Velocys Fischer-Tropsch Technology - Oxford Catalysts Group

Velocys Fischer-Tropsch Fischer Tropsch Technology
Economical smaller scale GTL enabled by microchannel
reactor technology and superactive catalyst
April 2, 2012
Steve LeViness Paul Schubert
Steve LeViness, Paul Schubert,
Jeff McDaniel, Tad Dritz

Summary
Velocys Fischer-Tropsch Technology
– Advanced microchannel reactor (Velocys)
– Super-active, remarkably stable catalyst (Oxford Catalyst)
Fischer-Tropsch performance
– Catalyst activity and activity maintenance
– Operating data
– Product composition
Development and commercialization status
– Catalyst manufacturing
– Reactor manufacturing and improvements
– Demonstrations
– Partners
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Microchannel Reactor (MCR)
The original technology came from PNNL/Battelle
The reactor can be considered a multi-tubular fixed bed
– Extremely small diameter tubes
– Particulate catalyst sized accordingly
– Very short “tubes” to minimize pressure drop
– Heat removal by yp partial vaporization p of boiler feed water
Heat removal is key
– VVery short h t hheat t transfer t f (HT) distances di t
– Very high HT surface area to catalyst volume ratio
– Enhanced HT (coefficient) by microchannel boiling
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Microchannel Process Technology
Conventional Microchannel
~ 1” for FT
Characteristic
dimension
Enhanced
mass & heat
transfer
~ 0.1-
10 mm
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Velocys Fischer Fischer-Tropsch Tropsch Reactor Core
Close integration of exothermic
Fischer-Tropsch Fischer Tropsch synthesis and
steam generation
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Microchannel technology systems
outperform conventional reactors
CControls t l reactions ti at t
optimal conditions (T)
Accelerates processes
by 10 – 1,000 fold
25 BPD at standard
conditions
~0.5 MW heat
generation/removal
FT Reactor Core
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Advanced Fischer-Tropsch Fischer Tropsch Catalyst
Th The microchannel i h l advantage d t enhanced h d with ith super-active ti catalyst t l t
– Highly active FT catalysts produce higher heat loads, which are effectively handled
by the enhanced heat transfer properties of microchannel reactors
FT catalyst technology was developed at Oxford University
– Oxford Catalysts spun out of the Chemistry Department
The catalyst composition is well within normal standards
– CCobalt b l bbased d - NNo unusual, l exotic, i extremely l rare components
– Operating conditions, reduction and regeneration procedures are consistent with
industry practices
Catalyst characteristics are comparable to other Co FT catalysts
– Except much higher activity and increased stability
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Highest FT Catalyst Productivity
st Prodductivityy
kg/m hr)
3 Catalys
( /h
1600
1400
1200
1000
800
600
400
200
0
Fixed Bed Slurry Bed OCG
(Shell) (SASOL)
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Catalyst Performance
Exceptional Stability & Selectivity
COO
Conversionn,
CH4 Selecctivity
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
420 420+ Days D without ith t
Regeneration
CO Conversion CH4 Select
Temperature
180
0 50 100 150 200 250 300 350 400 450
TOS (days)
(d )
430
405
380
355
330
305
280
255
230
205
/ psig, CT / ms m
Temper rature / degCC,
Pressure
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Alternative operating conditions
Syngas composition varies for GTL, BTL, CTL applications
- 2 stage once-through and single stage with recycle
Catalyst / Reactor robustness critical
Syngas Comp
Performance
Case 1 Case 2 Case 3 Case 4 Case 5 Case 6 Case 7 Case 8
H 2/CO 2.1 2.0 1.6 1.6 1.5 1.8 1.75 1.50
Dilution 8% 17% 24% 50% 40% 60% 75% 85%
CO Conversion 70.8% 70.0% 70.7% 65.8% 62.3% 70.0% 64.6% 54.8%
CH 4 Selectivity 9.1% 7.2% 4.9% 6.2% 4.8% 10.6% 8.8% 9.7%
C 5 + Selectivity 84.4% 87.0% 90.4% 88.0% 90.6% 82.2% 84.0% 80.7%
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Overall Product Distribution
Products
Mole M Percennt
of Total
100.000
10.000
1.000
00.100 100
0.010
0.001
Alpha = 0.917 0 917
0 20 40 60 80 100
Carbon Number
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Product Speciation
%)
Concentration
(mole
100.0000
10 10.0000 0000
