Professional Documents
Culture Documents
Widodo W. Purwanto
Syngas Production
FT synthesis
Product Upgrading
GTL Economics
GTL Projects
The Future
Motivation:
Net export/import petroleum fuel
(eksport/import petroleum
Source: OPEC, 2013, processed
fuel)/domestic production 3
Future Fuel Supply
CTL/
Source:APEC
Natural gas transportation
Pipeline
Gas-to-Liquid (GTL) fuels can be produced from natural gas using a Fischer-
Tropsch chemical reaction process. The liquids produced include diesel,
naphtha, and chemical feedstocks. GTL diesel can be used neat or blended
with today’s diesel fuel and used in existing diesel engines and infrastructure.
These fuels provide an opportunity to reduce dependence on petroleum-based
fuels and reduce tailpipe emissions. GTL fuel has virtually no sulfur,
aromatics, or toxics. It can be blended with non-complying diesel fuel to make
the fuel cleaner so it will comply with new diesel fuel standards.
FT-Diesel
Why Synthetic fuels?
but
Need chemical conversion
Diesel Quality Regulation
Source: Sasol
The GTL Process
Feedstock
H/C 1 2 4 0.1
H/C= 2
Gasification
Feed + O2 + H2O
H2/CO DME
Coal
POX (CH4+O2)
Gas
CO2R (CH4+CO2)
Electricity
Combined Ref. Olefins
NH3
Source: widodo, 2004
Direct process conversion
Pyrolisis
Synfuels (liquid/gas)
Coal
Hydrogenation
Ethylene
Heat
Methanol
Formaldehyde
CH4
Aromatics
Hydrogen
nanocarbon
Source: widodo, 2004
GTL Flow Diagram
H2S, CO2, H2O Electricity
CH4
Natural
Gas Desulphurizer Syngas Cogeneration
Unit Production Unit Unit
O2 H2,CO Tail
Air Gas
Air Separation Polybed PSA
Unit Unit
H2 Light
H2/CO=2 Ends
N2 FT Synthesis Upgrading
Unit Unit
Catalyst
Separation Naphtha,
Syncrude Diesel
Water Make
EE: 60% 17 Btu
CE: 77% 0 Carbon
Source: IEA
Product-Feeds-Technology
Source: Sasol
Poly-generation
(Fuels, Chemicals & Power)
• Natural gas composition: CO2 content
• Syngas production technologies: H2/CO, Energy
• - SMR: H2/CO >, E++
• - CO2R: H2/CO <, E ++
• - POX: H2/CO ~, E-
• - Combined (SMR+POX=ATR) H2/CO ~, E~
• FT synthesis: H2/CO, catalyst type, temperature
• Excess light ends & steam: Electricity
• Excess of H2 or CO: chemicals as co-products
Heat Integration
Tubular Reactor
Side Reactions
Water gas shift : H2O + CO CO2 + H2
Surface carbonaceous material : (x+(y/2)) H2 + x CO CxHy + x H2O
Dis-proporsionation Boudouard : CO + CO CO2 + C
Oxidation-reduction of catalyst : y H2O + x M MxOy + y H2
y CO2 + x M Mxoy + y CO
Carbide formation : y C + x M MxOy + y CO
Reaction Performances
•Conversion: reactant converted/initial reactant
•Product Selectivity:
Anderson–Flory–Schulz kinetics
=0.8 premium/gasoline
>0.9 diesel
Parameter Impacts
Nilai tinggi, produk mengarah diesel
Kondisi Proses.
Rasio H2/CO : rasio H2/CO naik, nilai turun
Suhu (T) : suhu naik, nilai turun
Tekanan (P) : tekanan naik, nilai naik
High Advanced
temperature Synthol
(350oC) Synthol
Gasoline &
olefins
Low
temperature Arge Slurry
(250oC)
Waxes &
diesel
Source: Sasol
FT Reactor Capacity
Source: Sasol
Pilot Slurry Phase Reactor (SPD)
1 m diameter x 20 m high
demonstration reactor:
Hydrodynamic and
Engineering Data
Source: Sasol
Slurry Phase Reactor (SPD)
Commercially proven
Designed, developed, operated and
licensed by Sasol
2500 bbl/day unit operated since
1993 first run - 7 months
5 years commercial operation
98% availability
Uses high efficiency catalyst
Source: Sasol
Typical Flow Regime
Source: Krishna
Reactor photos
Oryx GTL
Source: Sasol
Reactor GTL shell
Product Upgrading
Upgrading process
Tail Gas
Gas Sintesis
REAKTOR
Air FISCHER Steam
TROPSCH
Gas
Wax/Slurry
Katalis
H2 Nafta
SEPARASI UNIT SEPARASI
KATALIS HYDRO - PRODUK
& WAX PROCESSING
Diesel
Wax
Upgrading Process
GTL Economics
Gap between Gas-oil price
60
40
20
0
0 20 40 60 80 100 120
Kapasitas Plant GTL (1000 BPD)
South
40 Africa
Target
30 Exxon
Qatar
20
New Petroleum Refineries
10
0
1980 1985 1990 1995 2000 2005 2010 2015
Source: IFP
Indicative Capital Cost Breakdown
20%
30% Syngas Production
F-T Synthesis
Product Work-up
Other Process units
15%
Utilities
Offsites
10% 15%
10%
22%
52% Capex
Gas Price
$0.5/MMBtu
~ $4.5/bbl
Opex
Capex
~ $9.0/bbl
Opex
~ $4.5/bbl Feed Costs
Other Costs
24%
$18/bbl
Portions of NPV (Discount Rate = IRR)
40
30
20
10
0
PR30 PR50 GTL20 GTL35 CTL4 CTL8
Source: Sasol
Product value
and potential markets
Source: Sasol
Adding value of GTL products
Source: Sasol
GTL Project
Existing dan Proposed GTL project
Pre Feasibility
Feasibility
FEED
Commissioning
Onstream
-20 -12 0 9 14 47 50
MONTHS
GTL Project Performance Improvement
Source: Sasol
Source: Sasol
ORYX Progress at Site
Technip, )
Nat.Gas
Integrated GTL - Scenario 4
(SDR-FT-ACETIC ACID- POWER)
Integrated GTL - Scenario 5
(DR-FT-ACETIC ACID-POWER)
Nat.Gas
CO2