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CHEMICAL ENGINEERING PROGRAM Potentials for Ultra-clean Fuels Obtained from Natural Gas via GTL to Play a Role in Aviation and Automotive Industry Nimir O. Elbashir Texas A&M University at Qatar MEDW 2013 & Petchem Arabia Conferences May 14, 2013; Sofitel Hotel, Abu Dhabi, UAE

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Page 1: Potentials for Ultra-clean Fuels Obtained from Natural Gas ... 2 1510 MEDW_2013... · Replace RadFrac column with flash column Add a condenser after the flash column Optimize the

CHEMICAL ENGINEERING PROGRAM

Potentials for Ultra-clean Fuels Obtained from Natural Gas via GTL to Play a Role in

Aviation and Automotive Industry

Nimir O. Elbashir Texas A&M University at Qatar

MEDW 2013 & Petchem Arabia Conferences

May 14, 2013; Sofitel Hotel, Abu Dhabi, UAE

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CHEMICAL ENGINEERING PROGRAM

Content

Qatar leading role in Gas Processing Technologies.

Gas-to-Liquid technology and its potentials.

Commercial Fischer-Tropsch (FT) technologies

Enhancement in FT reactor and processing design to enhance ultra clean fuels production.

Synthetic jet fuels from GTL, the potentials and the challenges.

2

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CHEMICAL ENGINEERING PROGRAM

Oil

Gas

Coal

Hydro

Nuclear

Renewable

Total Primary Energy: 4 EJ/year

Potentials for natural gas to play a major role in the “Energy Market”

3

0 10 20 30

Russia

Qatar

United Arab…

Algeria

Venezuela

Indonesia

Malaysia

Total Reserve 6,607 tcf

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CHEMICAL ENGINEERING PROGRAM

Oil

Gas

Coal

Hydro

Nuclear

Renewable

Physical

1/600 volume

Natural Gas

Pipeline

LNG

GTL

Qatar’s aspiration to become the “World Gas Capital” led to the building the

largest GTL and LNG plants in the world.

Qatar contribution to the “Energy Market”

4

Total Primary Energy: 4 EJ/year

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CHEMICAL ENGINEERING PROGRAM

Dolfin Gas Project QatarGas Project

ExxonMobil Support LNG Facilities Shell the Pearl GTL Plant

5

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CHEMICAL ENGINEERING PROGRAM

Crude Oil Vs. Natural Gas ($/MMBTU)

6

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Natural Gas Production

7

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CHEMICAL ENGINEERING PROGRAM

LNG vs. GTL, which option is better?

From Mike Nel (Sasol) Presentation at the XTL World Summit in London – June 2011.

8

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Fuels transportation

- Major producers and users are located at great distances from each other.

- Fuels must be transported great distances.

- Due to transportation concerns, liquid fuels are favored.

Major trade movements 2009 (Millions of tons) [BP Statistical Review of world energy 2010]

9

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Synthetic Fuels Have Bright Future!

Obtained from SHELL Global Solution, 2007. Cherillo, et al. “Verification of Shell GTL Fuel as CARB Alternative Diesel”

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CHEMICAL ENGINEERING PROGRAM

Extremely low (0-5-ppm) sulfur, aromatics, and toxics

GTL fuels environmentally attractive

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CHEMICAL ENGINEERING PROGRAM

Syngas

H2 /CO

• Flexibility in feedstock's • Large product distributions • Ultra clean fuels (high cetane number and low sulfur content diesel + low

octane gasoline) & value added chemicals

Fischer-Tropsch

Lights HC (Feedstock)

Liquid Fuels

HC Wax Lubricants

Gas-to-Liquid Technology: Alternative

Energy Supply & Source of Value-Added Chemicals

Natural

Gas

Coal

Biomass

Synthesis Gas

Production

12

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α-olefins+ Gasoline + Jet Fuel+ Diesel +wax

CnH2n and CnH2n+2 + CO2, H2O, oxygenates

CO H2

H H C O

Catalyst Surface: Cobalt, Iron, Ruthenium, etc

O H

H

Fischer-Tropsch chemistry facilitates the conversion of syngas into liquids

13

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0

2

4

6

8

10

12

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Hy

dro

ca

rb

on

wt%

Carbon Number

Gasoline Diesel Wax

Jet Fuels

Selective control of hydrocarbon product distribution

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CHEMICAL ENGINEERING PROGRAM

