GTL.

F1 Technology
Synthetic Fuels via the GTL.F1 Fischer-Tropsch Process

Highlights of GTL.F1s Low Temperature Fischer-Tropsch Process

Complete technology packages and services can be offered through synergies of the technology portfolio of the GTL.F1 partners, Lurgi and PetroSA, ranging from feedstock treatment to product upgrading. Synthetic fuels generated with GTL.F1s Fischer-Tropsch technology from biomass, coal and gas as possible feedstocks are the alternative to oil based fuels and diesel with regard to combustion characteristics (high cetane number and high motor efficiency) and eco-friendliness (free from sulfur and aromatics). The technology has progressed and matured to a point allowing for the new phase of licensing, engineering and commercial operation. GTL.F1 stands for Gas-to-Liquids and implicates the application of the fuel products in Formula 1. With GTL.F1s Fischer-Tropsch process not only the transformation of gas-to-liquids (GTL) but also of coal-to-liquids (CTL) and of biomass-to-liquids (BTL) are possible. GTL.F1 has successfully run the worldwide biggest semi-commercial demonstration plant in Mossel Bay, South Africa. The know-how gained in the semi-commercial demonstration plant will be implemented in the prototype of the biomass unit Bure Saudron in France. GTL.F1s Fischer-Tropsch technology is a state-ot-the-art process with a slurry reactor and a cobalt catalyst developed by the GTL.F1. The Swiss registered company GTL.F1 is responsible for the commercial development, marketing and licensing of the new Fischer-Tropsch technology and developed Fischer-Tropsch catalyst.

Our Service
GTL.F1 brings its customers the simplicity of a single source for global scale Gas-to-Liquids, Biomass-toLiquids and Coal-to-Liquids plants by providing the following services: World-class syngas generation technology from natural gas The most modern Fischer-Tropsch synthesis technology The supply of a Fischer-Tropsch catalyst that meets the most arduous of specifications. Technology with which to upgrade the Fischer-Tropsch product to high performance diesel and chemical grade naphtha. The taking back and treatment of spent Fischer-Tropsch catalyst Conceptual design Basic and Front End Engineering Packages The supply of Fischer-Tropsch proprietary equipment Assistance with commissioning and start-up Ongoing operational support

Low Temperature Fischer-Tropsch (LTFT) offers a Solution to Increased Diesel Demand

Low Temperature Fischer-Tropsch High Temperature Fischer-Tropsch LPG 1 % Crude Equivalent LPG 1 %

LPG 5-10 %

Alcohols 9 %

Naphtha 9 %

Gasoline 30 % Naphtha 20-25 % Gasoline 48 %

Middle Distillates 40 % Middle Distillates 70-75 % Middle Distillates 39 % Fuel Oil 20 % Fuel Oil 3 %

Erecting the FT Reactor for the GTL.F1 Demonstration Plant

Semi-Commercial Demo Plant

The demonstration plant uses synthesis gas produced by the existing GTL plant and the product is integrated into the existing product refining, blending and storage facilities. Production capacity up to 1,000 bbl/d of oil and wax Demo-phase 2004-2008 Demonstration cost 95 mill Euro Technology licensor GTL.F1

Advantage of Slurry Bubble Column vs. Fixed-Bed Reactor

higher capacity higher productivity / volume easier construction less expensive higher catalyst efficiency better heat transfer almost isothermal lower dp

The GTL.F1 Reactor

The GTL.F1 Fischer-Tropsch reactor comprises a vessel partly filled with a slurry of liquid wax and catalyst. Syngas of the correct stoichiometric makeup is bubbled into the bottom of the reactor and, on its passage through the slurry, reacts in the presence of the catalyst to form predominantly normal alkanes of varying carbon number. The longer chain alkanes make up the wax in the reactor and the net production is separated from the slurry by means of a filtration system of proprietary design. The heat of reaction is removed, and the reaction temperature controlled, by generating medium pressure steam in a heat transfer surface immersed in the slurry. Shorter chain alkanes, together with the water of reaction, pass out of the reactor as vapour with the remaining unreacted syngas.

