Gas-to-Liquids Processes for Chemicals and Energy Production

Gas-to-Liquids Processes for Chemicals and Energy Production published by BCC Research in January, 2009. This report consists of 169 pages and the price starts from US $ 4850.

Introduction

Abstract

• Covers use of gas-to-liquid (GTL) processes for chemical and energy production is projected to make a rapid advance in the next few years as even more stringent environmental legislation is enforced.
• Analyzes methane-derived liquid fuels and chemicals and develops demand scenarios.
• Assesses the role of gas-to-liquids as an enabling technology for the production of high-quality clean transportation fuels and chemicals.
• Quantifies demand for GTL by type of product, application and production technology, and the relationships between major consumers and producers.
• Assesses the use of gas-to-liquids as feedstocks for premium chemicals and energy production during the period 2007-2012.
• Reviews the impact of offshore activity on gas-to-liquids chemicals demand in the U.S. and worldwide.
• Includes quantitative market forecasts, market share data, company profiles, patent analyses and more.

The gas-to-liquids (GTL) business is involved in the chemical conversion of stranded natural gas feedstocks to liquid products such as transportation fuels and chemicals. Insofar as beneficial processing of the world' s huge resource base of stranded natural gas is concerned, GTL processing is a relatively recent R&D focus of the petrochemical industry. Development of commercial-scale GTL plants, utilizing stranded natural gas is a relatively recent development, too. Hence, the need for this BCC report.

Liquid GTL products are primarily transportation fuels (and are defined as synthetic fuels) and chemical feedstocks such as methanol, hydrogen, and other petrochemicals. As the terms are presently used in the petrochemical industry, “GTL” and “GTL products” refer mainly to the output of plants (or refineries) that utilize stranded natural gas as feedstock. For that reason, conventional production of chemicals, including high-volume methanol, typically via steam methane reforming (SMR) of non-stranded natural gas, is not a principal focus of this report.

The objective of this BCC Research report is to provide an up-to-date and critical evaluation of the most dynamic and path breaking aspects of GTL technology and describe how recent breakthroughs in conversion technology have made GTL products competitive with products refined from crude oil. This report discusses the use of GTL processes to produce ultra-clean diesel fuels and high-quality chemical products such as waxes. BCC assesses the role of GTL as an enabling technology for the production of clean transportation fuels.

A principal focus of the report are individual company initiatives and R&D focus, Discussed as well is the status of all major GTL projects around the world that utilize stranded gas. Included are descriptions of technologies and products, and a forecast of the GTL market through 2014. The report quantifies demand for GTL by type of output, application, and production technology. A significant component of this report analyzes competitive synthetic fuel concepts, as the commercial success of competitive synthetic fuel concepts will weigh heavily on the ultimate trajectory of the GTL business. These competitive fuels include those derived from coal-to-liquids (CTL) and biomass-to-liquids (BTL).

In preparing this report, an overall study of the GTL market was undertaken. All areas of the GTL market are addressed, including identification of current and future technologies, product types, and market segments/end markets. Legislation and government and regulatory agency involvement are analyzed. The producing companies are discussed in light of technological strengths and weaknesses, market shares, marketing strengths, and innovative marketing practices.

This report, which is divided into seven sections, assesses and evaluates the demand and costs of GTL in the chemical and energy production markets. It begins with an overview that describes the importance of the GTL industry in relation to the overall U.S. economy, including a brief history and important indications for the GTL industry. Major products and applications are reviewed, and key findings from the study are presented.

Environmental and energy regulations as they apply to GTL are discussed. The structure of the GTL industry and competitive aspects are analyzed including the driving forces of the industry. Key strategies for staying competitive and important shifts in the industry are assessed. GTL industry trade practices and the impact of GTL on the oil industry are covered.

GTL markets by product type are evaluated, including synthetic fuels and chemicals. These are quantified with forecasts through 2014. Competing markets for gas are discussed including liquefied natural gas (LNG) and natural gas liquids (NGL). GTL technology is presented by covering patents and markets and investments by technology type. These technology types include Shell middle distillate synthesis (SMDS), Sasol slurry phase distillate (SSPD), Exxon' s advanced gas conversion technology 21st Century (AGC-21), Syntroleum process (SP), and Rentech. International GTL aspects also are considered, and major overseas companies involved in GTL processes and their activities also are assessed.

