In pursuing sustainable and decarbonized transportation fuel solutions, NiQuan Energy captures a transformative method for repurposing defunct or inefficient ammonia and methanol plants. This innovation aims to produce cleaner, low carbon fuels and products, including diesel, naphtha and GTL wax, while significantly reducing environmental impact. Let’s explore the practical steps and critical technologies behind this bold initiative.
NiQuan’s innovative approach involves integrating various cutting-edge systems within repurposed ammonia and methanol production plants, leveraging advanced engineering and process optimization. Key elements like Feed Gas Purification, the amine system, prism membrane units, refitted Fischer-Tropsch (FT) reactors, and specialized analytical tools are central to this strategy and success.
- Feed Gas Purification
The raw incoming feed gas is extremely high in sulfur (2,000 parts per billion or ppb) and must be cleaned up as this concentration will poison the Reforming and FT Catalysts, leading to rapid deactivation. The GTL pre-treatment Section is equipped with hydrogenation catalysts that convert organic sulfur into inorganic sulfur, which then goes to downstream desulfurizer catalysts, that adsorbs all the inorganic sulfur components, leaving the feed gas stream with less than 20ppb of sulfur. This low range meets the requirements of the reforming and FT system operation. The hydrogenation and desulfurizer catalysts last 2-3 years and once spent, they are replaced with a new batch. The process above therefore prevents release of sulfur gases to the environment.
- The Amine System: Carbon Dioxide Removal
The amine system is pivotal in the process and is specifically tailored for use in brownfield environments. Its primary function is to remove acid gases from natural gas efficiently, ensuring the feedstock’s purity for subsequent conversion processes. This carbon dioxide is reinjected back into the reformer to establish an equilibrium in the process that yield higher production. This system seamlessly collaborates with other plant units to purify syngas, a crucial precursor for hydrocarbon synthesis.
- Optimizing Syngas Composition with Prism Units
NiQuan’s blueprint incorporates prism units that are configured to achieve optimal hydrogen-to-carbon monoxide ratio in the syngas composition. This precise composition is essential for maximizing the conversion efficiency of feed syngas into valuable FT wax or Syncrude, ensuring the production process is both efficient and environmentally sustainable. The excess hydrogen removed via the membranes is utilized as fuel.
- Refitted Fischer-Tropsch (FT) Reactors: Enhanced Conversion Efficiency
Repurposed fixed bed FT reactors are equipped with specially designed heat transfer elements uniquely tailored for use in revitalized ammonia and methanol plants. These reactors employ a specialized FT catalyst to facilitate the conversion of syngas into Gas-to-Liquids (GTL) products, such as diesel, naphtha and wax, with enhanced efficiency and reduced environmental footprint.
- Real-Time Analysis with FT Analyzers
NiQuan integrates state-of-the-art FT analyzers to provide real-time analysis of key hydrocarbon streams. This advanced monitoring capability enables operators to make timely adjustments, optimize production processes, maximize yield, and ensure product quality.
- Accurate Measurement with Coriolis Flow Meters
To address challenges associated with wax production, NiQuan incorporates Coriolis flow meters designed to resist clogging. These meters ensure accurate measurement of liquid wax flow, enhancing operational reliability and efficiency.
- Revitalizing Abandoned Plants for Cost-Effective Production
NiQuan’s approach offers a cost-effective method for revitalizing abandoned or inefficient fuel production plants. Repurposing existing infrastructure and incorporating advanced technologies enables sustainable diesel and wax production while remaining compatible with established fuel transportation methods.
NiQuan’s practical steps toward decarbonizing transport exemplify the convergence of ingenuity, sustainability, and economic viability. Through investments in technology and process innovation, NiQuan is reshaping the role of traditional fuel production in the energy sector.