Catalyst optimization in gas-to-liquid technology : an operations view / Israel Olalekan Jolaolu

Abstract

Gas to Liquids (GTL) technology is a general term used for a group of technologies that has the capability to create liquid hydrocarbon fuels from a variety of methane rich feedstock. It utilizes Fischer-Tropsch synthesis (FTS) to convert the methane rich feedstock (mostly natural gas) into easily transportable hydrocarbon liquid in the presence of catalyst. In other words it is a catalytic process. GTL catalyst has continuously posed a great challenge in the emerging GTL industry. Interest in its development has also increase in the past five years, particularly with the challenges encountered with the new GTL plant around the world. This study identifies an aspect that needs attention if the GTL catalyst usage is to be optimized. It focuses on the relationship between process parameters, operators’ knowledge and catalyst performance. The empirical investigation undertaken as part of this research reveals that process parameters as well as operator’s knowledge and experience play a major role in GTL catalyst optimization. When process parameters (such as pressure and temperature) deviate from the design value the GTL catalyst degrades faster than expected. The outcome of catalyst degradation amongst others includes: loss of catalytic activity, off-spec product catalyst breakage and sintering. Analyses of experimental result reveal that operators have little or no knowledge of technical issues, notwithstanding that these issues are critical to catalyst performance. However, it is important to note that operators’ experience cannot replace technical knowledge. A blend and application of both will go along way to maintain a stable operation.