Analysis & Adaptation of Advanced Fischer Tropsch Catalyst Structures and Resulting BOP Reductions to Fulfill Future Navy Fuel Needs

Microfibrous Entrapped Catalysts (MFEC) are proposed for detailed analysis to determine their potential to meet future Navy fuel needs by means of highly selective Fischer Tropsch Synthesis (FTS). MFEC are comprised of small grains of supported catalysts (ca. 10-200 micron diameter) entrapped within sinter-locked networks of micron diameter metal fibers. Metal fibers comprise only 5-10 vol% of the solid matrix, yet increase effective thermal conductivity by 3 to 12 times compared to packed beds. High conductivity catalysts in a variety of reactor structures will be investigated as a means to reduce hot spots and thereby improve FTS selectivity. Improved selectivity and reduced downstream post-processing are critical to reductions in the Balance of Plant (BOP). Reduced BOP improves modularity and ease of deployment. MFEC are readily manufacturable and provide high effective heat transfer and high intraparticle & intrabed mass transport. MFEC combine the beneficial attributes of orientation independent "frozen fluidized beds" as well as "fixed slurry beds" not requiring difficult catalyst-product separations. Process modeling will also be conducted to determine those catalyst structures, reactor types, operating conditions, and integrated designs which have the greatest impact on feed flexibility, product selectivity, process robustness, modularity, thermodynamic efficiency, annualized operating costs, and BOP.