GTL technology in Qatar 24,000 bpd diesel

+ 9,000 bpd naphtha

+1,000 bpd LPG

1 million tons of

kerosene/ year

+ base oil

15

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Desired Characteristics Packed bed reactor

(gas phase)

Slurry phase reactor

(liquid phase)

Operational Consideration

High Catalyst hold-up

High reactor productivity

Easy catalyst separation

Easy catalyst regeneration

High mass transfer rates

High heat transfer rate

Wide product spectrum

Advantage Disadvantage

Comparison between FTS reactors

The ideal FTS reactor should combine the advantages of the two major reactor technologies; fixed-bed reactors of high reactant diffusivity and reaction rates coupled with steady performance to that of the slurry reactor of well-mixed phase and excellent temperature distribution inside the reactor bed coupled with higher overall productivity. One more feature is the capability of controlling the hydrocarbon product distribution.

16

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CHEMICAL ENGINEERING PROGRAM

Fixed Bed Reactor

Supercritical

Phase

Active

site

Liquid-like density and heat capacity

Gas-like diffusivity and transport properties

Solvent Propane

Pentane

Hexane

Syngas

P

T

SC

L

V

Supercritical

Phase Reaction

Introduction of supercritical hydrocarbon solvent

Elbashir, Bukur, Durham, Roberts. 2010 AIChE J. 56 (3) 997.

17

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Region 1: Exothermic reaction

occurring in single phase – focus on

hot spot prevention

Region 2: Wax formation – tailor pore structure to facilitate wax extraction from catalyst

Region 3: Trickle bed regime – tailor pore structure and surface wettability to maximize secondary reactions

18

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0

0.1

0.2

0.3

0.4

0.5

0.6

Light Hydr. Gasoline Diesel Heavy Hydr. & Wax

We

igh

t F

rac

tio

n

Gas-Phase

Sc-Hexane

T= 240 C, Psyngas=20 bar,

15% Co/ Al2O3 Ptot = 65 barCO Conv. = 65%

CO Conv. = 73%

Huang, Elbashir , Roberts 2005. Industrial & Engineering Chemistry Research 43, 6369.

Comparison SCF-FTS & Gas Phase FTS Product Distribution & Conversion

19

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CHEMICAL ENGINEERING PROGRAM

Start with the control of the polymerization nature of FTS reactions

Improve product yields and purity

Simplify separation processes

Minimize production cost

Why is the selective control of Fischer

Tropsch products important?

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What it takes to design a novel reactor technology?

Elbashir, Eljack. 2010 in Advances in Gas Processing: Elsevier ©, vol. 2; 369.

21

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Process Design: Energy Integration & Optimization

The Design Phases of Novel Reactor

Advisory Board

Elbashir, Eljack. 2010 in Advances in Gas

Processing: Elsevier ©, vol. 2; 369. 22

Process Control

Reactor Design & Experimental Campaign

Products Processing

Phase Behavior & Thermodynamics

Kinetics & Product Distribution

In situ Reactor Behavior

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Microscale Studies: Simulation & Experimental

23

Kinetics, Chain growth Hot Spots

Phase Behavior

Diffusion Limitations

Bao, El-Halwagi, Elbashir 2010. Fuel Processing Technology 91(7) 703-713.

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Macroscale Studies

24

Energy Optimization

Solvent Selection

Reactor Configuration

P&ID

Solvent Recovery

Process Control

Synthetic Fuels Formulation & Characterization

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Catalyst Bed Behavior in SCF-FTS

25

Mogalicherla , Elmalik& Elbashir (2012) Chem. Eng. Prog.: Proc. Intes. 62, 59-68.

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Liquid & gas velocity profile 3D visualization Gladden et al. 2009. JMR 196, 142.

NMR Relaxometry Gladden, et al. 2009. J Phys. Chem. C 113, 6610.

26

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Solvent Price ($ per tonne)*

n-Pentane 989 - 1055

n-Hexane 955 - 985

Light Naphtha 720 - 775

Naphtha 690 - 761

Solvent Naphtha 875 - 885

Gasoline 722 - 745

* Selected solvent prices, as provided from the ICIS price reports.