Data for this study were collected using both primary and secondary data research techniques. A literature search was conducted covering scientific, business and technical documents as well as patents. Since some segments of the GTL market are not routinely measured, BCC derived estimates from a variety of sources. Whenever market estimates are derived, they are fully noted. All forecasts are in current (nominal) dollars, unadjusted for inflation. Information sources include trade data (national and international), company literature, conference reports, world trade technical journals, and interviews with company representatives.

Gas-to-Liquids Processes for Chemicals and Energy Production

• MAJOR FINDINGS
• KEY FINDINGS OF THIS STUDY
• SUMMARY TABLE GLOBAL MARKET FORECAST OF PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, THROUGH 2014 ($ BILLIONS)
• SUMMARY FIGURE GLOBAL MARKET FORECAST OF PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, 2007- 2014 ($ BILLIONS)

• TABLE 1 DISTRIBUTION OF WORLD STRANDED NATURAL GAS RESOURCES BY REGION, 2008 (PERCENT DISTRIBUTION)
• CARBON REGULATIONS AND GTL MARKET PROSPECTS
• FACTORS DRIVING ADOPTION OF GTL PROCESSES
• OVERVIEW OF RECENT ACTIVITY
  • TABLE 2 KEY EXAMPLES OF GTL DEMONSTRATION PLANTS
• SASOL
• RENTECH
• SYNTROLEUM
• MODEC
• WORLD GTL
• BHP BILLITON
• EXXON
• SHELL
• QATAR AND EGYPT: MAJOR FOCUS FOR GTL PROJECTS
• PROJECT LIST
  • TABLE 3 LIST OF PRINCIPAL GTL PLANTS AROUND THE WORLD
  • TABLE 3 (CONTINUED)
• HISTORY OF THE GTL INDUSTRY
  • FIGURE 1 GTL PRODUCTION OPTIONS, TRANSPORTATION FUELS, AND CHEMICALS
  • TABLE 4 CURRENT WORLD COMMERICAL SYNFUELS CAPACITY (BBL/D)
  • TABLE 5 COMPARATIVE MERITS AND DRAWBACKS OF FT
• PRINCIPAL GTL PRODUCTION PROCESSES
• SHELL SMDS
• Shell SMDS (Continued)
• SASOL GTL PROCESSES
• Sasol GTL Processes (Continued)
• SASOL CTL PLANTS
• STATOIL AND PETROSA
• RENTECH
• Rentech (Continued)
• EXXONMOBIL' S ADVANCED GAS CONVERSION
• SYNTROLEUM
• BP PILOT PLANT IN ALASKA
• CHOREN INDUSTRIES
• SYNFUELS INTERNATIONAL
• CANMET ENERGY TECHNOLOGY CENTER- CETC SUPERCETANE TECHNOLOGY
• Canmet Energy Technology Center.....(Continued)
• Canmet Energy Technology Center.....(Continued)
• COMPACT GTL
• Compact GTL (Continued)
• LNG MARKETS AND CTL
• LNG MARKETS AND CTL (CONTINUED)
• COAL TO LIQUIDS
• National Energy Technology Laboratory Study
• Baard Energy CTL Plant
  • TABLE 6 OPERATING AND PLANNED LARGE COAL GASIFICATION/CTL PLANTS STATUS AS OF 2008
  • TABLE 6 (CONTINUED)
  • TABLE 6 (CONTINUED)
  • TABLE 6 (CONTINUED)
  • TABLE 6 (CONTINUED)
• GTL TECHNOLOGIES
• INTRODUCTION
• Introduction (Continued)
• Introduction (Continued)
• GTL OUTPUTS
• GTL Outputs (Continued)
• GTL Outputs (Continued)
• REFORMING
• Adiabatic Prereforming
• Tubular (or Primary) Reforming
• Advanced Reforming
• Sulfur-Passivated Reforming
• Autothermal Reforming (Catalytic Partial Oxidation)
• Two-Step Reforming or Combined Tubular/Secondary Reforming
• Heat Exchange Reforming
• HYDROGEN SHIFT CONVERSION AND METHANATION
• SHIFT CONVERSION
• METHANATION

