Velocys Fischer-Tropsch

Frequently Asked Questions

How is Velocys Fischer-Tropsch (FT) different from
competing FT technologies?
The application of advanced microchannel process
technology permits Velocys FT reactors to produce
commercially significant quantities of synthetic fuels in
compact, modular units. Systems based on this technology
are physically smaller and improve process economics, Water/Steam
especially for smaller scale synthetic fuel installations Water 0.2 – 5.0 mm

appropriate for biomass-to-liquids (BTL) and offshore or

CO + 2 H2 0.2 – 5.0 mm
distributed gas-to-liquids (GTL) facilities.
-(CH2)n- + H2O

Synthesis Gas Requirements

What synthesis gas generation technologies are compatible with Velocys FT?
Synthetic fuels, also known as FT fuels, can be made from any carbonaceous material, even municipal solid
waste. The first step of the process is to convert the feedstock material into synthesis gas (syngas), a mixture of
carbon monoxide (CO) and hydrogen (H2). Numerous technologies exist to perform this step. For natural gas,
the common choices are partial oxidation (POX) and steam methane reforming (SMR). For solid feedstock
materials such as coal and biomass,
materials, biomass a range of approaches are currently being employed or developed,developed
including conventional oxygen limited combustion schemes, molten metal, and plasma gasification. The right
syngas generation technology is application specific, determined by the feedstock characteristics, scale of
facility and other factors.

What composition of synthesis gas is required/ideal?

Consistent, clean syngas is required for all commercial FT processes. Normally, syngas entering the Velocys FT
unit will have a H2 to CO ratio of 1.6:1
1 6:1 to 2.1:1,
2 1:1 and have low levels of diluents,
diluents such as nitrogen (N2) and carbon
dioxide (CO2). Improper H2 to CO ratios can be corrected with a water gas shift (WGS) or reverse WGS prior to
the FT unit; alternatively excess H2 can be separated out for downstream upgrading of FT products. Diluents, in
low quantities, do not impact the ability to convert syngas into longer chain hydrocarbons, but they do lower
capacity and therefore asset utilization. These non-reactive gases can be expelled from syngas in various ways,
including adsorption, absorption and membrane separation.

What level of syngas contaminants can the Velocys FT catalyst handle?

All commercial FT catalysts, including those used in Velocys FT reactors, experience premature deactivation in
the presence of certain poisons, including sulfur, ammonia and chloride compounds. For this reason, thorough
syngas conditioning is required prior to the FT unit. In addition, one or more “guard beds” is recommended to
protect the catalyst. As stated above, non-reactive contaminants (N2 and CO2) lower capacity, but do not
otherwise impact performance.
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 Velocys FT – FAQs, Page 2

Velocys Fischer-Tropsch Unit

Wh t is
What i the
th smallest
ll t commercially
i ll viable
i bl capacityit off a Velocys
V l
FT unit?
A single full-scale microchannel FT reactor is rated for
approximately 30 barrels per day (bpd). These reactors are
manifolded together in assemblies of up to 10 reactors, resulting in
an incremental capacity of 300 bpd. Multiples of these 300 bpd
assemblies can be installed to match the capacity of the syngas
generation units. Since the syngas generation and conditioning are
the most capital intensive units of synthetic fuel facility, the optimal
commercial capacity is primarily determined by gasifier capacity
and other factors, such as feedstock availability.

30 bpd Velocys FT reactor measures

2’ x 2’ x 2’ (0.6m x 0.6m x 0.6m)
What are the optimal operating conditions for Velocys FT?
Velocys FT reactors operate optimally at temperatures and pressures comparable to conventional technology
FT systems – 210 to 240°C and 20 to 30 atmospheres.

What is conversion rate for Velocys FT reactors?

Under proper conditions, Velocys FT reactors convert ~70% of the incoming CO into longer chain hydrocarbons.
This high per pass conversion allows Velocys FT to operate in a single pass, one or twotwo-stage
stage configuration.
However, other configurations are possible, including adding a recycle loop to boost overall conversion. At 70%
conversion, approximately 1.2 million standard cubic feet per day (1360 Nm3/hr) of syngas produces 30 barrels
per day of FT products, a mixture of waxes, diesel and naphtha. Depending on the feedstock, gasification
technology and process configuration, about 40 gallons of liquid product can be generated from 1 ton of
biomass. A similar quantity of FT fuels can be produced from 10,000 SCF of natural gas or 0.5 tons of high BTU
coal.