Examining the most applicable solvent for commercial SCF-FTS based on phase behavior studies & cost

Elmalik, Tora, El-Halwagi, Elbashir 2011 Fuel Proc. Techn., 92; 1525.

Simulation Experimental

27

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CHEMICAL ENGINEERING PROGRAM 28

0

50

100

150

200

250

300

0 2 4 6 8 10

SS

I

Cost ($/gallon)

n-Pentane

n-Hexane

n-Heptane

n-Octane

n-Nonane

n-Decane

Blend 1

Blend 2

Blend 3

Blend 4

Blend 5

SSITotal=SSI1+ SSI2+ SSI3+ SSI4

Solvent Price ($ per tonne)*

n-Pentane 989 - 1055

n-Hexane 955 - 985

Light Naphtha 720 - 775

Naphtha 690 - 761

Solvent Naphtha 875 - 885

Gasoline 722 - 745

Examining the Most Applicable Solvent for Commercial SCF-FTS Based on Safety & Economic Assessment Cost

Hamad, El-Halwagi, Elbashir, Manann (2012) J. Loss Prevention in the Process Industries, online. Elmalik, Tora, El-Halwagi, Elbashir (2011) Fuel Proc. Techn., 92; 1525.

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Design of Optimized Sequence for Solvent Separation & Recycle

Flash column 1

Flash column 2

Flash column 3

RadfracDistillation 1

Radfrac Distillation 2

Radfrac Distillation 3

Flash column 4

Condenser

FT products

Heavy products

Permenant Gas 1

Permenant Gas 2

Solvent 1

Solvent 2

Water

FT reactor

Fresh feed (syngas, solvent)

recycle

mixer Condenser

Flash column 1

Flash column 2

Flash column 3

RadfracDistillation 1

Radfrac Distillation 2

Radfrac Distillation 3

Flash column 4

Condenser

FT products

Heavy products

Permenant Gas 1

Permenant Gas 2

Solvent 1

Solvent 2

Water

FT reactor

Fresh feed (syngas, solvent)

recycle

mixer

Replace RadFrac column with flash column Add a condenser after the flash column

Lowest Energy and Higher Efficiency

29

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CHEMICAL ENGINEERING PROGRAM

Flash column 1

Flash column 2

Flash column 3

RadfracDistillation 1

Radfrac Distillation 2

Radfrac Distillation 3

Flash column 4

Condenser

FT products

Heavy products

Permenant Gas 1

Permenant Gas 2

Solvent 1

Solvent 2

Water

FT reactor

syngas

recycle

mixer

Pressure and temperature control for

supercritical condition

mixer Fresh solvent

Pump

Flash column 1

Flash column 2

Flash column 3

RadfracDistillation 1

Radfrac Distillation 2

Radfrac Distillation 3

Flash column 4

Condenser

FT products

Heavy products

Permenant Gas 1

Permenant Gas 2

Solvent 1

Solvent 2

Water

FT reactor

Fresh feed (syngas, solvent)

recycle

mixer Condenser

Flash column 1

Flash column 2

Flash column 3

RadfracDistillation 1

Radfrac Distillation 2

Radfrac Distillation 3

Flash column 4

Condenser

FT products

Heavy products

Permenant Gas 1

Permenant Gas 2

Solvent 1

Solvent 2

Water

FT reactor

Fresh feed (syngas, solvent)

recycle

mixer

Replace RadFrac column with flash column Add a condenser after the flash column

Optimize the process

Process Alternatives

Process Simulation

Oil-Solvent input

Separation design constraints

Operating variables

Process Integration

Objective

Experimental Verification & Cost analysis

yes

no

Design, Operating output

Design of Optimized Sequence for Solvent Separation & Recycle

Buping, Elbashir, El-Halwagi, Elbashir (2012) ISSF, P0605; 1-8.

30

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Future generation of FTS Reactor Bed

31

N2 @0.2m/s

N2 @0.05m/s N2 @0.05m/s

N2 @0.2m/s

MFEC@ 207 mm

Particle and 3.6 vol%

12 mm Copper fibers

Packed Bed

@ 207 particles

(60 vol.%)

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CHEMICAL ENGINEERING PROGRAM

Cleaner skies

Qatar Airways makes historic journey with first GTL fueled commercial flight from London Gatwick to Doha

New Gas-to-Liquids fuel offers diversity of supply and better local air quality at busy airports

32

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CHEMICAL ENGINEERING PROGRAM

Consortium

A unique collaboration between industry and academia partners.