1.0000
0.1000
0.0100
0.0010
0.0001
0.0000
n-Paraffins (alpha = 0.918)
iso-Paraffins (alpha = 0.869)
Olefins (alpha = 0.466)
alcohols (alpha = 0.547)
Acids (alpha = 0.472)
0 10 20 30 40 50 60 70 80 90 100
Carbon Number (n)
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Development and commercialization status
Catalyst manufacturing
– Two large, well known manufacturing vendors fully qualified
– Almost 1.5 MT catalyst produced since January 2011
Reactor manufacturing
– External component supply chain and certified manufacturing partners
– Four (4) 25 BPD reactors produced in 2011 – ASME code stamped
– Additional 25 BPD reactors and prototype larger reactor in production
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Demonstration & Commercial FT Reactors
2010 2011 2012
0.5 bpd 25 bpd 125 bpd
50X 5X
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Velocys Reactor Demonstrations
Confidential
U.S. GTL facility
in 2013
Confidential
0.5 bpd
GTL in 2012
Microchannel FT
Microchannel FT and SMR
Velocys
Pilot Plant
0.5 bpd
GTL in 2012
Petrobras
Fortaleza, Brazil
6 bpd
GTL in 2012
SGC Energia
Güssing, Austria
0.5 bpd
BTL in 2010
Confidential
FT in 2012
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BTL Field Demonstration
FT technology demonstrated at the unique
showcase “eco-town” eco town of Güssing, Güssing in Austria
Fully funded by BTL / WTL partner, SGC Energia
Demonstration conducted 2010 – 2011 on
gasified wood
FT demonstration unit
Güssing
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Güssing Accomplishments
FT reactor operated for an extended period
– ~1800 hours and produced ~2.8 metric tons of product
– Available 100% of the time clean syngas was available
Steady performance
– Excellent temperature control
– Handled relatively y rapid p changes g in H2/CO 2 ratios
– Pressure drop in the process channels was consistent
Demonstrated ability to handle disruptions
– 193 syngas interrupts, 32 upsets and 36 shutdowns
– Responded well to changes and shutdowns
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GTL Field Demonstration
Small scale GTL to be demonstrated at
Petrobras in Fortaleza, , Brazil in 2012
Offshore GTL partners: Toyo Engineering,
MODEC and Petrobras
Installation complete, p , commissioning g underway y
2 2,000 000 bpd bpd GTL GTL facility will occupy
occupy
only ~¼ of deck space
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Offshore Modular Plant Design
24m
1000 bpd
Offshore GTL module
concept by Toyo
Engineering
Only 10% of the
footprint of a
conventional plant
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Full Single-core Single core Reactor Demonstration
Fully funded by diversified
energy client
Existing facility with FT
capabilities p
Reactor manufactured and
delivered to site
Start-up scheduled by
mid-year
Will support design basis
of multiple site licenses
Velocys
FT
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Velocys Pilot Plant & Training Facility
The Velocys Pilot Plant
FFully ll iintegrated t t d microchannel i h l SMR SMR,
FT & hydro-cracking pilot plant and
operator training facility (0.5 bbl/day)
Stage I complete: SMR operational
Stage II SMR & FT: operational Q3
Successful SMR Operations
1,000 hours operation of ~0.6 bbl/day
SMR reactors have demonstrated
robustness after multiple shutdowns and restarts
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Complete GTL Solution Partners
Resource
Holders
Field
Services
Technology
MModular d l
GTL
Equipment
&
MModules d l
Engineering
&
FPSO
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Summary
Velocys: leader in advanced distributed scale FT technology
– 15 years and $300 million invested in its unique innovative technology
– Exceptional catalyst and reactor performance
– Exhaustive global patent protection (>7 (>7,500 500 granted GTL claims)
– First class partners
At cusp of f commercialization i li ti
– 1 demonstration complete, 2 coming up, plus Velocys Pilot Plant in Q3
– Manufacturing successfully ramping up; commercial organization
expanding di
– Ready for further / larger commercial orders
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Steve LeViness Phone: 614-348-8792
www.velocys.com Email: leviness@velocys.com
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