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‫بسم هللا الرحمن الرحيم‬

University of Khartoum
Faculty of Engineering
Chemical Engineering Department

FISCHER-TROPSCH SYNTHESIS (FTS)

Prepared By

Ishag Haroon Mohamed

April 201
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The Fischer-Tropsch synthesis (FTS) refers to the process of converting synthesis

gas (from natural gas, biomass, and coal) into liquid hydrocarbons using a metal
catalyst. The FTS process can be used to produce liquid transportation fuels such
as gasoline, diesel and other chemicals. Fuels produced with the FT process are of
high quality due to a very low aromaticity and absence of sulfur. These fuels can
be used as blending stocks for transportation fuels derived from crude oil. Other
valuable products besides fuels can be tailor-made with the FT in combination with
upgrade processes: for example, ethane, propene, -olefins, ketones, solvents,
alcohols, and waxes. FT fuels also will lessen the dependence on foreign oil and
reduce environmental impacts. Also, due to the high quality of the transportation
fuels derived from the Fischer-Tropsch process, the product oil should fetch a
higher price than crude oil-derived fuels. At crude oil prices of $16-18 per barrel it
was estimated that the FT-derived oil could fetch $22-25 per barrel.[1]
The reaction of synthesis gas consisting of hydrogen and carbon monoxide, over an
iron catalyst to form hydrocarbon and oxygenated products was discovered by
German scientists, Fischer.F and H.Tropsch working at the Fuel Research
Laboratories of the Kaiser Wilhelm Institute for Kohlenforschung (i.e. coal
Research) in the 1920’s.This reaction was used by Hans Fischer and Franz Tropsch
to make fuels during World War II and they spent the next several years attempting
to increase the yield of hydrocarbons. However, Germany was not alone in its
efforts to commercialize the Fischer-Tropsch synthesis and there has been
continued interest world-wide in Fischer-Tropsch technology ever since. The US
Bureau of Mines began to study this process in the late 1920’s and continued with
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development work for more than forty years. In particular, studies carried out
during the 1940’s resulted in the development of a widely accepted overall kinetic
model and detailed models of chemical selectivity. The Bureau of Mines’ efforts
focused on the use of fused iron catalysts, but also included evaluation of
precipitated iron and cobalt catalysts. Several facilities are continuing to study the
iron-based Fischer-Tropsch synthesis (Bechtel 1990; Shell 2001, Sasol 1950’s, and
Joint venture (Qatar Petroleum & SASOL) 2010).[1] Current research interests
focus on the development of slurry reactor processes, which offer excellent
temperature control, high single-pass conversion, and flexible operating conditions.
Slurry reactor research, including new catalyst development, is also ongoing at
SASOL (South African State Oil) and in Germany and Japan.
There are three main points of consideration, concerning the Fischer-Tropsch
process. Firstly, there is the mechanism of the Fischer-Tropsch reaction, the details
of which are still not fully understood. In addition, from the perspective of
chemical engineering, there is the design and scale-up of the commercial Fischer-
Tropsch synthesis reactor and plant in which studies of the kinetic models play an
important role. To reach the ideal performance of the Fischer-Tropsch process, an
accurate comprehensive kinetic model which can describe the product distribution
of Fischer-Tropsch synthesis is required. Lastly, there is the economic point of
view, and potential processes are required to be operated on a large scale.
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There are four main steps to produce Fischer-Tropsch Products, namely: syngas
production, gas purification, Fischer-Tropsch synthesis and product upgrading. See
figure 1.1 for a generic process flow diagram.[2] High value added products are
usually obtained by upgrading the FT products with well-established refinery
processes, such as hydrocracking and isomerization.

Figure 1.1: FTS Generic Process Flow Diagram [2]

Depending on the types and quantities of FT products desired, either low (200-240
o
C) or high temperature (300-350 oC) synthesis is used with either a cobalt or iron
catalyst respectively. FT temperatures are usually kept below 400 oC to minimize
CH4 formation. Low temperature synthesis yields high molecular weight waxes
while high temperatures produce gasoline and low molecular weight olefins such
as ethylene and propylene. Production of gasoline products is highest under
conditions of high temperatures using an iron catalyst in a fixed fluid bed reactor.
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Production of diesel fractions is maximized in a slurry reactor using low

temperatures and cobalt catalyst. FT reactors are operated at pressures ranging
from 10 to 40 bar. [2]

Synthesis gas production and product upgrading rely on established technologies.

Synthesis gas manufacturing is widely applied in the production of methanol and
ammonia. Product upgrading processes originate directly from the refining
industry and are highly optimized. Fischer-Tropsch synthesis is needed to be
modified further to reduce the cost of production. Choi et al. (Choi, Kramer et al.
1996) gives a capital cost breakdown of the three individual process sections for a
45K BBL per day FT plant in Figure 1.2.

FIGURE 1.2: The capital cost breakdown of a general Fischer-Tropsch plants

(Choi, Kramer et al. 1996).[1]
As can be seen from the Figure 1.1, because of the expensive coal gasifiers
involved in the synthesis gas production unit, the capital costs are quite large in
spite of the low price of the coal feedstocks due to the costs associated with
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materials handling. The product upgrading and separation section also has high
capital costs and requires a big investment because a hydrogen production facility
is required to supply hydrogen and because high hydrogen partial pressure is
required in this unit.[2]

An optimal design of a commercial scale reactor requires detailed information of

the hydrodynamics, reaction kinetics, catalytic system and FT chemistry. Kinetic
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information is crucial for reliable design and scale up of commercial Fischer-

Tropsch processes.

1. Hyun-Jung Lee,
Optimization
of Fischer-Tropsch Plant, 2010.
2.Wiley series in renewable resources, Thermochemical Processing of Biomass:
Conversion into Fuels, Chemicals and Power, Robert C. Brown editor