Velocys Fischer-Tropsch Products

What are FT Products?
As shown graphically in the figure below, FT processes yield longer chain hydrocarbons and water.
Hydrocarbon products are typically grouped in four categories: 1) waxes – long chain hydrocarbons that are
solid at room temperature, 2) diesel – liquid product with between 10 and 22 carbon atoms, 3) naphtha – lighter
compounds, and 4) tail gas – methane and other gases. In addition, the highly exothermic FT process exports
heat in the form of steam. Effective utilization of tail gas and steam are important considerations for process
economics and will depend upon the process design, syngas generation technology, site characteristics, and
other variables.

nCO + (2n+1)H2 = CnH2n+2 + nH2O

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 Velocys FT – FAQs, Page 3

Do the FT products require post treatment?

Yes and no. The FT process produces synthetic crude (mixture of paraffinic molecules) that can be separated
into three streams: naphtha,
naphtha diesel and wax.
wax If off-take
off take agreements can be established for either the synthetic
crude or each of the FT products – diesel, waxes and naphtha – then a process can operate profitably without
post treatment. However, to maximize diesel production, the FT products can be upgraded in a hydrocracker.
This can be done on-site or at a separate refining facility.
Will fuel from Velocys FT meet applicable standards?
Yes. Testing has been conducted on products from various scale Velocys FT installations, ranging from a
1 gallon per day (gpd) pilot reactor operated at Velocys headquarters to a 25 gpd field demonstration at a
biomass gasification facility in Güssing, Austria. Test results shown in the table below, indicate that the diesel
cut from Velocys FT meet or exceed the ASTM requirements for number 2 diesel. (Note: FT fuels are typically
be blended with conventional fuels. Ability to meet the low temperature specification depends on the blending
level and local requirements.)
 
ASTM D975 Velocys FT
Property No. 2-D Diesel Cut
Flash Point (o C, min) 52 77.5
Water & Sediment (% vol, max) 0.05 0% Water
Distillation Temperature (o C, 90% volume recovered) min 282 330
max 338
Kinematic Viscosity (mm2/S at 40o C) min 1.9 2.2
max 4.1
Density at 15 o C (g/cc) n/a 0.77
Ash (% mass, max) 0.01 < 0.001
Sulfur (ppm, max) 15 <1
Copper Strip Corrosion Rating (3 hours @ 50o C, max) No. 3 No. 1a
Cetane No. (min) 40 > 65
Cetane Index, min. 40 74.7
Aromaticity (%vol, max) 35 1.1% (mass)
Cloud Point (o C, max - "Summer") -6.7 4.0
Carbon residue on 10% distillation residue (%mass, max) 0.35 < 0.01
Lubricity, HFRR @ 60o C (microns, max) 520 440

C
Commercial
i l Considerations
C id i
What is the capital and operating costs of Velocys FT units?
Facilities provided by Velocys include reactor assemblies, product separation and other auxiliary pieces of
equipment that comprise the FT unit of synthetic fuel facility. The current cost estimate for installed facilities,
inclusive of a process license, is $12,000 to $15,000 per bpd. This figure is expected to decrease over time as
reactor manufacturing operations ramp up. Therefore, a Velocys FT unit for a 2,000 bpd facility will cost
approximately $24 to $30 million in the early years of commercialization and will decline over time.
time Operating
costs, including catalysts, are between $3 and $5 per barrel of production.
When will Velocys FT reactor systems be available for commercial sales?
Reactors are available for sale to partnering organization. Velocys is currently demonstrating a 25 gpd FT
reactor at a biomass gasification facility in Güssing, Austria. Final preparations are underway for a second field
demonstration of 6 bpd Velocys FT in an integrated microchannel gas-to-liquid (GTL) process, in Brazil.
Additionally, construction has begun on full-scale reactors for a strategic partner’s commercial biomass-to-
liquids (BTL) facility.
How can my organization become involved?
Velocys has established partnerships with several leading companies and is focused on supporting those
partnerships. If you would like to engage Velocys to evaluate a specific project opportunity, the upfront cost of a
feasibility study is $25,000 to $50,000, depending on the scope. Please contact Jeff McDaniel at (614) 733-3319
for further details.
January 2011