catft(r) fischer-tropsch process presentation
TRANSCRIPT
The New CatFT® Process By
Dr. Thomas Holcombe President
Green Impact Fuels, LLC July 31, 2014
CatFT!!!!!!!! ! ! ! ! ! ! ! !
®
Fischer-‐Tropsch Challenges
• Heat management • Tight control of catalyst temperature
Fischer-‐Tropsch Challenges
• Heat management • Tight control of catalyst temperature • Scalability to small applicaLons • ProducLvity of cobalt catalyst • Reduced capital costs
New CatFT Process
• CatFT® addresses each of these challenges • U.S. patent 8,278,363 assigned to Green Impact Fuels, LLC
• US Air Force is interested in small, modular, mobile systems – and funded construcLon of the first CatFT pilot plant
• Novel geometry gave very promising results • Project received naLonal recogniLon award from ACEC
Novel Design of CatFT
Syngas
Boiling Water
Syngas + Inert Gas
Boiling Water
ConvenLonal Design CatFT Design
-‐ Thin catalyst coaLng -‐ Heat conducLon by fins -‐ Much lower gas velociLes
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Benefits of CatFT Design • Thin catalyst coaLng
– Less catalyst, lower catalyst cost – Catalyst does not move or a[rit – Reactor can be transported with catalyst inside
• Heat conducLon by fins – Faster heat removal, Lght temperature control – High gas velociLes not required
• Lower gas velociLes – Lower pressure drop – Smaller, shorter reactor – Smaller compressors
• Lower cost – Evaporators = low cost, off-‐the-‐shelf substrates – Significantly lower capital and operaLng costs
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Catalyst CoaLng of Substrates
• Well-‐established industrial processes are available for coaLng substrates with catalyst
• Various methods: spraying, vacuuming, dipping and passing under a “water fall”
• Used extensively to control emissions from engines, power plants, factories, etc.
• Examples of well-‐known companies: BASF, Johnson Ma[hey, Umicore
Coated Evaporator
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Close-‐up of Coated Fins
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Catalyst Core Photos
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Simplified CatFT Flow Diagram
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Water Storage Vessel
FISCHER-TROPSCH BLOCK FLOW DIAGRAM
CONFIDENTIAL
CatFT Reactor
Boiling Water
Steam
Turbine
Pump
Cooling
Water
Cooler3-Phase Sepa- rator
Product Tank
Cooler
Heater
Syngas
Water
FT Product
Blower
Gas
Recycle
Vent
Heater
Heat
Excha-
nge
Power
Final Pilot Plant Photo
Pilot Plant Performance Performance as
Operated Performance with
gas Recycle
Syngas feed rate, lb/hr 19.5 19.1
Liquid hydrocarbons produced, BPD
0.39 0.50
CO conversion per pass, % 66.2 40.0
Total hydrocarbons produced, lbs/hr per lb of catalyst
0.48 0.60
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Catalyst Core Scale-‐up
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100 BPD Catalyst Core Layout
Large Small
Number 156 60
Dimensions (inches)
Height 40 40
Width 33.6 26.5
Thickness 1.8 1.8
CatFT vs. ConvenLonal Process
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Catalyst thickness, micronsCatalyst productivity, lb/hr per lb of catalystReactor productivity, BPD per bbl of reactorMax. catalyst temperature variations, deg FSyngas velocity over catalyst surface, in/secReactor pressure drop, psiReactor length, feetPhysical attrition of catalystInert gas or liquid recycle added to feed?Removal of catalyst during transportation?
CatFT Process Fixed Bed ProcessConventional TubularThe New
20-30 15000.62 0.1-0.22-3 15 10+
10 100+1 50
6-10 36-50
No YesNo Yes
No Yes
Overall FT Block Flow Diagram
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CatFT Process
FT Product
Hydro- treating
Hydro- processing
Distil- lation
Diesel & Naphtha
Recycle
Overall Process Block Flow Diagram
Syngas
Wax
Light Ends Recycle
Syngas Production
Natural Gas MSW
Biomass Biosolids
Etc.
Vent Recycle
Recycled Steam and
Water
Basis of CatFT Economics • 100 BPD C5+ paraffins produced • Syngas composiLon: 2.1/1 H2/CO raLo with 3% nitrogen, 5% CO2 and 4% CH4
• Syngas cost: $3.00/kscf • Shared post-‐treatment: diesel and naphtha separated (disLlled) from wax and hydrotreated
• Wax sold as final product • Budgetary capital costs from ICARUS or quotaLons • All equity model (no debt leverage)
100 BPD CatFT EsLmated Capital Costs
Case 100 BPD CatFT® Plant - All Equity ModelH2/CO feed rate 3.15 million SCF/day at 2.1/1 H2/COOn-stream factor 90 % Distillation &
Total CatFT HydrotreatingInitial Capital Costs $ $ $
ISBL with multiple plants 2014 base year 4,065,763 3,337,285 728,478Off-sites 15 % of ISBL 609,864 500,593 109,272Initial spare parts 2.0 % of fixed inv 93,513 76,758 16,755Startup and commissioning 5 % of ISBL 203,288 166,864 36,424Project development 50,000 41,041 8,959
Total 5,022,428 4,122,541 899,888
100 BPD CatFT EsLmated Cash Flow Product Sales Unit Values $/year $/year $/year
Diesel and naphtha 3.00 $/gal 2,445,219 2,445,219 0Wax 5.00 $/gal 2,823,521 2,823,521 0Total product sales 5,268,739 5,268,739 0
Cost of Goods SoldSyngas 3.00 $/kscf 3,105,810 3,105,810 0Power 8.0 cents/kwh (263,697) (274,210) 10,513Catalyst & chemicals 160,317 158,228 2,090Direct operating labor, man-yrs 80 k $/man-yr 160,000 131,332 28,668Contract maintenance 0.3 %/yr fixed inv 11,514 9,451 2,063Maintenance labor @ 0.4 %/yr fixed inv 15,352 12,601 2,751Control lab labor @ 5 % of oper labor 8,000 6,567 1,433Maintenance materials @ 1.0 %/yr fixed inv 38,379 31,502 6,876Equipment replacement @ 0.5 %/yr fixed inv 19,189 15,751 3,438Operating supplies @ 20 % of oper labor 32,000 26,266 5,734Plant overhead @ 60 % of oper labor 96,000 78,799 17,201Total cost of goods sold 3,382,863 3,302,097 80,766
Gross Profit 1,885,876SG&A @ 1.0 % of sales 52,687EBITDA 1,833,189Taxes and insurance @ 2.0 %/yr fixed inv 93,513Est. depreciation & amortization 502,243Operating income 1,237,433Est. depreciation & amortization 502,243First-year cash flow (before income tax) 1,739,676IRR to owners (before income tax) 30.1%
Conclusions • CatFT geometry offers major advantages over convenLonal processes: – Tight temperature control – Scalable to small applicaLons – High catalyst producLvity – Low capital cost
• Plants as small as 100 BPD can be profitable
Syngas
Boiling Water