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SPE-183161-MS Using Small-Scale Gas to Liquids Technology for Flare Gas Mitigation Dr. Conrad Ayasse, PhD, FCIC
THE VALUE OF SYNTHETIC FUELS
FT Diesel = Reduced Vehicle Emissions
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
THE FISCHER TROPSCH PROCESS
Polymerization of carbon monoxide nCO + 2n H2 = (-CH2-)n- + nH2O Δ H = -165 kJ/mol Highly exothermc Possible paraffinic chain length C2-C60
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
THE TRADITIONAL APPROACH
A typical FT plant converts natural gas to synthesis gas (CO+2 H2) Then makes the maximum amount of wax which is hydrocracked to products including NGLs, naphtha, diesel and lubricants
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
SHELL PEARL GTL PLANT, QATAR
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
ECONOMICS OF THE VERDIS GTL PROCESS SHELL BINTULU 16,000 bpd
VERDIS OFFSHORE 2000 bpd
V-CPOX
GTD Diesel
Verdis Technology
Simplicity and capital cost reduction through elimination of operating units SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
THE TRADITIONAL FISCHER TROPSCH PRODUCT
Traditional FT Reactor Product WAX
Weight percent
Diesel
Carbon Number SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
TRADITIONAL FT PLANT PRODUCTS
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
VERDIS BUILDS SMALL FT PLANTS
The economies of scale are not available for small FT plants: must be compensated with new chemistry and engineering and a
Narrow high-value product slate
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
VERDIS PROCESS SIMPLIFIED SCHEMATIC Feed
Reformer
Syngas conditioning
FT Reactor
Reactor tail gas recycle
Waste gas recycle Product conditioning
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
CONSEQUENCES OF OPERATING PARAMETERS
Fischer Tropsch is a multi-variable process. One must select the BEST combination
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
HIGH SYNGAS INERT CONTENT + Easier heat control Uses air instead of reformer oxygen: Eliminates oxygen plant - Vessels larger Syngas compression costs higher Lower CO conversion rates Lower liquid rates: Loss of lighter components Lower carbon efficiency
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
SMALLER CATALYST PARTICLE SIZE
+ Higher activity - Exotherm difficult to control - Higher wax content
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
MICROCHANNEL FT REACTORS
+ Small catalyst particles Very active Excellent heat removal Small FT reactors Low pressure drop - High pressure High-wax product Expensive reactors
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
MICROCHANNEL
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
HIGH FT TAILGAS RECYCLE RATE + Higher conversion (>2x) Improved C5+ selectivity Improved catalyst life
-Requires a booster compressor Requires tailgas reheating
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
HIGH REACTOR TEMPERATURE + Higher CO conversion - Lower C5+ selectivity Higher exotherm Shorter catalyst life Higher operating costs
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
HIGH REACTOR PRESSURE + Smaller plant Higher CO conversion - Higher wax content Higher compression costs Possible safety issue
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
TRADITIONAL FT REACTOR Shell & narrow tube
BP FT Reactor SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
SHELL AND TUBE REACTOR + The standard for World-scale plants - Expensive Poor use of reactor space 90% conversion to liquids SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
DISPOSAL OF WASTE GAS TO CONTROL INERTS BUILD-UP • Burn to raise steam • Burn for power generation • Send to Reformer
VERDIS process efficiency if sent to reformer: 7500-9300 scf methane equivalent/bbl liquid
SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
PROPRIETARY VERDIS FT CATALYSTs Unique FT Catalysts* 1. Completely eliminates wax generation- Don’t need hydrocracker 2. Can be optimized to produce naphtha, aviation fuel or diesel 3. Designed for low pressure operation 4. Ideal for flare gas and Biogas 5. High carbon efficiency: 7500-9300 scf methane/bbl SPE-183161-MS • Small-Scale GTL For Flare Gas Mitigation • Dr. Conrad Ayasse
*Patents held by Canada Chemical Corporation in 24 Countries
Thank you !
Any questions?
SPE-177660-MS • New Syngas Reforming Solutions for Enhanced Gas to Diesel Conversion • Dr. Conrad Ayasse
