The Problem
Current methods of converting gas to liquid, used for effective transport of natural gas, require large scale equipment and storage facilities, which are costly on off-shore platforms.

Novel Process Intensification concepts may offer effective, safe solutions for gas-to-liquid conversion processes - but more research is needed.

The Approach
BHRSolutions with support from the OGID of the DTI has carried out a feasibility study to assess the technical and commercial viability of novel Process Intensification (PI) concepts for Gas-to-Liquid (GTL) conversion for the production of hydrocarbons.

In particular to carry out the significant process steps for:

• Steam Reforming (SR) which produces syngas
• Fischer-Tropsch (FT) synthesis of syngas into hydrocarbon and oxygenated species.

The application of PI techniques for these key process steps could result in a significant difference between a conventional GTL and PI-based GTL Plant as the PI solution removes the need for oxygen storage in the Syngas Production stage and conventional process equipment in the production, conversion and possibly upgrade stages. This would eliminate major large scale equipment and storage facilities which are at a premium in offshore installations.

The Work Programme
The work reviewed the three main steps involved in GTL conversion namely:

• Syngas Production
• Syngas Conversion
• Product Upgrade

covering both conventional GTL processes and novel processes (including PI). The technical and economic viability of the reactor concept has also been evaluated based on an assessment of the key technical variables that determine GTL productivity.

This included determining catalyst conversion and selectivity, in particular for surface coated catalysts which would be used in a HEX reactor over a typical range of operating conditions.

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