• TIER 1- LARGE DEVELOPERS/PATENT HOLDERS
• BHP BILLITON
• BP
• CHEVRON CORP.
• CONOCOPHILLIPS CO.
• EXXONMOBIL
• IVANHOE ENERGY
• MARATHON OIL CO.
• METHANEX CORP.
• PETROSA
• RENTECH, INC.
• REPSOL
• ROYAL DUTCH SHELL
• SASOL CHEVRON
• SASOL SYNFUELS INTERNATIONAL (SSI)
• STATOIL
• SYNTROLEUM CORP.
• TOTAL
• Total (Continued)
• TIER 2- COMPONENT AND ENGINEERING SERVICES SUPPLIERS
• ABB LUMMUS GLOBAL GMBH
• AIR LIQUIDE GROUP
• AIR PRODUCTS AND CHEMICALS, INC.
• AMEC PROCESS AND ENERGY, LTD.
• AXENS
• BASF CORP.
• BLACK &VEATCH HOLDING CO.
• CHICAGO BRIDGE AND IRON CO.
• Chicago Bridge and Iron Co. (Continued)
• CRYOMECH, INC.
• DELTA HUDSON ENGINEERING, LTD.
• DESCON ENGINEERING CO., INC.
• DOW CHEMICAL CO.
• ELTRON RESEARCH & DEVELOPMENT, INC.
• FLUOR CORP.
• Fluor Corp. (Continued)
• FMC TECHNOLOGIES
• FOSTER WHEELER CORP.
• Foster Wheeler Corp. (Continued)
• HALDOR TOPSOE A/S
• INTEGRATED CONCEPTS AND RESEARCH CORP. (ICRC)
• JAPAN OIL, GAS, AND METALS NATIONAL CORP. (JOGMEC)
• JOHNSON MATTHEY CATALYSTS
• KINETICS TECHNOLOGY INTERNATIONAL CORP. (KTI), INC.
• THE LINDE GROUP
• LURGI AG
• MODEC, INC. (MITSUI OCEAN DEVELOPMENT & ENGINEERING CO., LTD)
• NIPPON STEEL
• OXFORD CATALYSTS
• Oxford Catalysts (Continued)
• PALL CORP.
• PRAXAIR, INC.
• SIEMENS
• STORK BV
• SYNFUELS INTERNATIONAL
• TECHNIP
• UOP-HONEYWELL
• TIER 3- DEVELOPMENT STAGE COMPANIES
• ARKENOL
• BAARD ENERGY, LLC
• CARBON SCIENCES, INC.
• COMPACTGTL, PLC
• HYDROGENICS CORP.
• POWER ECALENE FUELS, INC. (PEFI)
• SYNTHESIS ENERGY SYSTEMS
• WORLD GTL
• SCIENTIFIC, GOVERNMENT AND EDUCATION ORGANIZATIONS
• ALASKA NATURAL RESOURCES TO LIQUIDS, LLC
• ALLIANCE FOR SYNTHETIC FUELS IN EUROPE
• ARGONNE NATIONAL LABORATORY (ANL)
• CANMET ENERGY TECHNOLOGY CENTER (CETC)
• DOE OFFICE OF FOSSIL ENERGY
• NATIONAL ENERGY TECHNOLOGY CENTER
• IDAHO NATIONAL LABORATORY (INL)
• INSTITUTE FRANCAIS DU PETROLE (IFP)
• LEHIGH UNIVERSITY
• NATIONAL RENEWABLE ENERGY LABORATORY (NREL)
• OAK RIDGE NATIONAL LABORATORY (ORNL)
• OFFICE OF INDUSTRIAL TECHNOLOGIES- DOE
• UNIVERSITY OF HOUSTON
• UNIVERSITY OF KENTUCKY
• University of Kentucky (Continued)

