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Velocys, Toyo Engineering and MODEC Form Alliance for Offshore Gas-To-Liquids

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The partners are targeting installation of the GTL process on an FPSO (above).

Battelle subsidiary Velocys Inc., Toyo Engineering Corporation and MODEC, Inc. have formed a joint development agreement (JDA) to develop and commercialize gas-to-liquids (GTL) facilities for offshore applications.

Under the agreement, Velocys will advance its microchannel reactor and catalyst technologies (earlier post) to improve the economics of producing synthetic fuels. Then, working with Toyo and MODEC, the process will be made suitable for installation offshore on an FPSO (Floating Production, Storage and Offloading vessel). The agreement is expected to result in a commercial offshore GTL facility by 2012.

Velocysmicro
Process intensification via microchannel reactor. Click to enlarge.

Velocys chemical processors are characterized by parallel arrays of microchannels, with typical dimensions in the 0.01 to 0.20 inch range. Processes are intensified by decreasing transfer resistances between process fluids and channel walls. This structure allows use of more active catalysts than conventional systems, greatly increasing the throughput per unit volume. Overall system volumes can be reduced by ten to one hundred fold compared to conventional hardware.

The size and cost advantages of [Velocys’] microchannel technology offers the best opportunity to produce commercially significant quantities of synthetic fuels on FPSOs (Floating Production, Storage and Offloading vessels).

—Yutaka Yamada, President and CEO of Toyo Engineering
Velocysft
Commercial FT reactor assembly. Click to enlarge.

The Fischer-Tropsch (FT)-based GTL process has two primary steps: gasification via steam methane reforming and FT synthesis. Velocys’ proprietary microchannel process technology can reduce the size and cost of each of these key steps. A compact footprint will be essential for permitting the economical production of clean transportation fuels in space constrained offshore applications.

More than 3,000 trillion cubic feet of natural gas are currently stranded (without access to world markets)—enough to produce over 350 billion barrels of synthetic fuels, the equivalent of 70 years of US oil imports.

Resources

Comments

Ben

Nice, but preventing the channels from clogging will be a problem.

Polly

Synfuels will play a large role in supplementing fuels from crude oil with crude oil prices above $35 per barrel long term.
Synfuels are very capital intensive. Velocys claim on page 24 of the linked pdf file:
90% size reduction
33% capital expenditure reduction
100% increase in profit margin.
If Velocys can scale microchannel synfuel reactors from laboratory scale, they could have a significant impact in making Synfuels less capital intensive & thus less expensive.
Velocys see 2 main markets:
Mega Scale - GTL CTL
Distributed - BTL & WTL (Waste to Liquid)

This press release refers to Mega Scale GTL on a ship, made possible by the 90% reduction in plant size.

Velocys also plan distributed Microchannel FT reactors transportable in containers, so might enable Waste To Liquid using on site crop wastes of the great plains, forestry waste & municipal waste.

Also, small Microchannel reactors might enable distributed Biomass To Liquids plants fed by mixed prairie grasses.

Roger Pham

Would it be cheaper and more efficient scheme for GTL to simply cool down the gas until it becomes a liquid, like LNG? (liquefied natural gas)
Then, the NG can be used in modified trucks, train and buses with less particulate emission than diesel fuel.

Harvey D

How will this total process reduce or increase GHG/Km over current fossil fuel ICE vehicles?

Is this, more or less, a way to extend the use of our high pollution ICE liquid fossil fuel gas guzzlers another 50-70 years?

Could this gas be economically transformed into clean electricity, with large fuel cells or NG power plants, (on-board the mother ship or platform) and be transported to nearby shore power grid via undersea power cables?

Roger Arnold

In answer to Roger Pham, my research into GTL from a couple of years ago, IIRC, showed that both the energy and the capital cost for cryogenic liquification of NG are on the order of one-third to one-half the energy and capital costs of available GTL processes. So, yes, liquification by cooling is more efficient.

But that's by no means the whole story. Transport is a problem. Long distance pipelines are impractical for LNG, and the insulated cryogenic tanks for truck and rail transport are expensive. So is any kind of semi-long term storage facility. The liquids produced by FT GTL, by contrast, are easy to store and transport, and they command a premium value over LNG in feeding a hungry market for storable, clean-burning diesel and jet fuels. (FT liquids have no sulfur and no polycyclic aromatic hydrocarbons, which are responsible for nearly all of the soot and unburned hydrocarbon emissions from diesel and jet engine combustion.)

