Description
The Gas-to-e-paraffinic Fuel pilot plant is a turnkey, modular skid solution that reproduces Fischer–Tropsch synthesis and downstream fuel upgrading under true industrial conditions to produce e-gasoline, e-diesel, and e-kerosene, enabling clients to make confident, data-driven scale-up decisions before full-scale deployment.
Step 1 – Fischer–Tropsch Synthesis (Gas-to-Liquids Conversion)
The first step converts synthesis gas (CO + H₂) into long-chain hydrocarbons through the Fischer–Tropsch (FT) reaction. High-pressure gas feeds (H₂, CO, CO₂, N₂) are accurately metered using thermal mass flow controllers and mixed to achieve the desired syngas composition. The gas mixture is preheated and sent to a fixed-bed tubular FT reactor operated under isothermal conditions. The reactor typically operates at 200–350 °C and up to ~40 barg, using an industrial-shaped catalyst. Catalyst activation is performed beforehand by reduction under hydrogen. The exothermic nature of the FT reaction is controlled via a furnace and double-jacket heat exchange system to maintain a flat temperature profile. Reaction products include heavy waxes, liquid hydrocarbons, water, and unreacted gases. Downstream of the reactor, high-pressure separation enables efficient recovery of waxes and liquids while gases are depressurized, metered, and optionally recycled or analyzed.
Step 2 – Liquid Product Upgrading (Hydroprocessing Stage)
In the second step, the liquid hydrocarbons produced in the FT section are upgraded to improve fuel quality. Liquid feeds (FT liquids or external hydrocarbons) are stored in heated vessels and pumped using high-pressure metering pumps. Hydrogen is introduced to enable reactions such as hydrocracking, hydrogenation, and desulfurization. Gas and liquid streams are mixed using miniature static mixers before entering the upgrading reactor. The reactor operates at higher pressures (up to 200 barg) and temperatures up to 550 °C, depending on the targeted upgrading reaction. The reactor design allows either single-reactor or series operation, enabling process flexibility and kinetic studies. After reaction, products pass through high- and low-pressure separators with nitrogen stripping to maximize gas–liquid disengagement. Upgraded liquid fuels and water are collected separately, weighed, and sampled, while gases are measured and routed to vent or analysis systems. This step enables the transformation of FT products into market-relevant fuels such as diesel-range hydrocarbons
Features
Process Configuration
Integrated two-stage process architecture: Fischer–Tropsch synthesis followed by catalytic fuel upgrading
Continuous operation mode enabling steady-state data acquisition
Modular design allowing reconfiguration, expansion, or process customization
Gas Feed & Conditioning
Independent high-pressure gas lines for H₂, CO, CO₂, and N₂
Thermal mass flow controllers (MFCs) with high accuracy for each gas component
Electronic pressure regulation enabling pressure-controlled reactor operation
Static gas mixers ensuring homogeneous syngas composition upstream of reactors
Reaction Section
Fixed-bed tubular reactors designed for industrial catalyst geometries
Isothermal reactor operation via split furnaces and/or double-jacket heat exchange
Multi-point internal thermowells for axial temperature profiling
Wide operating envelope:
FT synthesis: 200–350 °C, up to ~40 barg
Upgrading: up to 550 °C and 200 barg
Catalyst activation capability under controlled hydrogen atmosphere
Thermal Management
Dedicated preheaters for gas and liquid feeds
Active heating and cooling systems to manage highly exothermic reactions
High length-to-diameter reactor ratio for enhanced heat transfer
Separation & Product Recovery
High-pressure separators for primary gas–liquid disengagement
Secondary low-pressure separators with nitrogen stripping to improve recovery efficiency
Heated transfer lines to prevent condensation or wax solidification
Separate recovery systems for waxes, hydrocarbons, and aqueous phases
Measurement, Sampling & Data Quality
Online gas flow measurement with pressure and temperature compensation
Continuous liquid mass measurement using weight scales
Multiple sampling points (gas and liquid) for kinetic and compositional analysis
Designed to ensure high-accuracy mass balance closure
Control, Automation & Safety
Fully integrated PLC-based automation system with PC supervision
Real-time monitoring of temperature, pressure, flow rates, and product weights
Multi-layer safety architecture including alarms, interlocks, PSV, and emergency shutdown
Designed for safe, unattended operation
Scale-Up & R&D Capability
Generation of industrially representative kinetic and selectivity data
Suitable for catalyst screening, reaction modeling, and process validation
Enables direct transposition of pilot results to demonstration and commercial scale
Benefits
Scale-up de-risking: Generates industrially representative kinetic, selectivity, and mass-balance data, enabling confident transition from R&D to demonstration and commercial scale.
Maximum process flexibility: Wide operating envelope (pressure, temperature, feed composition) and modular reactor configuration allow rapid testing of catalysts, process schemes, and fuel slates.
High data quality and reliability: Isothermal reactor design, advanced thermal management, and comprehensive measurement and sampling systems ensure accurate, repeatable, and decision-grade results.
