GTL or Gas to Liquids technology is the chemical process by which natural gas is converted to liquid products such as diesel or methanol. Dason Technology is an early stage Company that owns a shallow bed high throughput syngas (SBHTX) technology. The patented technology is a game changer for the Natural Gas to Syngas stage of the GTL process.
Process flow diagram and schematic for compact 200 barrel/day GTL plants
The reactions occur in phases, and the key to all GTL processes is the intermediary product Syngas. Syngas has the chemical composition to be easily refined into a variety of useful liquid products. Traditionally the bulk of capital investment for GTL plants has been for the first part of the reaction which produces Syngas. Dason's goal is to significantly improve this step by increasing efficiency and decreasing plant size and costs.
The world demand for oil is growing at a rapid pace, while the world supply of oil is limited. As more oil is extracted production costs rise due to the rapid usage of land based and shallow water oil supplies and increasing substitution for more expensive sources such as oil sands, heavy oil, and deep water oil. The price of oil is not only sensitive to market economics, but also to geopolitical factors. The world supply of natural gas on the other hand is largely untapped, and could be used to supplement and extend the supply of crude oil. Recent discoveries of immense natural gas deposits, and technological innovations allowing for the extraction of shale gas likely will keep the price of gas low for the foreseeable future.
Currently natural gas reserves must be near a pipeline, or facilities where it can be compressed or converted into LNG (liquefied natural gas) in order to be transported. Such infrastructures are capital intensive and only economically feasible for large gas deposits, and are unsuitable for gas located in remote areas or deepwater platforms. When drilling for oil under these conditions, natural gas pockets that are uncovered are frequently flared, or burned. This is not only a waste of a precious resource, but is a source of pollution and fines. As of 2007, the World Bank estimated that $30 billion worth of gas is still being flared annually. In addition there exists an estimated 3000 TCF (proven + probable + possible), as much as 40% of the world's gas supply, considered "stranded" and left undeveloped.
GTL technology directly impacts a company's bottom line, by allowing it to convert unused gas assets into cash flow and revenue. The economics of gas and crude oil prices also make GTL operations extremely profitable and desirable.
Fuels produced from GTL are significantly cleaner than those refined from conventional crude oil. GTL fuels contain only a fraction of the pollutants of conventional diesel, and can be mixed with refined crude products to create clean fuels that meet rising governmental emissions standards. In addition the potential to reduce green house gas emissions and air pollution from flaring has made GTL one of the most sought after technologies.
Design/Engineering Services
Technology
Natural Gas
Capital
Licensing fees
Producers that have flare or stranded gas properties, and can get added value to operations from Dason
Lack GTL technology licenses or internal patents
The most common industrial method is currently steam methane reforming. Major integrated oil companies have large GTL projects using this technology. Steam methane reforming is an extremely mature technology, but only very minor improvements have been made since its discovery and key inefficiencies are still prevalent. Steam methane reforming produces a product that is chemically not optimal for diesel production.The reactors are very large and capital intensive, and thus only suitable on a very large scale. In addition the reaction can only occur in a very high temperature range, requiring the burning of valuable natural gas to fuel the reaction producing higher carbon emissions and causing wear on equipment and catalysts.
The demand for smaller scale reactors that are more efficient and portable has led major integrated oil companies and technology firms to invest hundreds of millions of dollars for research into other designs. The most promising process is Partial Oxidation, but it is currently not commercially viable due to low catalyst lifespan.
Dason's patented technology is a commercially viable form of Catalytic Partial Oxidation, we believe it will revolutionize the market for GTL by meeting key industry needs for efficiency and size. (To learn more about our Technology click here)
Dason's reactor combines natural gas with purified O2 and a catalyst. The resulting reaction has an extremely high conversion rate and requires no heat. The Syngas produced is chemically ideal for diesel production. Further Dason's reactor design allows it to be applicable to both small scale and large scale operations without losing efficiency.
Dason's technology is superior to existing processes. In addition, it is highly appealing to major oil and gas firms because of its modular nature. It can replace the syngas production phase of existing plants, allowing for parallel construction and minimal plant shutdown time.
Dason constructed a pilot plant in Chonqing, China in conjunction with the Chongqing Research Institute of Chemical Industry (www.ccqci.com). Upon completing the pilot plant test runs CCQCI and Dason applied for a research grant and were awarded the maximum amount of 5 million RMB from the China National Development and Reform Committee for support to build a commercial demonstration plant with the Chongqing He Feng Chemical Plant for its pursuit of a technology that holds the future to supplying growing energy needs in an environmentally conscious way.
Dason's technology increased efficiency and quality of the products, while reducing CO2 production.
Results from Liu et al. AIChE J. 58(2012) 2820-2829
1/2" OD stainless steel reactor tube with monolith catalyst insert
Comparison of the same catalyst in different forms
Steam reforming reactor has large footprint and low carbon efficiency for GTL