• PRODUCT OVERVIEW
  • TABLE 7 GLOBAL MARKET FORECAST FOR PRODUCTS PRODUCED VIA GTL WITH COMPARISONS TO CTL AND BTL, THROUGH 2014 ($ BILLIONS)
• TOTAL UNCONVENTIONAL FUELS MARKET
  • TABLE 8 PROJECTED GLOBAL UNCONVENTIONAL LIQUID FUELS MARKET, 2005- 2014 (MBBL/D)
• GTL-FT FUEL DEMAND BY PRODUCT TYPE
• DIESEL
• GASOLINE
• OTHER GTL PRODUCTS
  • TABLE 9 PROJECTED GLOBAL MARKET FOR FT-GTL TRANSPORTATION FUELS BY PRODUCT TYPE, 2007- 2014 ($ BILLIONS)
• FT-GTL CHEMICALS DEMAND BY PRODUCT TYPE
  • TABLE 10 PROJECTED GLOBAL MARKET FOR FT-GTL CHEMICALS BY PRODUCT, 2007-2004 ($ BILLIONS)
• GTL CHEMICALS PROCESSING
• THE METHANOL MARKET
• METHANOL TO GASOLINE PROCESSING
• Methanol to Gasoline Processing (Continued)
• GTL PRODUCTS- WAXES
• GTL PRODUCTS- WAXES (CONTINUED)
• GTL PRODUCTS- WAXES (CONTINUED)
• FUELS THAT WILL COMPETE WITH GTL
• GTL COMPETITORS
• Alaska North Slope Possible for GTL by 2015
• GROWING GLOBAL LNG DEMAND
• CHANGING LNG PROJECT ECONOMICS
• WORLDWIDE DEMAND FOR NATURAL GAS
• RESOURCE DEVELOPMENT POLICIES- EFFECT ON SUPPLY FOR GTL PLANTS
• COAL-TO-LIQUIDS
• COAL-TO-LIQUIDS (CONTINUED)
• COAL-TO-LIQUIDS (CONTINUED)
  • FIGURE 2 FLOW CHART: TWO APPROACHES TO PRODUCING LIQUID FUELS FROM COALS
• CTL PROJECT ECONOMICS
• BIOMASS-TO-LIQUIDS DEVELOPMENTS
  • TABLE 11 COMMERCIAL BIOMASS-BASED GASIFICATION PLANTS, 2008
• BIOMASS-TO-LIQUIDS DEVELOPMENTS (CONTINUED)
• BIOFUELS AND RENEWABLE BIOFUELS
• ETHANOL
• BIODIESEL
• OTHER SYNTHETIC CRUDE OILS
• OIL SANDS
• EXTRA-HEAVY OIL
• SHALE OIL
• Shale Oil (Continued)

• EARLY SYNTHETIC FUELS LEGISLATION
• 2007- 2008 DEVELOPMENTS
• 2007- 2008 DEVELOPMENTS (CONTINUED)
• GHGS WILL BECOME A PRIORITY IN LAW AND REGULATION
• STATE INITIAVES RELATIVE TO FUELS' CO2 EMISSIONS
• STATE INITIAVES RELATIVE .....(CONTINUED)
• FUEL STANDARDS ARE DRIVING THE ADOPTION OF GTL
• EARLIER INITIATIVES
• EARLIER INITIATIVES (CONTINUED)
• GOVERNMENT FUNDING FOR GTL RESEARCH AND DEVELOPMENT
• GOVERNMENT FUNDING FOR GTL .....(CONTINUED)
• SNYGAS RESEARCH FUNDING VIA THE HYDROGEN FUEL INITIATIVE
• SNYGAS RESEARCH FUNDING .....(CONTINUED)

