Precision Combustion is developing a variety of technologies for chemical and fuel manufacturing applications. These technologies, funded by DOE and others, provide high value in a compact package, thus providing opportunities for chemical and fuel manufacturers to increase efficiency, increase production capacity, improve product quality and reduce cost in these competitive commodity materials applications.
For refinery applications, PCI has developed a cetane sensor, refinery/still gas fuel reformer, and a solid catalyzed isobutane/olefin alkylation reactor. The cetane sensor or Advanced Cetane Number Analyzer performs a direct analysis of diesel, jet fuels, and bio-diesels to provide an accurate measurement of the cetane number – as compared to inferring the CN with a cetane index methodology. This device replaces alternative measurement technologies that are expensive, time consuming and that require skilled operators. The compact, cost effective sensor provides a reading in less than a minute and is applicable to pre-process (input material validation), in-process (quality monitoring) and post-process (product verification) applications.
PCI is developing a refinery/Still Gas reformer for H2 recovery that is tolerant of compositional challenges in Still Gas, in particular olefinic compounds and sulfur. The technology, which consists of a unique catalyst composition coated onto PCI’s proprietary Microlith® substrate provides complete conversion of organic sulfur (up to 300 ppmv) present in Still Gas to easily removable H2S and reduces olefins in Still Gas to less than 1.0 vol.% (dry) thus producing an acceptable feed for steam reforming.
Alkylate from isobutene and olefin is a key component of reformulated gasoline, allowing more complete combustion without the health and safety concerns of MBTE. Alkylates burn readily, help enable use of internal combustion engines with higher compression ratios and thus better mileage, and reduce emissions. Implementing our solid catalyzed isobutane/olefin alkylation catalytic reactor offers to eliminate the environmental and safety complications from using liquid acids, simplify plant design (e.g. by eliminating acids handling and refrigeration), reduce capital costs, and reduce energy consumption and operating costs. It also offers the potential for higher quality alkylate.
In a new Navy SBIR project, PCI is developing a filter for removal of copper contamination of fuel from use of Cu-Ni pipes for fuel storage and delivery. The filtration is accomplished by utilization of a nanostructured sorbent supported onto a short contact time, low pressure drop and high mass transfer rate substrate. The sorbent is chemically tuned to selectively attract and strongly retain dissolved copper ions without affecting fuel additives or the fuel itself.
For gas to chemicals applications, PCI is developing an improved reactor and catalyst for conversion of Light Alkanes to Olefins and Liquid Fuels, a filter to remove metal ions from liquid process feeds, CO2 capture technology, a process for separation and purification of ethylene, integrated process for converting carbon dioxide into transportation fuels or chemicals, a process-intensified Solar Catalytic Receiver Reactor (SCRR) for use in the conversion CO2 to liquid fuel products, and direct conversion of methane to ethylene via oxidative coupling of methane (OCM) to enable shale gas production.
A key issue for use of gas in marginal, stranded and shale gas production areas is transport of the gas for use in chemicals or fuels production. Production of ethylene from plentiful and relatively inexpensive shale-gas will enable replacement of crude oil fractions as a source of this important commodity chemical, which is in increasing demand. Our process can also supplement ethane and propane cracking, additional important sources of ethylene. For stranded or low volume gas production, our process can be deployed as the first step in an economical gas to liquids process, enabling cost-effective utilization of what are considered to be uneconomical resources.
Ethylene is a primary petrochemical intermediate and feedstock used as the basic building block to produce a wide range of plastics, solvents, cosmetics, and other products. Ethylene is produced from petroleum fractions (naphtha, propane or ethane), or from ethane and propane, extracted from natural gas or shale gas, using large thermal cracking reactors. Products from these reactors typically include 35-80% C2H4, with the balance being H2, CH4, C2H2, C2H6, and C3-C5 range hydrocarbons, depending on the feedstock. Ethylene purification is accomplished using separation units, starting with quenching. In the recovery process, ethylene is separated and purified using distillation columns, heat exchangers, refrigerants, steam and cold water. Due to similar molecular weights of products, ethylene and other chemicals are hard to separate in distillation columns. The distillation columns require refrigeration, high amounts of energy, and multiple stages resulting in a large capital and operating costs, as well as significant ongoing maintenance. The recovery, separation and purification of ethylene are critical in the production process both in terms of cost and in terms of purity. PCI is developing a novel advanced sorption-based ethylene separation technology that offers to reduce energy use associated with the ethylene separation and purification portion of ethylene manufacturing.
To support market desires to manage CO2, PCI is developing carbon capture and CO2 conversion technologies. The CO2 capture technologies being developed are for post-combustion capture of CO2 in flue gas and for direct air capture. Flue gas CO2 capture is being developed under DOE SBIR projects and offers low pressure drop, high volumetric utilization and high mass transfer, and is suitable for the rapid heat transfer and low temperature regeneration operating modes needed for cost-effective carbon capture. We are currently working to extend this technology and approach to direct air capture opportunities.
Once CO2 is captured, there is a need for use of the compound. PCI is developing a novel system for converting excess variable generated electric power, derived from solar photovoltaic or wind generation, for conversion of waste carbon dioxide into transportation fuels or chemicals. Our process features a proprietary regenerable solid-oxide fuel cell stack operating in electrolysis mode (SOEC) using low value off-peak (excess) power from wind or solar renewable electricity sources, producing syngas, from zero-value carbon dioxide and water feed stocks, that is then upgraded in a novel Fischer-Tropsch (FT) reactor design. The products are a range of hydrocarbon chemicals or transportation fuels that are drop-in replacements from the equivalent products produced from crude oil. The system is designed to fully function continuously regardless of electric power availability, avoiding system shutdowns and eliminating harmful thermal cycling.
Another CO2 conversion method under development is for conversion of CO2 to liquid hydrocarbons. The process uses solar power and catalysts to as the initial reaction to economically convert CO2 to fuels or chemicals. This novel combination permits high efficiency with little to no heat loss. The chemical composition can be further reacted to obtain liquid hydrocarbons.
PCI is seeking partners to collaborate on further development and evaluation efforts.
Contact PCI to learn more about how our solutions may be adapted for your needs.