Jim G.

Sort of overlapping with what Roger is saying, it seems the goal is mostly to be able to deliver energy in the future via our existing petroleum infrastructure (e.g., pipelines and liquid ICE's) rather than energy efficient conversion. Synthetic fuels must have the capacity to be somewhat cleaner than diesel or coal to liquids, as there are (I think) no sulfurs and heavy metals and whatnot, but they are going to add carbon; and extending the life of fossil fuels is unfortunate from an environmental perspective.

Ben

GTL using gasification and FT synthesis is not very efficient, the waste heat could be using the produce electricity.

John Baldwin

were is this stranded gas? Its a myth, Siberia apart any gas that can be made into GTL can be made into LNG and sold into booming world markets. If you can name a stranded gas field, I can guarantee an LNG producer will be looking at it!!

GTL is crazy when you take into account the energy and CO2 cost of making it. The Shell Qatar GTL plant will produce an extra amount of CO2 equal to the savings from all Europe's biodiesel plants by 2010!

All other possible GTL plants have been cancelled - Exxon, Algeria etc....

Jack

Yes, yes, I agree, there is little point in GTL - the gas is a valuable fuel that can easily be liqufied and transported by ship say to a port terminal and supply a major city.
They should focus on BTL. These microreactors will do better in BTL. That's only a little bit harder but gives a CO2 neutral fuel.

Jack

I forgot to add - BTL gives CO2 neutral liquid fuel from basically useless trash. And if you can get cheap labor to collect it, you are set! I think it is going to move that way - biomass collection in poor countries and transport to BTL plants elsewere.

Paul Dietz

biomass collection in poor countries and transport to BTL plants elsewere.

Biomass is somewhat expensive to transport long distances, so it would have to be processed near the point it is produced.

Francis Stabler

Use of this GTL process and equipment works well for 'stranded' natural gas deposits (no nearby pipeline) and for natural gas that is seperated from oil wells at sea (currently burned for safety - flared). This makes a lot of sense for a country like Japan that has to import all of its transportation fuel. They will have a way to produce a relatively clean gasoline and diesel fuel independent of the oil market. The real push by Japan is likely to be to use this process to make liquid fuel from deep sea methane hydrate deposits. The Japanese government has been working on ways to harvest the huge amount of methane that is available in unclaimed deep sea deposits.

Francis Stabler

Use of this GTL process and equipment works well for 'stranded' natural gas deposits (no nearby pipeline) and for natural gas that is seperated from oil wells at sea (currently burned for safety - flared). This makes a lot of sense for a country like Japan that has to import all of its transportation fuel. They will have a way to produce a relatively clean gasoline and diesel fuel independent of the oil market. The real push by Japan is likely to be to use this process to make liquid fuel from deep sea methane hydrate deposits. The Japanese government has been working on ways to harvest the huge amount of methane that is available in unclaimed deep sea deposits.

Jack

To Paul:

Yes, this is essentially how I see it too. A medium scale FT plant at the location that produces only FT liquids. They are then shipped to an overseas refinery. But this FT crude plant has to be located where somebody can collect and bring biomass over to it because the collection of biomass is hand labor.

"use this process to make liquid fuel from deep sea methane hydrate deposits"

They should use the methane to supply their cities with NG.

Polly

Jet fuel sells for 2.6 times as much as natural gas.
GTL jet fuel is a premium grade low-sulfur (5ppm)jet fuel.

GTL emits less CO2 than jet fuel kerosene or road fuel diesel made from crude oil, so will command a premium price in future when carbon trading and carbon taxes are implemented.

Hence small Microchannel reactors are potentially much more profitable than LNG.


urls for source data from IATA DOE & SASOL:

http://www.iata.org/whatwedo/economics/fuel_monitor/price_analysis.htm
Jet fuel price
$2.814 / gal or $118 / barrel
58% more than a year ago.

http://tonto.eia.doe.gov/oog/info/ngw/ngupdate.asp
Natural Gas price
$7.835 / MMBtu or $ 45 / barrel
$118 / $45 = 2.6

http://www.sasolchevron.com/GTLChallenge/newsroom_entry.asp?ID=8


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