(187i) An Innovative Technology for the Production of Value Added Chemicals Using Fischer Tropsch Synthesis

INFRA Technology uses a novel Cobalt catalyst supported on Al₂O₃-based composite substrate for the production of paraffinic hydrocarbon from pipeline quality natural gas. Our commercial catalyst designated as “S1” produces mainly a mixture of gasoline and middle distillate fractions in 60/40 proportion. Within middle distillate, up-to 45% is kerosene fraction good for use in the aviation industry. The full spectrum of this technology is based on a GTL (gas to liquid) chemical process which entails a purification section for the removal of contaminant sulfur from pipeline quality gas. Further, heavier hydrocarbons are removed using a pre-reforming process. The main reforming process entails an environmental friendly tri-reforming process, which in addition to conventional wet reforming, also converts greenhouse carbon dioxide to a valuable syn-gas. Above 85% conversion is achieved in a single reformer, an endothermic reactor with 16 tubes. Commercially tested Nickel catalyst used for this purpose. The reforming process achieves hydrogen to carbon monoxide product at a ratio of 2.8:1, with carbon dioxide as a by-product. This by-product carbon dioxide from the reformer is recycled back to reformer using the conventional amine contactor-regenerator system. Less than 1% carbon dioxide slips through amine and goes to synthesis section as an inert. Syngas ratio correction is achieved via a membrane unit that utilizes the high solubility and diffusivity of hydrogen within the membrane fibre. Ratio corrected syngas (H₂ to CO at 2.1:1) is fed to the first stage of FT reactor. Approximately 60% conversion is achieved in the first stage of exothermic reactors. After inter-stage cooling and product removal, the reactants are left over syngas is fed to the second stage to achieve an overall conversion of 80%. FT reactors are fixed bed, shell and tube type of reactor that utilizes water-steam phase equilibrium for precise control of reactor temperature. This unit also eliminates the flaring by using the product gas as fuel to the process. It is also self-sufficient in meeting the process water demand from the product water. Thus it reduces the load on water table and improves ground sustainability. The application of INFRA’s technology are enormous, including monetization of stranded gas reserves, conversion of refinery flare gas to value added chemicals, improving shale gas economics and providing a useful add-on in conjunction with any bio-gasification technology for BTL (biomass to liquid) commercialization. INFRA technology is also undergoing rapid innovation in the technology design and catalyst development. The aim is to further simplify the reactor design and improve catalyst yield, selectivity and stability. Further ENCON (energy conservation) projects are underway to improve the overall energy efficiency of the unit.