Each partner works on specific topics and collaborate towards the overall objective.

The testing is split up as follows:

Properties Testing Combustion Testing Performance Review

Technical Guidance

Funding Agencies

33

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Hydrocarbon Groups

Species & Carbon Number distribution in a conventional jet fuel (Jet A-1) versus a synthetic GTL kerosene (SPK).

*GCxGC data provided by Shell

34

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Hydrocarbon Groups

Group Structure

normal-Paraffins

iso-Paraffins

Naphthenes (cyclo-Paraffins)

mono-Aromatics

di-Aromatics

Naphthenic-mono-Aromatics

35

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Research Goals

Our role is to develop experimental, statistical and visualization techniques capable of correlating fuel’s hydrocarbon structure with their properties.

Working with industry & academia partners to develop future synthetic jet fuels obtained via Gas-to-Liquid [GTL] (i.e. Synthetic Paraffinic Kerosene [SPK]).

36

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Overview of TAMUQ Fuel Characterization Lab

State-of-the-art experimental facilities

37

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GTL Kerosene

Region of optimal properties

Raza, Elmalik & Elbashir 2011. Perp. Fuel Chem. Div. 56; p. 431.

Property Min Max

Density (g/ml) 0.775 0.84

Property Min Max

Freezing Point

(°C)

-47

Property Min Max

Flash Point (°C) 42

Area of crucial focus

n-Paraffin iso-Paraffin

cyclo-Paraffin

38

ASTM specification D1655

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Properties role on fuels’ performance

39

Courtesy of Dr. John Moran from Rolls Royce

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Detailed Composition & Products

Analysis

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Optimized synthetic jet fuel composition Heat Content Density

Freezing Point Flash Point

41 Rhman, et al. 2012. ENERGY & FUELS. ACS Meeting. San Diego, CA.

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Freezing Point

Optimized synthetic jet Fuel composition

42 Rhman, et al. 2012. ENERGY & FUELS. ACS Meeting. San Diego, CA.

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Explaining trend of composition

vs. properties

43

Freezing Point

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Freezing Point - Images

IB6 = -51.6

IB10 = -46.1

IB21 = -33.7

SPK = -56.5

Raza, Elmalik & Elbashir 2011. Perp. Fuel Chem. Div. 56; p. 431.

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Further Step

Purpose of the next phase is to enhance our understanding of how the properties vary with jet fuel hydrocarbon composition.

Objectives Role of aromatics on enhancing certain properties (Density,

Elastomer compatibility) and improving elastomer swelling behavior

Role of hydrocarbon number in determining the behavior of jet fuel

Role of other hydrocarbons, which can mimic the role of aromatics on certain properties (i.e.: Density) 45

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Skeleton of 3-D Pyramid

46

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Artificial Neural Network 3-D Visualization

47

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Summary

The first phase of the micro & macro scale design successfully

completed and resulted in an advanced SCF-FTS lab scale reactor.

Designed technology capable of maximizing the production of ultra-

clean fuels and value-added chemicals.

Established global collaborations with both industry and academia.

Conducting major research campaign in advancement of synthetic

jet fuels’ properties and formulation of new generations.

48

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Research Team

49

Dr. Bao Buping; Mohamed Noureldin

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Students Participations &

Awards

First Place Poster in the 3rd International Gas Processing Symposium. March 2012

Poster American Chemical Society Meeting in San Diego. Mar 2012

Recognition from the Energy & Fuels Division of the American Chemical Society

Research Team Award from the Chemical Engineering Program Texas A&M University: April 2012

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Student Researchers

Maryam Manjohari

Maha Kafood

Natalie Hamad

Mariam Al-Meer

Dhabia Al-Mohandi

Maria Orillano

Haider Ramadhan

Jahanur Rahman

Asma Saida

Moiz Bohra

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Research Associates

Dr. Suresh Reddy

Syed Hussani

Bilal Raza

Dr. Aswani Mogalicherla

Elfatih Elmalik

Dr. Jan Blank

Samah Warrag

Salima Mamikova

Ibrahim Al-Naimi

Laial Bani Nasser Dr. Rehan Houssein

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Acknowledgements

Prof. Mahmoud El-Halwagi Prof. Juergen Hahn Prof. Benjamin Whilhite

Prof. Christopher Roberts Prof. Fadwa Eljack

Prof. Dragomir Bukur Prof. Marcelo Castier Prof. Lynn Gladden

Collaborators

Industry Advisory Board

Willem Scholten Dr. Jim Rigby Dr. Ernest De Toit (former) Rashid Al-Rashdi

Willem Scholten Dr. Joanna Bauldreay

Prof. Chris Wilson

Dr. John Moran

Prof. Manfred Aigner Dr. Patrick deClerqe

Paul Bogers

Funding Agencies:

