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Highly Selective Fischer-TropschSynthesis for Production of Jet Fuel

from Syngas

Santosh K Gangwal

9th International Freiberg Conference on IGCC and XTL

Technologies

Closing the Carbon CycleBerlin, GermanyJune 3 – 8, 2018

Southern Research

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• Southern Research Institute is an Independent Non-profit Corporation.

• Energy-related process research (biomass, coal, solar, waste heat) with a $30+ million initial investment from SR in 2007

• Lab, bench and pilot scale technology development, 30,000 ft2 high bay pilot plant, complete lab facility for process development

• Develop cutting edge technology with support from Government (e.g. DOE), private industry and internal funding

• License technology at appropriate stage, JV, spin off

Southern Research Energy and Environment Division Technology Development Business Model

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SR Supports The Full Pathway to Energy Technology Commercialization

- Lab Prototyping

- Feasibility Study

- Initial Commercial Design

- Pilot Plant

- Test/Optimize

- Commercial Design

- Commercial Demo.

- 3rd Party Verification

- Final Design Tweaks

Proof of Concept

Proof of Technology

Viability

Proof of Commercial

Viability

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SR XTL Technology Concept

Southern Research

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TECHNOLOGY DEVELOPMENT TEAM

• Southern Research (Lead, ATR catalyst development, FT reactor design/testing, Olefin upgrading)

• Chevron (Co-zeolite hybrid FT catalyst supplier)

• IntraMicron (Thermally conductive reactor packing)

Southern Research

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SR XTL Technology Development Status

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• Technology development began in 2012 with an initial grant from DOE—process is currently at large bench scale

• Total funding to date from Government and Southern Research $ 7.0 million (not including Chevron contributions)

• Technology Components

• SR patent pending sulfur tolerant Ni reforming catalyst

• Chevron Co-zeolite hybrid FT catalyst—over 20 patents

• Intramicron patented microfiber entrapped catalyst (MFEC) packing for FT

• SR FT Reactor design and operational know-how

• SR FT patent-pending olefin upgrading process add-on (significantly increases jet fuel yield)

• SR currently in discussions for scale up to pilot plant with a couple of companies but is open to further collaborations

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Chevron Cobalt-Zeolite Hybrid Catalyst

Production of clear wax free liquids

Reference: Kibby C. L., Jothimurugesan K., Das T., Saxton; R. J., Burton, Jr. A. W., US Patent Application 20110144219 (2011)

• Highly selective: >70% hydrocarbon liquids

• 5x greater yield than traditional catalysts

• Eliminate production of undesirable wax

• CAPEX and OPEX reductions

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IntraMicron’s MicrofibrousEntrapped Catalysts (MFEC)

Cu-entrapped FT Catalyst

Particles

MFEC Allows

• Use of simpler fixed beds• Large diameters up to 2-6

inches• Very high activity catalyst

particles• Isothermal operation

Resulting in

• High productivity and selectivity

• Shorter and fewer tubes• Reduced cost

Images from http://www.intramicron.com

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SR 2 Inch and 4 Inch Diameter Fixed-Bed Reactors

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SR XTL Technology Concept

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Reformer and FT Test Program

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• Lab-scale catalyst development and testing with simulated syngas

• Field testing using actual syngas from Kellogg transport gasifier (TRIG) at the National Carbon Capture Center (NCCC)

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Reformer Installed in Cabinet for Operation in Class 1 Div. 2 Industrial Environment at NCCC

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Fischer-Tropsch Skid Installed at NCCC

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Reformer and FT Skids Installed at NCCC for Testing with Actual Syngas

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ATR Catalyst Field Testing• High conversion of methane in

the presence of 380 ppm H2S –tars and ammonia not detected in effluent

• Ability to control H2:CO ratio

• Strong effect of temperature on methane conversion

• No evidence of catalyst poisoning

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Adjusting H2:CO Ratio

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FT Field Testing; 2 inch Diameter Reactor

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FT Field Testing; 4 inch Diameter Reactor

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CO Conversion Liquid Selectivity

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FT Liquid Selectivity from 4 inch reactor Testing• ~75% selectivity to

liquid hydrocarbons

• ~86% of liquid hydrocarbons in jet fuel range

• Improved Economics!

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• ATR Catalyst Testing– Laboratory-scale reformer was successfully modified and tested with coal-derived syngas for 125

hours at NCCC

– Catalyst had high methane conversion in the presence of 380 ppm H2S with no apparent poisoning

– Experiments demonstrated ability to adjust H2:CO ratio by adjusting steam flow (WGS not needed)

• Selective FT Synthesis– 2 and 4 inch ID FT reactors were successfully tested with Chevron catalyst and IntraMicron MFEC

technology in SR reactor

– ~75% selectivity to liquid hydrocarbons

– ~86% of the liquid hydrocarbons in the jet fuel range after SR upgrading

• Positive results warrant scale up of both technologies. SR currently in discussions with a company but would welcome other collaborations

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Conclusions

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