Novel Fischer-Tropsch Reactor

73123 In an effort to increase U.S. energy security, there has been considerable investment during the past two decades in research and development efforts directed toward the economic production of liquid fuels and chemicals from domestic coal and natural gas supplies. Although the worldwide inventory of uncommitted gas reserves likely exceeds 2,000 trillion cubic feet (Tcf), equivalent to ca. 360 billion barrels of oil equivalent (boe), none of these gas reserves are located in North America. The conversion of coal-derived synthesis gas to clean transportation fuels via Fischer-Tropsch Synthesis (FTS) using iron-based catalysts offers an economically attractive pathway in the near-term to achieving increased energy independence and security; however, the general consensus for FTS operations using an iron catalyst has been that separation of catalyst fines from the FTS heavy product is very difficult and may be a fatal flaw with currently available technology, such that catalyst/wax separation is one of the most important technical risks and a critical issue that must be resolved. CeraMem Corporation has demonstrated (in Phase I) and plans to develop (in Phase II) and ultimately commercialize (in Phase III) an advanced process for catalyst-wax separation that has potential to enable the production of clean transportation fuels from synthesis gas derived from hydrogen-deficient feedstocks (such as coal). In the Phase I program, CeraMem designed, assembled, and successfully operated a bench-scale, advanced monolith membrane filtration loop (AMML), and demonstrated the efficacy of a ceramic ultrafiltration membrane installed in the AMML for the production of near-catalyst-free product wax. In the Phase II program, CeraMem plans to work intimately with its Phase II/III commercialization partner to further develop the subject technology demonstrated in the Phase I program. Specifically, CeraMem plans to (1) design, construct, and operate a pilot-scale, advanced membrane process system; (2) determine the influences of key process and membrane element variables on system performance; (3) optimize CeraMem's advanced process for both primary and secondary catalyst/wax separation processes; (4) develop engineering designs for potential commercial installations; (5) perform economic analyses for each design; and (6) initiate execution of CeraMem's commercialization strategy. Commercial Applications and Other Benefits as described by awardee: The primary commercial application for the advanced membrane process under development in this program is separation of iron-catalyst fines from wax produced from synthesis gas derived from hydrogen-deficient resources, such as coal. If successful, CeraMem's technology will enable the commercial production of clean transportation fuels from the domestic coal supply at a cost as low as $0.50 per barrel, thereby providing a mechanism to significantly reduce dependence on oil imports, leading to increased energy security for the United States. Other potential applications are foreseen in the petrochemical industry, including the removal of particulate contaminants from amine strippers, the regeneration of used lubricating oils, and the removal of catalyst fines from fluid catalytic cracking oil.