THE KEY TO CLEAN FUELS

The motor fuels sector faces a double challenge: provide an increasing quantity of ever-cleaner fuels and find sources that do not rely on crude oil. Our Gasel Technology Suite answers this challenge through the conversion of synthesis gas (H2+CO) from various origins - natural gas, biomass, coal, petcoke, residues - into ultra-clean liquid fuels (XTL). This route is commonly accepted as one of the most promising mid-term solutions for the production of alternative fuels and petrochemicals.

FISCHER-TROPSCH AND UPGRADING

The Gasel Technology Suite consists of three main steps:

(1) Final Syngas purification

This step ensures a syngas purity suitable for the Fischer-Tropsch (FT) catalyst. It can treat syngas from any conventional acid gas removal process.

(2) Fischer-Tropsch Synthesis n (CO + 2 H2) ↔ (-CH2-)n + n H2O

with n ranging from 1 to over 90

(3) Upgrading of the FT Product

Upgrading of the FT product is a process that combines hydrotreating, isomerization and selective cracking of the long FT paraffinic chains into high quality middle distillates and naphtha.

GASEL PRODUCTS FUELS OF THE HIGHEST QUALITY

The main products (75%) of the Gasel Suite are ultra-clean (no sulfur, no aromatics) middle distillates (large Diesel cut or Jet and Diesel) with excellent combustion and cold flow properties.

• FT Diesel The cetane number of FT Diesel (> 75), its very good cold flow properties (-20 to -40°C) and its lack of sulfur and aromatics make it a perfect product for blending into a conventional diesel pool.

• FT Jet Fuel Gasel FT Jet meets ASTM D7566 requirements, in particular density (>730 kg/m3) and freezing point (< -40°C). Up to 50 vol% of it can be introduced into the jet A-1 pool.

• FT Naphtha / Gasoline FT Naphtha is a high-purity paraffinic naphtha making it an ideal steam cracker feedstock for the production of petrochemicals. Alternatively, depending on your market requirements, it can be upgraded into RON 92 gasoline using Axens’ proven technologies.

PROPRIETARY GASEL CATALYSTS

The Gasel Technology Suite is based on proprietary catalysts developed, manufactured and guaranteed by Axens: • Syngas purification catalysts and adsorbents • Cobalt-based FT reaction catalyst • A combination of product upgrading catalysts

dedicated to FT products.

Gasel® THE XTL TECHNOLOGY SUITE FOR THE CONVERSION OF SYNGAS TO JET AND DIESEL

BACKGROUND

The Gasel Suite is the result of a 15-year process and catalyst co-development program initiated by eni, IFPEN and Axens. Within this program, Axens was in charge of pilot plant design and was the leader of the catalyst development and production phase. A 20-bpd FT pilot plant, installed at eni’s Sannazzaro refinery, has been running since 2001 on a continuous improvement basis. In parallel, large mock-ups (equivalent to 1,000 bpd reactors) and other specific tools reproducing industrial reactor conditions demonstrated the mechanical stability of the catalyst and provided the basis for the mechanical design of the reactor. Axens’ applied its extensive experience in hydroprocessing to optimize product upgrading and to tailor catalysts to this specific application (hydrocracking & isomerization).

Figure 2: FT Pilot Plant – eni Refinery in Sannazzaro, Italy

CONCLUSIONS

The “Gasel” offer is analogous to Axens’ offer for complete refineries in that it includes integration studies, the license, the basic design package, start-up assistance, technical services and catalyst manufacturing. This approach, backed by 50 years of commercial achievements, has been successfully applied to a large number of technology projects in refining, petrochemicals and biofuels. Indeed, Axens has already licensed more than 2000 units worldwide. This makes Gasel the only available syngas to jet & diesel technology that is supplied by professionals of technology licensing and catalyst supply.

Figure 1: Simplified Process Flow Diagram

GASEL PROCESS DESCRIPTION

Fischer-Tropsch Synthesis: The reaction takes place in a three-phase slurry bubble column (SBC) reactor where synthesis gas is brought into contact with the solid FT-catalyst to produce long chained liquid hydrocarbons. The liquid products are recovered in L/S and G/L separators and sent to the upgrading section (cf. figure 1).

FT Product Upgrading: The raw FT liquid product is stabilized, hydrotreated (olefins & oxygenates), hydrocracked & isomerized. The fully converted product is then separated into approximately 25% Naphtha and 75% Jet + Diesel (cf. figure 1).

GASEL KEY FEATURES

• Low-temperature FT synthesis with a Co-based catalyst in an SBC reactor

• Product upgrading by mild hydrocracking & isomerization

• Production of high quality jet, diesel and paraffinic naphtha

• Maximum capacity per FT train: from 15,000 to 20,000 bpd, depending on syngas characteristics

• Technology co-owned by eni S.p.A. and IFP Energies nouvelles (IFPEN)

• Fully licensed by Axens. Catalysts manufactured and guaranteed by Axens.

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