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Fischer-Tropsch synthesis generally involves the synthesis of alkane waxes (of varying
chain lengths) and oxygenates from synthesis gas (syngas), which consists primarily of a mixture
of carbon monoxide and hydrogen. When configured to maximize the production of paraffinic
hydrocarbons, the resulting intermediate product mix is often described as synthetic crude oil
(syncrude).
Since most of worlds gas reserves are in the form of relatively small fields that would be
inadequate for world-scale Fischer-Tropsch gas-to-liquids (GTL) production capacities, interest is
increasing in new and improved Fischer-Tropsch GTL production technologies that may be viable
at low production capacities (below 10,000 bpd) because less than 10% of the worlds gas fields
are large enough to sustain a 10,000+ bpd Fischer-Tropsch GTL plant. Reducing the production
rate to 2,000 bpd makes approximately 40% of gas fields viable sources. Also of particular
interest would be process technologies that would enable Fischer-Tropsch GTL production on
floating production, storage, and offloading (FPSO) vessels which are finding increased use in
the development of oil fields in remote deep water tracts with no alternative economical outlet for
associated gas.
The primary limitations of conventional Fischer-Tropsch GTL technology include the removal
of process heat that can produce hot spots and severely shorten catalyst life, and effective
management of two-phase flow as synthesis gas transforms into liquid hydrocarbons via Fischer-
Tropsch chemistry. Both of these issues can be addressed with microchannel process
technology, which improves heat transfer and controls flow through many parallel channels.
When utilized in modular fashion, the application of microchannel process technology is a natural
fit for converting associated gas into synthetic crude via the Fischer-Tropsch GTL process.
This PEP report reviews the leading technologies for sub-world scale production of natural
gas-derived synthetic fuels via Fischer-Tropsch synthesis. Two gas-to-syncrude production
process designs and their estimated production economics are presented, one of which is based
on Syntroleum GTL technology, and the other is a modular GTL process based on microchannel
technology offered by Velocys.
Process Economics
Program
Report No. 247B
by Victor Wan
December 2011
For detailed marketing data and information, the reader is referred to one of the SRI
Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS
HANDBOOK Program covers most major chemicals and chemical products produced in the
United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and
their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL
PRODUCERS services provide detailed lists of chemical producers by company, product, and
plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.
CONTENTS
GLOSSARY........................................................................................................................ XI
3.2 F-T GTL Opportunities Increase in Number as Plant Size Decreases ................. 3-2
4.9 Methane Conversion, CO Selectivity and H2/CO Ratio versus S/C Ratio ............ 4-22
4.13 Microchannel SMR with Integrated Methane POX and Combustion .................... 4-29
3.3 North America Natural Gas Supply and Demand ................................................. 3-6
3.5 Middle East Natural Gas Supply and Demand ...................................................... 3-7