• TABLE 12 COMPANIES ASSIGNED MULTIPLE U.S. PATENTS RELATING TO GTL PRODUCTION DURING THE LAST YEAR (NUMBER)
• SELECTED PATENTS
• CONVERSION PROCESS
• HIGH SURFACE AREA, SMALL CRYSTALLITE SIZE CATALYST FOR FISCHER-TROPSCH SYNTHESIS
• PRODUCTION OF ALCOHOLS FROM SYNTHESIS GAS
• AMMONIA PLANT CONFIGURATION AND METHODS
• METHOD AND APPARATUS FOR PRODUCING PRODUCTS FROM NATURAL GAS INCLUDING HELIUM AND LIQUEFIED NATURAL GAS
• METHOD OF GENERATING HYDROCARBON REAGENTS FROM DIESEL, NATURAL GAS, AND OTHER LOGISTICAL FUELS
• PROCESS FOR SYNTHESIZING HYDROCARBONS
• HIGH PURITY OLEFINIC NAPHTHAS FOR THE PRODUCTION OF ETHYLENE AND PROPYLENE
• PROCESS FOR IMPROVING PREREFORMING AND REFORMING OF NATURAL GAS CONTAINING HIGHER HYDROCARBONS ALONG WITH METHANE
• SYNTHESIS GAS AND CARBON DIOXIDE GENERATION METHOD
• PROCESS FOR THE PREPARATION OF A SUPPORTED CATALYST
• PROCESS AND SYSTEM FOR PRODUCING SYNTHETIC LIQUID HYDROCARBON FUELS
• PREPARATION OF TITANIA AND COBALT ALUMINATE CATALYST SUPPORTS AND THEIR USE IN FISCHER-TROPSCH SYNTHESIS
• PROCESS FOR REMOVING ALUMINUM CONTAMINANTS FROM FISCHER-TROPSCH FEED STREAMS USING DICARBOXYLIC ACID
• HYDROGEN RECOVERY FROM HYDROCARBON SYNTHESIS PROCESSES
• PROCESS FOR THE PRODUCTION OF MIDDLE DISTILLATES BY HYDROISOMERISATION AND HYDROCRACKING FEEDS FROM THE FISCHER-TROPSCH PROCESS
• STABILIZED TRANSITION ALUMINA CATALYST SUPPORT FROM BOEHMITE AND CATALYSTS MADE THEREFROM
• RECOVERY OF ALCOHOLS FROM FISCHER-TROPSCH NAPHTHA AND DISTILLATE FUELS CONTAINING THE SAME
• PRODUCTION OF SYNTHETIC TRANSPORTATION FUELS FROM CARBONACEOUS MATERIAL USING SELF-SUSTAINED HYDRO-GASIFICATION
• PROCESS FOR PRODUCING SYNTHESIS GAS FOR THE FISCHER-TROPSCH SYNTHESIS AND PRODUCING APPARATUS THEREOF
• LOW SULPHUR DIESEL FUEL AND AVIATION TURBINE FUEL
• PROCESSES FOR MAKING LUBRICANT BLENDS WITH LOW BROOKFIELD VISCOSITIES
• PROCESS AND APPARATUS FOR THE PRODUCTION OF USEFUL PRODUCTS FROM CARBONACEOUS FEEDSTOCK
• PRODUCTION OF LOW SULFUR, MODERATELY AROMATIC DISTILLATE FUELS BY HYDROCRACKING OF COMBINED FISCHER-TROPSCH AND PETROLEUM STREAMS
• CATALYSTS
• FISCHER-TROPSCH COMPOSITION AND PROCESS
• SUPPORTED CATALYST
• FISCHER-TROPSCH CATALYST PRODUCTION
• PROCESS TO PREPARE A HEAVY AND A LIGHT LUBRICATING BASE OIL
• HYDROPROCESSING METHODS AND APPARATUS FOR USE IN THE PREPARATION OF LIQUID HYDROCARBONS
• SYSTEMS AND METHODS OF IMPROVING DIESEL FUEL PERFORMANCE IN COLD CLIMATES
• METHOD FOR PRODUCING LONG-CHAIN HYDROCARBONS FROM NATURAL GAS
• FISCHER-TROPSCH CATALYST, PREPARATION, AND USE THEREOF
• HOMOGENEOUS MODIFIED-ALUMINA FISCHER-TROPSCH CATALYST SUPPORTS
• BLENDING FOR DENSITY SPECIFICATIONS USING FISCHER-TROPSCH DIESEL FUEL
• OXYGENATE TREATMENT OF DEWAXING CATALYST FOR GREATER YIELD OF DEWAXED PRODUCT
• PROCESS FOR REMOVING CONTAMINANTS FROM FISCHER-TROPSCH FEED STREAMS
• PROCESS TO PREPARE A WAXY RAFFINATE
• PROCESS FOR THE PRODUCTION OF MIDDLE DISTILLATES BY HYDROISOMERISATION AND HYDROCRACKING FEEDS FROM THE FISCHER-TROPSCH PROCESS
• RECEPTION, PROCESSING, HANDLING, AND DISTRIBUTION OF HYDROCARBONS AND OTHER FLUIDS
• PRODUCTION OF HYDROCARBONS
• METHOD AND APPARATUS FOR REGENERATING AN IRON-BASED FISCHER-TROPSCH CATALYST
• PROCESS FOR CONVERTING GASEOUS ALKANES TO LIQUID HYDROCARBONS
• INTEGRATED PROCESSING OF NATURAL GAS INTO LIQUID PRODUCTS
• GAS-TO-LIQUIDS FACILITY FOR FIXED OFFSHORE HYDROCARBON PRODUCTION PLATFORMS
• MODIFICATION OF A METHANOL PLANT FOR CONVERTING NATURAL GAS TO LIQUID HYDROCARBONS
• PROCESS FOR THE RECOVERY OF OIL FROM A NATURAL OIL RESERVOIR
• APPARATUS FOR PRODUCING HIGH MOLECULAR WEIGHT LIQUID HYDROCARBONS FROM METHANE AND/OR NATURAL GAS
• MANAGING HYDROGEN IN A GAS TO LIQUID PLANT
• METHOD FOR CONVERTING NATURAL GAS TO LIQUID HYDROCARBONS

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