Prof. Rafiqul Gani

54

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This publication was made possible by following Grants from the Qatar National Research Fund (a member of Qatar Foundation). The statements made herein are solely the responsibility of the authors.

55

Funding :

Acknowledgements

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CHEMICAL ENGINEERING PROGRAM

CHEMICAL ENGINEERING PROGRAM

336F Texas A&M Engineering Building

Education City

PO Box 23874

Doha, Qatar

Tel. +974.423.0017

Fax +974.423.0065

[email protected]

http://chen.qatar.tamu.edu

Thank you

56

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Backup Slides

57

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0

5

10

15

20

25

30

35

40

45 55 65 75

Syngas conversion%

Sele

cti

vit

y %

CH4 Selectivity

CO2 Selectivity

Linear (CO2

Selectivity)Linear (CH4

Selectivity)

Gas-phase FTS, 230-250 C, P = 15-20 bar 15% Co/SiO2 (HSA), Syngas FR = 50-100 sccm/gcat

Comparison SCF-FTS & Gas Phase FTS Selectivity vs. Conversion

Elbashir , Dutta, Seehra, Roberts 2005. Applied Catalysis A: General 285, 169.

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0

5

10

15

20

45 50 55 60 65 70 75 80

Syngas Conversion %

Sele

cti

vit

y %

CH4 Selectivity %

CO2 Selectivity %

Linear (CO2

Selectivity % )Linear (CH4

Selectivity % )

Sc-Hexanes FTS, 230-250 C, P = 45-65 bar 15% Co/SiO2 (HSA), Hexanes/syngas (molar) = 3 Syngas FR = 50-100 sccm/gcat

Elbashir , Dutta, Seehra, Roberts 2005. Applied Catalysis A: General 285, 169.

Comparison SCF-FTS & Gas Phase FTS Selectivity vs. Conversion

59

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0

20

40

60

80

100

0 50 100 150

Time-on-stream (hr)

Acti

vit

y &

Sele

cti

vit

y

Syngas Conversion %CH4 Selectivity % Series3Series4Series5Series6230 C

250 C

230 C

Co3O4, Co+2

-Al2O3

Co3O4

fcc Co0

Stability of the same Catalyst in

Gas-Phase FTS

Elbashir , Dutta, Seehra, Roberts 2005. Applied Catalysis A: General 285, 169.

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0

20

40

60

80

100

0 50 100 150 200 250

Time-on-stream (hr)

Acti

vit

y &

Sele

cti

vit

y

Syngas Conversion %CH4 Selectivity % Series3Series4Series5Series6Series7Series8

240 C

230 C

240 C 250 C

Co3O4, Co+2

-Al2O3 hcp Co0

Stability of the same Catalyst in

Supercritical Phase FTS

Elbashir , Dutta, Seehra, Roberts 2005. Applied Catalysis A: General 285, 169.

61

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-13

-11

-9

-7

-5

-3

-1

0 4 8 12 16 20 24

Carbon number

ln(W

n/n

)

250

α = 0.83 P

T

SC

L

V

P=65 bar

Opportunity for Selective Control of Hydrocarbon Product Distribution

Elbashir , Roberts 2005. Industrial & Engineering Chemistry Research 44, 505.

