Selective Fischer-Tropsch Catalyst for Producing C9-C16 Hydrocarbons
DOD-Navy Phase I STTR Contract N00014-07-M-0394
This STTR Phase I project is a conceptual Fischer-Tropsch (FT) based process for converting synthesis gas to C9-C16 hydrocarbons suitable for use as synthetic JP-5 fuel by the Navy. Eltron is developing an advanced FT catalyst, selective for C5-C8 olefins, that will be subsequently dimerized to C10-C16; optionally, the process will include product upgrading, e.g., partial reduction. Two crucial issues will be investigated in Phase I research:
- Development of a suitable FT catalyst based on zeolite-supported ruthenium (at Eltron).
- Design of a novel FT multi-channel reactor (MCR) with ultra-efficient heat removal capability for near-isothermal operation at relatively low temperature and high pressure (at Florida Institute of Technology).
The developed catalyst will first be tested for its performance potential using a packed-bed mini-reactor with highly efficient heat removal; initial MCR testing will follow. Issues to be investigated during Phase II include full operation of the MCR, the dimerization reaction, product separation, recycle and upgrading. Further catalyst development will include aging and regeneration studies in addition to optimization, full characterization, and manufacturing scale-up. Successful Phase I and II work will lead to building and operating a fully-integrated prototype JP-5 FT mini-plant based on syngas from natural gas reforming.
There is an urgent need in the U.S. military (as well as in the commercial sector) for synthetic fuels derived from alternative and diverse resources; there is also a special desire to make those fuels in small-scale, on-board mobile transportation systems and in remote locations where conventional primary raw materials such as natural gas (NG) and crude oil may not be readily available or usable.
Our energy economy needs to move away from its heavy dependence on foreign sources, a dependence that threatens our national security, and toward using more environmentally benign energy sources such as biomass instead of the GHG (greenhouse gas) generating conventional carbonaceous resources. A spectrum of hydrocarbon fuels similar in nature to conventional petroleum crudes can be obtained through Fischer-Tropsch synthesis (FTS).
One serious drawback of FTS is its inherent lack of product selectivity. This is a problem especially if one desires to maximize a hydrocarbon middle cut such as C9-C16 light diesel. Low chain-growth probability will shift the product to the undesired hydrocarbon gases (C4-) whereas high chain-growth probability will enhance production of heavy diesel and wax. Eltron’s research addresses this problem in a novel way: Eltron proposes developing a FT process with very low selectivity to gas but also a cutoff in product growth to completely avoid wax formation and the associated operational difficulties, especially on a small scale and when using a compact, mobile plant. The Navy will be able to install many “mini-plants” based on our research. Thus, we anticipate that a JP5 mini-plant capable of producing 10 bpd (barrels per day) may cost $2 3 million to build; it will be able to use NG, coal, biomass, or any other carbonaceous source as feed. This plant is expected to be portable (by air or surface), modular and (due to its unique design), easily scaled up or down; for example, it could be built at an estimated cost of roughly $100 million as stationary station, supplying 1,000 bbd. The commercial sector could also benefit from this technology. For example, it could enable utilizing biomass at relatively small supply in remote locations where light diesel fuels, such as jet fuel, are desired.