CatFT(r) Fischer-Tropsch Process presentation

The  New  CatFT®  Process    By  

Dr.  Thomas  Holcombe  President  

Green  Impact  Fuels,  LLC  July  31,  2014  

CatFT!!!!!!!! ! ! ! ! ! ! ! !

®

Fischer-­‐Tropsch  Challenges  

•  Heat  management  •  Tight  control  of  catalyst  temperature    

Fischer-­‐Tropsch  Challenges  

•  Heat  management  •  Tight  control  of  catalyst  temperature  •  Scalability  to  small  applicaLons  •  ProducLvity  of  cobalt  catalyst  •  Reduced  capital  costs  

New  CatFT  Process  

•  CatFT®  addresses  each  of  these  challenges  •  U.S.  patent  8,278,363  assigned  to  Green  Impact  Fuels,  LLC  

•  US  Air  Force  is  interested  in  small,  modular,  mobile  systems  –  and  funded  construcLon  of  the  first  CatFT  pilot  plant  

•  Novel  geometry  gave  very  promising  results  •  Project  received  naLonal  recogniLon  award  from  ACEC  

Novel  Design  of  CatFT  

Syngas  

Boiling  Water  

Syngas  +  Inert  Gas  

Boiling  Water  

ConvenLonal  Design                              CatFT  Design  

-­‐  Thin  catalyst  coaLng  -­‐  Heat  conducLon  by  fins  -­‐  Much  lower  gas  velociLes  

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Benefits  of  CatFT  Design  •  Thin  catalyst  coaLng  

–  Less  catalyst,  lower  catalyst  cost  –  Catalyst  does  not  move  or  a[rit  –  Reactor  can  be  transported  with  catalyst  inside  

•  Heat  conducLon  by  fins  –  Faster  heat  removal,  Lght  temperature  control  –  High  gas  velociLes  not  required  

•   Lower  gas  velociLes  –  Lower  pressure  drop  –  Smaller,  shorter  reactor  –  Smaller  compressors  

•   Lower  cost  –  Evaporators  =  low  cost,  off-­‐the-­‐shelf  substrates  –  Significantly  lower  capital  and  operaLng  costs  

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Catalyst  CoaLng  of  Substrates  

•  Well-­‐established  industrial  processes  are  available  for  coaLng  substrates  with  catalyst  

•  Various  methods:  spraying,  vacuuming,  dipping  and  passing  under  a  “water  fall”  

•  Used  extensively  to  control  emissions  from  engines,  power  plants,  factories,  etc.  

•  Examples  of  well-­‐known  companies:  BASF,  Johnson  Ma[hey,  Umicore  

Coated  Evaporator  

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Close-­‐up  of  Coated  Fins  

10  

Catalyst  Core  Photos  

11  

Simplified  CatFT  Flow  Diagram  

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Water Storage Vessel

FISCHER-TROPSCH BLOCK FLOW DIAGRAM

CONFIDENTIAL

CatFT Reactor

Boiling Water

Steam

Turbine

Pump

Cooling

Water

Cooler3-Phase Sepa- rator

Product Tank

Cooler

Heater

Syngas

Water

FT Product

Blower

Gas

Recycle

Vent

Heater

Heat

Excha-

nge

Power

Final  Pilot  Plant  Photo  

Pilot  Plant  Performance  Performance  as  

Operated  Performance  with  

gas  Recycle  

Syngas  feed  rate,  lb/hr   19.5   19.1  

Liquid  hydrocarbons  produced,  BPD  

0.39   0.50  

CO  conversion  per  pass,  %   66.2   40.0  

Total  hydrocarbons  produced,  lbs/hr  per  lb  of  catalyst  

0.48   0.60  

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Catalyst  Core  Scale-­‐up  

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100  BPD  Catalyst  Core  Layout  

Large   Small  

Number   156   60  

Dimensions  (inches)  

Height   40   40  

Width   33.6   26.5  

Thickness   1.8   1.8  

CatFT  vs.  ConvenLonal  Process  

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Catalyst thickness, micronsCatalyst productivity, lb/hr per lb of catalystReactor productivity, BPD per bbl of reactorMax. catalyst temperature variations, deg FSyngas velocity over catalyst surface, in/secReactor pressure drop, psiReactor length, feetPhysical attrition of catalystInert gas or liquid recycle added to feed?Removal of catalyst during transportation?

