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Gas-to-Liquids (GTL)
What is Gas-to-Liquids?
Conversion of natural gas to liquid fuels (e.g., diesel).
Natural Gas
SYNGAS
PRODUCTION
FISCHER-TROPSCH
SYNTHESIS
HYDROCRACKING
Diesel
Environmental
US EPA regulations require reduction of sulfur content.
GTL naturally produces extra low-sulfur diesel.
Design Basis
GTL plant to be located in Ohio.
Minimum DCFRR of 12% required.
Evaluate ion-transport membrane
technology for syngas production.
Ion-Transport Membrane
CH 4 + 1/2 O2
CO + 2H
CH 4 + H O
2
CO + 3H 2
Oxygen
-Depleted
Air
Oxidizing
atmosphere
Syngas
Reducing
atmosphere
Reforming
Catalyst
Natural Gas
Steam
O 22e-
Oxygen
Reduction
Catalyst
Air
Membrane
Courtesy of Air Products, Inc.
Ion-Transport Membrane
Membrane material: non-porous mixed conducting metallic oxides.
Perovskites
LaxA1-xCoFe1-yO3-z
(La = Lanthanides, 0<x<1, A = Sr, Ba, or Ca, 0<y<1, z = number which renders the compound charge neutral)
1.
Air
ITM Reactor
(Syngas
Production)
Turbine and
Generator
Syngas
Excess Electricity
2.
Fischer-Tropsch
Synthesis
H2
3.
Synthetic wax
Hydrocracking
Fuel Gas
Hydrocracked wax
4.
Naphtha
Kerosene
Diesel
Fischer-Tropsch
Reactor
Hydrocracker
Distillation
Design Details:
CH4 + O2 CO + 2H2
CH4 + H2O CO + 3H2
Steam Reforming
Catalyst Bed
ITM Membrane
Steam Reforming
Catalyst Bed
ITM Membrane
Air
O2-depleted Air
Fischer-Tropsch
Reactor
Hydrocracker
Distillation
Fischer-Tropsch Reactor
Function:
Design Details:
Fischer-Tropsch Products
Anderson-Schulz-Flory Distribution
M{n} = (1 - ) n-1
W{n} = n (1 - )2 n-1
For Co/Ru, = 0.94
Mole Fraction M{n}
Diesel
Fischer-Tropsch
Reactor
Hydrocracker
Distillation
Hydrocracker Reactor
Function:
Design Details:
Fischer-Tropsch
Reactor
Hydrocracker
Distillation
Fractionation Tower
Function:
Design Details:
Auxiliary Units
Process Summary
Raw Materials
Products
Diesel
Kerosene
Naphtha
HGO
Electricity
2,700 bbl/day
1,800 bbl/day
200 bbl/day
90 bbl/day
10,500 kW
Profitability Analysis
Diesel Fuel
Kerosene
Naphtha
HGO
Electricity
$1.82/gal*
$1.24/gal
$1.00/gal
70/gal
6/kW-hr
Source: US DOE
*Assumed 15% higher than typical diesel due to low-sulfur and high
cetane number.
PROBLEM:
Analysis assume no price correlation
between liquid fuels and natural gas!
Actual
Predicted
1.400
1.200
1.000
0.800
0.600
0.400
0.200
0.000
0
Conclusions
Profitability is weakly dependent upon natural gas
cost.
ITM/GTL profitable at any NG price below $12.5/MSCF.
Current NG prices well-below this limit ($6/MSCF).
Recommendations
Confirm ITM O2 flux rate
Flux rate of 10 cm3/cm2-min assumed for design.
Current research report values from 0.1 to 20 cm3/cm2-min.
Required membrane area strongly dependent on O2 flux
rate.
Acknowledgements
Professor Leonard Fabiano
Dr. Stuart Churchill
Industrial Consultants
Gary Sawyer
Peter Schmeidler
Adam Brostow
William Retallick
David Kolesar
Henry Sandler
John Wismer