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Modular, Compact Fischer-Tropsch Technology
13 October, 2008
Jeff S. McDaniel
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Agenda
Velocys Introduction
Modular FT Technology
Conventional FT Technology
FT Demonstration Status
Modular Hydrocracking Technology
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Velocys Incorporated
Battelle Memorial Institute spin-out company in 2001
60+ employees
Commercializing microchannelprocess technology
82 U.S. Patents
Over $100 million of funding from industrial partners
Modular Fischer-Tropsch
• Microchannel reactor architecture• Excellent performance
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~ 25-150 mm
~ 0.1-1.0 mm
Conventional
Characteristic dimension
Microchannel
Microchannel Technology
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Impact of Technology
Velocys® Technology systems outperform conventional reactors• Accelerates chemical
processes by 10 – 1,000 fold • Enables smaller, more
productive reactors• Allows use of new, novel,
more active catalysts• Controls reactions at optimal
conditions
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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
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Commercial FT Reactor Assembly
Capacity = 300 – 500 barrels/day
1.5 M
8 M
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2nd Generation Demo Reactor
TestReactor
• Capacity: ~8 liters/day• Same fundamental design as commercial unit
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Key Performance Results
• Pressure: 350 psi• Temperature: 210 - 225°C• Diluent Level: 4 - 18%• 3,500+ hours of operation• Contact time: 210 - 290 milliseconds• CO Conversion: >70% • CH4 Selectivity: 8 - 12%• Alpha: ~0.90• Productivity: 28 – 40+ BPD/full-scale reactor
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FT Pilot ReactorDemonstrated Capacity
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
Demonstrated capacity of 40+ BPD/reactorDemonstrated capacity of 40+ BPD/reactor
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Catalyst Regeneration
Activity recovered with in-situ regenerationActivity recovered with in-situ regenerationTime-on-Stream (hr)
0 500 1000 2000 2500
Con
vers
ion,
Sel
ectiv
ity (%
)
0
10
20
30
40
50
60
70
80
Tem
pera
ture
(°C
)
170
190
210
230
250
270
290
310
330
350
370
CO ConversionCH4 SelectivityTemperature
Reg
ener
atio
n
Conventional FT Technology
• Two established FT technologies• Both optimized for large-scale facilities
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FT Technology Today – Slurry Bed
--
Vapor ZoneVapor Zone
Slurry Bubble Zone
(small catalystparticles)
Vapor product
Liquid product
Catalyst/Wax
Separator
CatalystReturn
SyngasBoiler Feed
Water
Slurry bubble FT Reactors among the largest in the worldSlurry bubble FT Reactors among the largest in the world
FT Reactor during shippingCapacity = 15,000 bpdWeight = 2,200 tonsHeight = 60 mOuter Diameter = 10m
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FT Technology Today – Fixed Bed
Key Reactor Stats:• Weight: 1,200 tonnes• Capacity: 5,800 bpd• Diameter: 7m• Height: 20m• Reactor tubes: 29,000• Tube length: 12m• Tube diameter: 2.5cm
Fixed bed FT Reactors are also massiveFixed bed FT Reactors are also massive
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0
200
400
600
800
1000
1200
1400
1600
Cat
alys
t Pro
duct
ivity
(k
g/m
3 /hr)
Fixed Bed Slurry Bed Velocys
Catalyst Productivity Comparison
Velocys FT reactors enable 10x catalyst productivity increase
Velocys FT reactors enable 10x catalyst productivity increase
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Reactor Productivity Comparison
0
2
4
6
8
10
12
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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
Microchannel FT matches capacity requirements of BTL and WTL applications
Microchannel FT matches capacity requirements of BTL and WTL applications
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FT Reactor Comparison
Able to scale down cost effectively––Reactor costs - BTL
Numbering-up approach–Scale-up
Catalyst maintained in reactor–Need for liquid-solid separation
Catalyst held stationary–Catalyst attrition
Slurry reactors enable simpler catalyst change-out––Catalyst exchange
High heat transfer performance–Isothermal behavior
Avoid CO mass transfer limitation through wax–Gas-liquid mass
transfer
Fixed bed enables high catalyst loading–Catalyst loading in
process channel
Small catalyst particles (~300 µ)–Pore diffusion
Velocys Advantage
Micro-Channel (Velocys)
Slurry (Sasol)
Fixed Bed
(Shell)Technology Characteristics
Ref – Reactors for FT Synthesis, Guettel et al, Chem. Eng. Tech., 2008
–Scale-up
–Need for liquid-solid separation
–Catalyst attrition
–Catalyst exchange
–Isothermal behavior
–Gas-liquid mass transfer
–Catalyst loading in process channel
–Pore diffusion
Slurry (Sasol)
