Enabling smaller scale GTL with microchannel Fischer-Tropsch reactors
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The document discusses Velocys' microchannel Fischer-Tropsch technology for smaller scale gas-to-liquids (GTL) projects. Their high activity catalyst is 10 times more productive than conventional catalysts. Microchannel reactors provide enhanced mass and heat transfer allowing for high conversion rates. Velocys has developed manufacturing methods to produce reactors at scale for modular GTL facilities between 1,500 to 15,000 barrels per day. Pilot plant results demonstrate the stable performance of their catalyst and reactor design. Case studies highlight several commercial GTL projects utilizing Velocys technology that are enabled by factors like low cost feedstocks and existing infrastructure integration.
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Enabling smaller scale GTL with microchannel Fischer-Tropsch reactors
- 2. Microchannel Fischer-Tropsch reactors: enabling smaller scale GTL • Technology package to deliver smaller scale GTL – High activity catalyst – Microchannel reactors – Mass manufacturing methods – Modularisation • Latest results from Velocys Pilot Plant • Technology case studies: enabling factors
- 3. Velocys Technical Team Plain City, OH • 65 employees • Reactor design Houston, TX • 13 employees • Process engineering Milton Park, UK • 30 employees • Catalyst development
- 4. Super-active FT catalyst Velocys catalyst is 10x more active than conventional 0 200 400 600 800 1000 1200 1400 1600 Fixed Bed Slurry Bed Velocys CatalystProductivity (kg/m3/hr)
- 5. High conversion and selectivity CO conversions are held above 70% at all times – very high single pass conversion. Results are for a commercially manufactured lot – lab performance is scalable selectivity
- 6. High productivity FT catalyst >90% overall conversion with minimal recycle Equal to 91-92% overall conversion Equal to 94.5% overall conversion 180 190 200 210 220 230 240 250 260 270 280 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 50 100 150 200 250 300 350 Temperature,ºC %conversion,%selectivity Time on stream (days) Regeneration Loss of cooling system - high t. CO conversion Temperature Methane selectivity
- 7. Long in-place operating life is supported by stable regeneration
- 8. Microchannel reactors Microchannel FT reactorConventional FT reactor Microchannel Enhanced mass and heat transfer ~ 25-150 mm ~ 0.1- 10 mm Shell-and-tube
- 9. Commercial FT reactor FT reactor core • Principles of design and operation – Particulate catalyst in small channels – High catalyst volume fraction – Syngas downflow, products exit bottom – Coolant water / steam generation – Heat removal by steam generation • Strengths – High per pass conversion (75%+) – Isothermal behavior – thermally stable – Extremely robust to upsets – Strong economy of mass manufacturing – Accommodates high activity catalysts – Installed spares relatively cheap – High on-stream factor – Tail gas recycle only to achieve high conversion – Extremely high volumetric productivity – Ease of modularization Compact, robust, efficient and economic Microchannel technology
- 10. Microchannel FT reactor score card Property Tubular fixed bed Slurry bubble column Velocys microchannel Flow patterns Plug flow Well-mixed Plug flow Reactor scale-up methodology Easy/known Not well-known Easy/known Heat transfer limitations Very high Low Low Mass transfer limitations High Low Medium Thermal stability Poor Excellent Excellent Catalyst reaction rate Low Moderate Very high Reactor volumetric production Low Low High Differential pressure Moderate Low Moderate Gas recycle requirements High Moderate Low Catalyst wax separation Excellent Problematic/difficult Excellent Catalyst strength requirement Low High Low Regeneration equipment Minimal Significant Minimal Regeneration ease Difficult Complicated Simple Catalyst replacement Offline-slow On-stream Offline-rapid On-stream factor Low High High Feed poisoning Local Global Somewhat local Upset robustness Low Generally good High Shutdown robustness Good Poor Excellent Modularization Low Low High Mass manufacturing economies Low-medium Poor Excellent Boiler feed water quality Low Low Moderate Capital cost per bpd High Low (large plants) Low (distributed plants) Legend: poor ok good
- 11. Mass manufacturing and supply chain • Commercial FT reactor manufactured – Optimized final design for manufacture at volume • At state-of-the-art production facility at Shiloh • Reactor approved as fit for deployment by independent third party • Catalyst service partner trained and certified catalyst loaded in commercial reactor Reactor manufacture Catalyst loading
