Two-stage process for conversion of synthesis gas to high quality transportation fuels. Final report

Abstract

This report describes development studies on a two-stage slurry Fischer-Tropsch/ZSM-5 process for converting synthesis gas to high quality transportation fuels (gasoline and distillate). Successful gasoline-mode operation of a similar process was demonstrated under a previous DOE Contract (AC22-80PC30022). Three Fischer-Tropsch catalysts of Fe/Cu/K/sub 2/CO/sub 3/ type were evaluated for low methane + ethane (high reactor-wax) mode operation in eight separate runs. A total hydrocarbon production of 350 g/gFe was achieved, the only experimentally established number for this mode of operation. Various process studies were also performed including development of a continuous reactor-wax removal system and the testing of a new feed-gas distributor. Bubble-column hydrodynamics were studied using two newly built tall, hot-flow columns. Data were acquired on gas holdup and bubble-flow patterns using sintered-metal-plate and orifice type feed-gas distributors. Actual reactor-waxes were used for the first time. Also the carbon-number distributions of the reactor-waxes were characterized up to C/sub 150/ using the Field Ionization Mass Spectrometry. Proprietary reactor-wax upgrading studies were carried out and are described in the Appendix-Restrictive Distribution of this report. Non-proprietary studies, including reactor-wax vacuum fractionation and thermal cracking of a Fischer-Tropsch reactor-wax vacuum bottom, were also carried out. Finally, a conceptual process design and scoping costmore » estimate were developed. The design for the slurry Fischer-Tropsch and the ZSM-5 reactor sections is similar to that given in our previous DOE Contract. The design of the reactor-wax upgrading and product separation sections, as well as the scoping cost estimate are given in the Appendix-Restrictive Distribution. 58 refs., 113 figs., 29 tabs. « less

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