Fixed Bed
(Shell)Technology Characteristics
Demonstration Status
• Key obstacles have been overcome • First field demonstration in spring 2009
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Fouling: Potential Issue with Microchannels
Vaporizer after 2,000 hours operation
Significant performance degradation over 2000 hours
Solids at 15 ppm, 80% initial vapor quality
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Fouling:Demonstrated Success for >1 Year
Vaporizer after 9,600 hours operation
No performance degradation over 9600 hours
Solids at 1ppm, 30% vapor quality
00.20.40.60.8
11.21.41.61.8
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0:00:00 2400:00:00 4800:00:00 7200:00:00 9600:00:00Time (hh:mm:ss)
Del
ta P
(psi
g)
020406080100120140160180200
Tem
pera
ture
(C) ,
%
Stea
mDelta P
Steam Quality
Outlet Air Temp (C)
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Catalyst:Demonstrated Success
Demonstrated.Process developed and demonstrated on multiple devices
Removing wax build-upRemoving catalyst after extended operation
Unloading
Demonstrated.Current device at 1,500+ hoursMultiple regenerations demonstrated in earlier devices
Achieving long, steady runsRemoving wax which blocks catalyst sites
Regeneration
Demonstrated.Successfully loaded multiple devices and identified commercial vendors
Evenly distributing and packing catalyst particles in microchannels
Loading
StatusPrimary ChallengeAspect
Demonstrated.Recent device at ~1,800 hoursMultiple regenerations demonstrated in earlier devices
Achieving long, steady runsRemoving wax which blocks catalyst sites
Regeneration
Demonstrated.Successfully loaded multiple devices and identified commercial vendors
Evenly distributing and packing catalyst particles in microchannels
Loading
StatusPrimary ChallengeAspectDemonstrated.Successfully loaded multiple devices and identified commercial vendors
Evenly distributing and packing catalyst particles in microchannels
Loading
StatusPrimary ChallengeAspect StatusPrimary ChallengeAspect
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Velocys devices minimize time and cost to commercialization
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Reducing development risk by “Numbering-up” vs Scaling-up
Number upScale up
Critical dimensionsremain constant in
Velocys Technology
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U.S. Air Force Demonstration Project
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
Velocys participating in key U.S. Air Force fuel demonstration
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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
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FT Reactor Field Demonstration Skid
FT Demonstration Unit under ConstructionFT Demonstration Unit under Construction
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Air Force Project Schedule
Current Status:• Project initiated in late April• Construction of reactor and testing skid by February
Initial Test:• Operate on slip stream at Gas Technology Institute• Timing: March – May 2009
Long-Term Test• Begin upon completed construction of new testing
facility at Wright Patterson Air Force Base• Timing: December 2009 – May 2010
Microchannel Hydrocracking Technology
• Initial evaluations successful• Help enable BTL applications
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Gasification CO / H2 FT Products
H2O
Steam
Fischer Tropsch
Coal, Biomass or Waste
Hydro-Cracking
Velocys technology demonstrated at the
pilot scale
Synthetic Fuel Process
JP8 or Diesel Fuel
Gas Recycle
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Gasification CO / H2 FT Products
JP8 or Diesel Fuel
H2O
Gas Recycle
Steam
Fischer Tropsch
Coal, Biomass or Waste
Hydro-Cracking
Market need for modular hydrocracking technology for
< 5,000 bbl/day facilities
Synthetic Fuel Process
Velocys developing modular hydrocracking technology
Velocys developing modular hydrocracking technology
Velocys Microchannel Technology
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Microreactor HydroprocessingOpportunity
Uniform and controlled contact between oil and hydrogen
Very high catalyst productivity
Optimize hydrogen utilization to lower operating cost
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Initial Results
Feedstock: wax cut from Velocys FT reactor
Hydrocracking with very high productivity• LHSV 10 - 40 hr-1
• High conversion, >90% single pass• Very low C1 and C2 yield
Wax
FeedstockLight
ProductHeavy
Product
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Summary
Microchannel technology greatly improves FT synthesis
Velocys FT and hydrocracking technologies unlocks BTL opportunities
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Contact Information Jeff McDaniel
Business Development [email protected]
Velocys Inc 7950 Corporate Blvd. Plain City, OHIO 43064 USA Phone: 614/733-3300 Web: www.velocys.com
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