- 12. Supply chain partnership with Shiloh • North America’s supplier of engineered metal products to the automotive industry – Cost effective mass production – Consistent high quality – Initial capacity supports 10,000 bpd/yr of orders – Plans in place to support a 4x capacity increase • Partnership to – Continuously improve FT reactor manufacturing – Enhance overall GTL plant costs • Shiloh contributing – Several $M in manufacturing resources – Dedicated team of engineers
- 13. Modular GTL “for the mainstream” • Broader range of sites – 1,500-15,000 barrels per day – Suitable for remote locations • Lower risk – Smaller investments – Less risk of cost over-runs • Reduced costs – Standardized modules and reactors – Possible integration with existing facilities • Easier to execute and expand – Quicker plant construction (18-24 months) – Easier to permit, supply, build and operate – Additional trains can be added later 1,400 bpd FT process unit designed by Ventech Engineers 90 ft L x 46 ft H x ~40 ft W
- 14. Engineering partner example – Ventech Engineers • Placed reactor order for 1,400 bpd capacity – 8 commercial scale reactors ($8million) – Kick-started supply chain – Production underway • Several GTL plants in engineering – Considering investing in some of these • Participating in JV with Velocys, Waste Management and NRG Energy
- 16. Pilot plant and training facility • Integrated GTL pilot plant in Ohio • Designed to provide – Performance data to support differing client designs – Product for client studies – Permanent training facility for plant operators • Platform for – Developing our own field support staff – Demonstrating future product generations Add pilot plant photo Pilot plant
- 18. Pilot plant results Catalyst Productivity and Average Reactor Temp vs. Time on Stream
- 20. TECHNICAL CASE STUDIES – ENABLING FACTORS
- 21. • Project description — First GTL plant that will use a combination of renewable biogas and natural gas • Enabling factors — Low cost landfill gas as feedstock — RIN credits under the Renewable Fuel Standards — WM’s existing experience of operating GTL technology – Pilot plant on site since 2010 • Status — Final investment decision taken July 2014 — Construction proceeding; purchase of major equipment begun — Entered into all major contracts – EPC, land lease, gas purchase and product offtake Existing GTL pilot plant at East Oak JV with Waste Management, NRG Energy and Ventech – Oklahoma City
- 22. Ashtabula GTL • Project description – 2,800 bpd GTL plant in Ashtabula, Ohio, USA • Enabling factors – Integration with substantial existing infrastructure gives reduction in capex • Waste water treatment; power plant; cooling water pumping; air separation; gas pipeline; rail and barge; local customers for bi-products • Status – Velocys acquired the Ashtabula GTL project, and its project developer, in June 2014 – Initial engineering completed by Ventech (EPC), Haldor Topsoe & Velocys – Air permit recently granted Ashtabula GTL
- 23. GreenSky London • Project description – Commercial 2,500 bpd waste-biomass-to- jet fuel plant being developed by Solena Fuels in Development with British Airways • Enabling factors – Negative feedstock cost (tipping fees) – Regulatory incentives for aviation biofuels – Support of a major air-line that takes its environmental performance very seriously • Status – Pre-Front End Engineering completed – Site selection announced April 2014 Picture courtesy of British Airways
- 24. Red Rock Biofuels • Project description – 1,100 bpd forestry waste to liquids plant in Oregon, USA • Enabling factors – Supported by US DoD and US DoE • Received $4.1m phase 1 grant for engineering • 1 of 4 projects eligible to apply for $70m construction grant • Status – FEED study complete and submitted with phase 2 proposal – US DOD targeting late August for phase 2 grant decision
- 25. Ventech integrated modular GTL/DPU • Low cost Diesel Production Unit (DPU) integrated with GTL facility – DPU wide diesel cut combined with GTL hydro-processing may double diesel output – Synergy significantly reduces overall project capex and opex per barrel of product – Co-processing opportunities for naphtha enhanced Integrated GTL/CDU concept Off-Gas LPG Heavy Fuel Oil Naphtha Steam Fuel Gss Steam Syn-Gas FT Products Waste heat steam from reforming and FT reactor(s) Crude Oil or Crude Condensate Natural Gas and/or Refinery Fuel Gas Cogeneration Plant Fischer Tropsch Reactor Crude Oil Distillation Unit Reforming (auto- thermal reformer, steam methane reformer, or partial oxidation unit) Hydroprocessing System Main Steam Header Wide Cut Diesel Stabilizer Naphtha and Off- Gas Ultra Low Sulfur Diesel Ventech Patent Pending
- 26. Summary • Active catalysts and microchannel reactors enable smaller scale GTL • Mass-produced for cost-effectiveness • Modular construction methods provide a platform to deliver GTL “for the mainstream” • Commercial deployment underway
- 27. Thank you Jeff McDaniel Commercial Director jeff.mcdaniel@velocys.com Plain City, Ohio office +1 614 733 3300 Houston office +1 713 275 5840 www.velocys.com ®