Unlocking Small-Scale GTL: Cost-Effective Platform for Producing Drop-in Fuel From Syngas via a Single-Loop, Catalytic Thermochemical Process

We describe a new gas-to-liquids technology that converts syngas to high-quality gasoline, diesel, and/or jet fuel through a catalytic thermochemical process that minimizes complexity, improves product quality and increases yield. Syngas-to-gasoline plus (STG+) converts 1 MMBtu of natural gas feed into ~5 US gallons of liquid fuels, enabling the use of cost-effective, small-scale (6,000 bpd) GTL plants. Our data are from laboratory research, pilot and demonstration plant operations, and independent laboratory testing. We also compare the two leading GTL technologies (Fischer-Tropsch and Methanol-to-Gasoline) to the STG+ process. Our results are applicable to the GTL supply chain, development and operation of GTL plants, and end users of syngas-derived drop-in fuels. Because STG+ is cost-effective at scales as small as 400 bpd, it is particularly attractive for stranded or flared gas. From pilot and demonstration plant operations, independent lab testing, university research, Aspen simulation and financial analyses, we show: • The gasoline product has >91 octane, contains <1 ppm sulfur and ~0 benzene, and meets or exceeds other ASTM standards. • It only requires ~$120M to build a 2,000 bpd commercial plant and produces high-quality gasoline at the cost of $65 per barrel crude oil because of its high yield and efficiency. • STG+ is consistently more cost-effective, both in capital and overall costs, than Fischer-Tropsch and even the MTG processes at small, medium and large scales through a series of comprehensive technical and economical analyses. This is the first in-depth presentation of the STG+ process comparing its properties and benefits with the FT and MTG processes.