Slurry Reactor Concept

Scanning electron micrograph of the catalyst

The GTL.F1 Catalyst

In summary, the cobalt catalyst-slurry reactor combination has proven to be successfull, and the technology has been brought to a level where it can be confidently used for industrial applications. GTL.F1s experience has also confirmed that the idea of carrying out a demonstration at a semi-commercial scale was well founded, as up-scaling aspects were identified that would not have been apparent even if a large pilot plant had been used.

Successful Bid for BTL Bure

Biomass, such as agricultural residue, is pretreated to reduce moisture and particle size. It is then converted into so-called Syngas using a gasification reactor, a process that begins with the production of a flame reaction under high pressure and temperatures above 1300 C through the addition of oxygen and steam. The next step involves removing CO2 and impurities such as sulfur from the syngas. The pure syngas that results is then converted, using the Fischer-Tropsch technology from GTL.F1. It then becomes a green wax that is subsequently upgraded during downstream processes, resulting in a diesel product of the highest quality and purity.

Mastering the Scale-up Challenge

Attrition of FT catalyst
Sustainable Wax Separation Rate (relative) Laboratory Semicommercial

Scale-up of Wax Separation System

Catalyst Attrition Rate (relative)

Laboratory

Semicommercial

Increasing Reactor Diameter

Increasing Reactor Diameter

History
The GTL.F1 FT technology development started with early R&D work by Statoil from 1986 onwards. As a result, one of the first patents in the area of modern FT has been filed for the proprietary cobalt catalyst on alumina support with rhenium as promoter and for the three-phase slurry bubble column reactor. Today, GTL.F1s IPR portfolio includes patents for catalysts, reactor components and the conversion process itself. The participating interests in the joint venture are now PetroSA 50 percent and Lurgi 50 percent. PetroSA is owner of the until recently largest GTL plant which they operate in Mossel Bay, South Africa. Lurgi is bringing into the joint venture its know-how from earlier FT activities and vast experience in commercializing first-of-its-kind technologies.

GTL.F1
GTL.F1 is a Swiss-registered limited company established in 2005 and jointly owned today by PetroSA and Lurgi. GTL.F1 offers an integrated concept for GTL technology comprising Lurgis MegaSyn technology, its proprietary low-temperature Fischer-Tropsch technology based on cobalt catalyst, and product upgrading. For BTL and CTL, we offer our slurry Fischer-Tropsch process integrated with upgrading technology licensed from a 3rd party.

The Petroleum Oil and Gas Corporation of South Africa (Pty) Limited, known as PetroSA, is South Africa's national oil company. It owns, operates and manages the South African government's commercial assets in the petroleum industry. PetroSA is a pioneer in the Gas-to-Liquids (GTL) technology, recognised internationally for operating the first commercial GTL plant. The refinery has been in operation since 1992. It is one of the worlds largest GTL refineries, producing about 36,000 bbls day of high quality fuels from Natural Gas and Condensate. The GTL refinery not only boasts with both High Temperature (HT) and Low Temperature Fischer-Tropsch (LTFT) technologies, but also with the Conversion of Olefins to Distillate (COD) technology.

Lurgi GmbH is a member of the Global Engineering & Construction (E&C) division of Air Liquide. Air Liquide Global E&C Solutions is a leading engineering company and a technology provider operating worldwide in the fields of process engineering and plant contracting. Based on syngas, hydrogen production and clean conversion technologies for fuels or chemicals, the Lurgi technology portfolio offers innovative solutions that allow operation of environmentally compatible plants with clean and energy-efficient production processes. With its proprietary MegaSyn concept, a key Lurgi technology was developed allowing ultra-large capacities suitable for FischerTropsch and other down-stream applications. Furthermore, Air Liquide Global E&C Solutions can supply the oxygen required for syngas production either from an air separation unit (ASU) integrated in the project or supply over the fence (OTF). We are continually exploring and developing possibilities to achieve

www.petrosa.co.za

still larger syngas capacities at significantly lower capital and operating costs. In this light, we designed the syngas units for most Fischer-Tropsch plants currently in operation worldwide. Air Liquide Global E&C Solutions www.lurgi.com

Lurgi is a member of the Air Liquide Group.

Contact:
GTL.F1 AG Witikonerstrasse 61 8032 Zurich

Denis Cieutat Managing Director Phone: +49 (0) 69 5808-2333 Fax: +49 (0) 69 5808-2766 E-mail: denis.cieutat@gtlf1.com