CatFT Process Fixed Bed ProcessConventional TubularThe New

20-30 15000.62 0.1-0.22-3 15 10+

10 100+1 50

6-10 36-50

No YesNo Yes

No Yes

Overall  FT  Block  Flow  Diagram  

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CatFT Process

FT Product

Hydro- treating

Hydro- processing

Distil- lation

Diesel & Naphtha

Recycle

Overall Process Block Flow Diagram

Syngas

Wax

Light Ends Recycle

Syngas Production

Natural Gas MSW

Biomass Biosolids

Etc.

Vent Recycle

Recycled Steam and

Water

Basis  of  CatFT  Economics  •  100  BPD  C5+  paraffins  produced  •  Syngas  composiLon:  2.1/1  H2/CO  raLo  with  3%  nitrogen,  5%  CO2  and  4%  CH4  

•  Syngas  cost:  $3.00/kscf  •  Shared  post-­‐treatment:  diesel  and  naphtha  separated  (disLlled)  from  wax  and  hydrotreated  

•  Wax  sold  as  final  product  •  Budgetary  capital  costs  from  ICARUS  or  quotaLons  •  All  equity  model  (no  debt  leverage)  

100  BPD  CatFT  EsLmated  Capital  Costs  

Case 100 BPD CatFT® Plant - All Equity ModelH2/CO feed rate 3.15 million SCF/day at 2.1/1 H2/COOn-stream factor 90 % Distillation &

Total CatFT HydrotreatingInitial Capital Costs $ $ $

ISBL with multiple plants 2014 base year 4,065,763 3,337,285 728,478Off-sites 15 % of ISBL 609,864 500,593 109,272Initial spare parts 2.0 % of fixed inv 93,513 76,758 16,755Startup and commissioning 5 % of ISBL 203,288 166,864 36,424Project development 50,000 41,041 8,959

Total 5,022,428 4,122,541 899,888

100  BPD  CatFT  EsLmated  Cash  Flow  Product Sales Unit Values $/year $/year $/year

Diesel and naphtha 3.00 $/gal 2,445,219 2,445,219 0Wax 5.00 $/gal 2,823,521 2,823,521 0Total product sales 5,268,739 5,268,739 0

Cost of Goods SoldSyngas 3.00 $/kscf 3,105,810 3,105,810 0Power 8.0 cents/kwh (263,697) (274,210) 10,513Catalyst & chemicals 160,317 158,228 2,090Direct operating labor, man-yrs 80 k $/man-yr 160,000 131,332 28,668Contract maintenance 0.3 %/yr fixed inv 11,514 9,451 2,063Maintenance labor @ 0.4 %/yr fixed inv 15,352 12,601 2,751Control lab labor @ 5 % of oper labor 8,000 6,567 1,433Maintenance materials @ 1.0 %/yr fixed inv 38,379 31,502 6,876Equipment replacement @ 0.5 %/yr fixed inv 19,189 15,751 3,438Operating supplies @ 20 % of oper labor 32,000 26,266 5,734Plant overhead @ 60 % of oper labor 96,000 78,799 17,201Total cost of goods sold 3,382,863 3,302,097 80,766

Gross Profit 1,885,876SG&A @ 1.0 % of sales 52,687EBITDA 1,833,189Taxes and insurance @ 2.0 %/yr fixed inv 93,513Est. depreciation & amortization 502,243Operating income 1,237,433Est. depreciation & amortization 502,243First-year cash flow (before income tax) 1,739,676IRR to owners (before income tax) 30.1%

Conclusions  •  CatFT  geometry  offers  major  advantages  over  convenLonal  processes:  – Tight  temperature  control  – Scalable  to  small  applicaLons  – High  catalyst  producLvity  – Low  capital  cost  

•  Plants  as  small  as  100  BPD  can  be  profitable  

Syngas  

Boiling  Water