed
Water
Slurry bubble FT Reactors among the largest in the world
FT Reactor during shippingCapacity = 15,000 bpdWeight = 2,200 tonsHeight = 60 mOuter Diameter = 10m
Process Intensification Approaches for FT
Microchannel Technology
~ 25-150 mm
Conventional
~ 0.1-1.0 mm
Characteristic dimension
Microchannel
Impact of TechnologyMicrochannel technology systems outperform conventional reactors–Accelerates chemical
processes by 10 – 1,000 fold
–Allows use of new, novel, more active catalysts
–Controls reactions at optimal conditions
–Enables smaller, more productive reactors
Microchannel Fischer-Tropsch Reactor Concept
-(CH2)n- + H2OCO + 2 H2
Water Water/Steam
Close integration of the exothermic Fischer-Tropsch synthesis and steam generation
0.1 – 5.0 mm
0.1 – 5.0 mm
MicrochannelReactor
Oxford Catalysts’ OMX preparation method produces a crystallite size
distribution 50% narrower than conventional, leading to more active and
stable FT catalysts
Co Crystallite Size
Freq
uenc
y
Low activity Low stability
OxfordOther
TestReactor
• Capacity: ~8 liters/day• Same fundamental design as commercial unit
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 200 400 600 800 1000 1200 1400 1600 1800
Time on stream (hr)
Con
vers
ion,
Sel
ectiv
ity (%
)
170
190
210
230
250
270
290
310
330
350
370
Tem
pera
ture
(°C
)
CO Conversion
CH4 Selectivity
Temperature
36 bpd/reactor
44 bpd/reactor
28 bpd/reactor
Number up
Scale up
Critical dimensionsremain constant in
Velocys Technology
Microchannel FTPreparing for Market Entry
Commercial FT Reactor Assembly
Capacity = 300 – 500 barrels/day
Coolant Out - Vapor
Coolant Out - Liquid
(under shell - not shown)
Coolant In
Process Out
RepeatingUnits
Process In
Specifications• Shell Diameter = ~1.5 m• Shell Length = ~8 m• Coolant flow length = ~0.6m• Process flow length = ~0.6m
Comparison with Conventional FT
Catalyst Productivity Comparison
Reactor Productivity Comparison
0
2
4
6
8
10
12
14
0 2,000 4,000 6,000 8,000 10,000 12,000
Scale of Single Reactor (bpd)
Rea
ctor
Pro
duct
ivity
(b
pd/to
nne
- rea
ctor
wei
ght)
360 bpd MicrochannelReactor Assembly
Shell - Bintulu
Shell - Pearl
Sasol - Oryx
Demonstration Phase
Assured Aerospace Fuels Research Facility–Wright Patterson Air Force Base (Dayton, OH)–Phase I
Under construction Steam reformer + Fischer Tropsch + Hydrocracker ~100 liters/day of FT capacity
–Extensive fuel evaluation program
Velocys supplying microchannel FT reactor system
Velocys participating in key U.S. Air Force fuel demonstration
Air Force FT Project Schedule
Initial Test:– Operate on slip stream from
Güssing biomass gasifier– Timing: Early 2010
Long-Term Test– Begin upon completed
construction of new testing facility at Wright Patterson Air Force Base
– Timing: Early 2011
FT Reactor Field Demonstration Skid
FT Reactor Assembly
Wax SeparatorVapor Liquid
Separator
Coolant surge Tank
Coolant Pumps (2)
ZnO Bed
Coolant Water Filters
Product Drums
Flash Drums
2.5
M
4 M
~6 M
Electrical Controls
Control Panel
Velocys FT Demonstration Skid
FT Demonstration Skid currently being installed at Güssing biomass gasification facility for initial operation
FT Demonstration Skid currently being installed at Güssing biomass gasification facility for initial operation
Microchannel Hydrocracker PerformanceHigh throughput demonstrated. 10 – 30x conventional
Good selectivity and yield to diesel fraction – can be adjusted
Low gas production
High throughput takes advantage of higher reactivity of larger over smaller hydrocarbons
Carbon Number Distribution
0.0001
0.0010
0.0100
0.1000
1.0000
0 10 20 30 40 50 60 70 80 90
carbon number
mas
s fr
actio
n
feedproduct, 10 hr-1 WHSVproduct, 20 hr-1 WHSVproduct, 30 hr-1 WHSV
Hydrocracked Product Distribution
Summary
Microchannel technology + highly active catalysts greatly improve FT synthesisVelocys FT technology is one key to unlocking BTL opportunities
Thank you for your time and attention
Derek AtkinsonBusiness Development Director
Oxford Catalysts115e Milton ParkOxfordOX14 4RZ Tel: +44 1235 841700Email: