Book Description

In principle, syngas (primarily consisting of CO and H2) can be produced from any hydrocarbon feedstock, including: natural gas, naphtha, residual oil, petroleum coke, coal, and biomass. The lowest cost routes for syngas production, however, are based on natural gas, the cheapest option being remote or stranded reserves. Economic considerations dictate that the current production of liquid fuels from syngas translates into the use of natural gas as the hydrocarbon source. Nevertheless, the syngas production operation in a gas-to-liquids plant amounts to greater than half of the capital cost of the plant. The choice of technology for syngas production also depends on the scale of the synthesis operation. Syngas production from solid fuels can require an even greater capital investment with the addition of feedstock handling and more complex syngas purification operations. The greatest impact on improving the economics of gas-to liquids plants is through (1) decreasing capital costs associated with syngas production and (2) improving the thermal efficiency with better heat integration and utilization. Improved thermal efficiency can be obtained by combining the gas-to-liquids plant with a power generation plant to take advantage of the availability of low-pressure steam. The extensive research and development efforts devoted to syngas conversion to fuels and chemicals are documented in a vast amount of literature that tracks the scientific and technological advancements in syngas chemistry. The purpose of this report is to review the many syngas to products processes and summarize the salient points regarding the technology status and description, chemistry, catalysts, reactors, gas cleanliness requirements, process and environmental performances, and economics. Table 1 lists the products examined in this study and gives some facts about the technology as well as advantages and disadvantages. Table 2 summarizes the catalysts, process conditions, conversions, and selectivities for the various syngas to products processes. Table 3 presents catalyst poisons for the various products.