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0

0.1

0.2

0.3

0.4

0.5

0.6

0 0.5 1 1.5 2 2.5

H2/CO feed ratio

r CH

4 f

orm

ati

on

(m

mo

l/g

ca

t.m

in)

gas-phase actual-rate

gas-phase predicted rate

Experimental and predicted rate of methane formation in high pressure gas-phase FTS

T = 240 C, PT = 60 bar Psyngas = 15 bar, Phelium = 45 bar, Helium/syngas (molar ratio) = 3

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0

0.1

0.2

0.3

0.4

0.5

0.6

0 0.5 1 1.5 2 2.5

H2/CO feed ratio

r CH

4 f

orm

ati

on

(m

mo

l/(g

ca

t.m

in) SCH-actual rate

SCH predicted-rate

Experimental and predicted rate of methane formation in SCH-FTS

T = 240 C, PT = 60 bar Psyngas = 15 bar, Phexane = 45 bar, Hexane/syngas (molar ratio) = 3

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Enhanced α-olefin incorporation in the chain growth process Dynamic adsorption/desorption equilibrium

1 Heat of adsorption

2 Pressure & residence time

3 Reaction media and phases

4 Feed ratio, catalyst type, temp., etc.

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Modified Reaction Pathway and Chain Growth Model for SCF-FTS

CH3.S

R1

Rn.S

Rn+1 +S

Rn.H+S H.S

CH3.S

Rn-2-CH+S

CH3

Rn+2 .S*

Rn+3 +S*

H.S*

CH3.S

Rn-CH+S*

CH3

Rn+2.H+S*

Regular chain growth model on S Enhanced olefin incorporation on S*

C.S*+H.S* CH.S*+S*

CH3.S*

(4) Kinetics of the SCF-FTS

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Enhanced incorporation of α-olefins in SCH Phase

C1*

+ C1* C2*

C2H4

+ C1* C3*

C3H6

C3H8

C4*

C4H8

C4H10

+ C1* + C1*

C3H8

-9

-7

-5

-3

-1

0 5 10 15 20 25

Carbon Number

ln(W

n/n

)

C5*

C5H10

C5H12

+ C1* Cn*

CnH2n

CnH2n+2

+ C1* Cn+1*

Cn+1H2(n+1)

Cn+1H2n+4

+ C1* Cn+m*

Cn+mH2(n+m)

Cn+mH2(n+m)+2

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Energy Integration

& Overall Techno-economic Assessment

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Techno-economic Assessment of the

Optimized Sequence

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Comparison between the three reactors

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with condenser with no con replace radfrac flash sequence heavy column

Category Item unit unit Pricesnote Amount/yr total MM$/yr

Chemicals

4760BTU/LB syngas $/GJ 13 59,847,124 778.01 56,220,266 731 56,220,266 731 56,220,265 731 56,220,266 731

Catalyst fixed bed 4 1 1 - 1 1 1

hexane $/gal 1.15 89,790,385,440 103,258.94 89,790,385,440 103,258.94 89,790,385,440 103,259 89,790,385,440 103,259 89,790,385,440 103,259

- - - - - -

- - - - - -

- -

- -

annual operating O&M labor%FCI/yr 4 54 54 - 56 52 52

operating labor 131 131 - 131 131 131

supervision, plant overheads, laboratory%labor 90 118 118 - 118 118 118

capital charge, insurance, local taxes, royalties%FCI/yr 15 203 202 - 210 196 194

Energy utility

1,715 1,715 - 1,880 1,530 1,592

after heat integration 1,064 1,064 - 1,110 1,047 945

- -

- -

- -

- -

- -

- -

Porducts sale sale 3,619 sale 3,619 sale 3,619 sale 3,621 sale 3,611

diesel $/bbl 82 43,800,000 3,592 43,800,000 3,592 43,800,000 3,592 43,827,060 3,594 43,709,310 3,584

gasoline $/bbl 63 - - - - - -

H2 $/kg 2 - - - - - - - - - -

H2O $/1000gal 1.2 1,044,119 1 1,026,183 1 1,026,183 1 1,026,183 1 1,044,119 1

tailgas $/bbl 50 517,570 26 525,562 26 525,562 26 525,563 26 517,570 26

hexane $/gal 1.15 89,774,303,982 103,240 89,699,200,892 103,154 89,699,200,892 103,154 89,698,503,869 103,153 89,774,303,982 103,240

- -

Total operating cost 3,017 3,056 - 3,231 2,863 2,836

- -

annual after cash profit 466 437 - 307 583 596

ROI 0.29 0.28 - 0.19 0.38 0.39

after heat integration operating cost 2,366 2,405 2,461 2,381 2,189

annual after cash profit 954.68 925.71 884.56 945.18 1,080.92

ROI 0.60 0.58 0.54 0.62 0.71

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