Technology

INFRA.xtl is the 4th generation of the Fischer-Tropsch technology. Developed by INFRA Technologies, INFRA.xtl finally makes production of synthetic oil economically feasible, ensuring that GTL process is profitable as a rule, rather than as an exception.

Current techologies

Current techologies

INFRA.xtl technology

INFRA.xtl technology

It is differentiated by the use of unique proprietary pelletized cobalt-based catalyst in the Fischer-Tropsch step of the process with the new generation tubular fixed-bed reactor.

The reactor and the catalyst have been shown to deliver significant productivity and catalyst performance benefits, allowing to improve the efficiency of the Fischer-Tropsch process dramatically, lowering capital and operating expenses, reducing the size of the reactor and eliminating certain stages required in other versions of this technology, making modular and scalable plant design economically viable. The process efficiency was independently verified and benchmarked.

The process efficiency was independently verified and benchmarked.

INFRA.xtl produces more than 400 kg of the liquid hydrocarbon product per 1,000 m3 of dry gas (methane equivalent).

Main advantages of INFRA.xtl include:

High quality monoproduct – liquid light hydrocarbon mixture (no heavy waxes) – straight out of the Fischer-Tropsch reactor – which does not require cumbersome and capital-intensive hydrocracking and upgrading stage;

Elimination of hydrocracking and product upgrading facility increases the efficiency of the process and feedstock utilisation;

Reduction in the size of the Fischer-Tropsch reactor due to higher catalyst productivity (270-300 kg of product per 1 m3 of reactor volume per hour) – an almost threefold increase in comparison with the industry’s benchmarks. This is confirmed by independent testing;

Versatility – technology allows for utilization of feedgas with varying density, from dry methane up to heavy gases with average molecular weight 24. This is made possible by application of two technologies: firstly, by break-up of heavier hydrocarbons in adiabatic pre-reforming and; secondly, by steam/dry reforming, where H2/CO ratio in produced syngas is controlled by variation of CO2 feedrate;

High temperature (250°С) of Fischer-Tropsch process in INFRA.xtl’s reactor allows to generate power-generating steam (40 bar), increasing the overall unit energy efficiency, and consequently, apply it to drive pumps and compressors of the plant, as well as generate electric power for external use – making the plant self-sufficient in utilities;

Use of the large quantities of the Fischer-Tropsch off-gas containing hydrogen and methane – this feature allows to apply the proprietary design of the reforming flowsheet, where the flow of the fresh gas enters intratubular space only, while the flue gas is used as fuel gas (competing technologies use fresh gas for this purpose);

Efficient and stable catalyst – it does not contain any precious metal promoters, reducing its cost. Very slow deactivation means longer lifetime (up to 2 years), which drives down operating costs and also requires fewer catalyst replacement service breaks;

Ecological benefits – INFRA.xtl process generates just traces of oxygenates, eliminating the need for rejection units, thus allowing to use Fischer-Tropsch water in steam reforming block immediately or after a minimal express treatment in degassing boiler, and lowering the environmental impact;

CO2 emission footprint minimisation – use of steam/dry reforming allows – unlike competing technologies – to sequester and utilise 75% of the carbon dioxide generated in the technology process.

INFRA.xtl GTL units produce light synthetic oil, which is close to a product, characterized by Shultz-Flory alpha of 0.77. INFRA.xtl’s unique quality characteristics include:

Properties of INFRA.xtl catalyst family also allow to fine-tune the process for the production of clean diesel and jet fuel.

INFRA.xtl GTL products are fully compatible with the existing oil industry infrastructure, processes and technologies and with the existing fleet of transportation vehicles without any alterations.

Its synthetic fuels have ultra-high quality and correspond to the highest ecological requirements: zero aromatics, zero sulphur, zero nitrogen, etc.

Some comparative characteristics of INFRA.xtl and 3rd generation GTL are provided in the table below

Parameter 3rd Generation Fischer–Tropsch INFRA.xtl
F–T reactor size (diameter x height in m)
Large-Scale (34,000 bbld) 10.7 × 60 5 × 20
Small–scale (300 bbld) not provided by the licensors — not considered economically feasible 1.0 × 6
Productivity, kg/1 m3 per hour 40–100 270-300
Upgrade reactors Necessary Not needed
Product Diesel+Naphtha+LPG +oxygenate+ lubricant precursors MONOPRODUCT
Product yield (kg per 1,000 m3  of gas) 390–440 (function of heat utilization) 390–440 (function of heat utilization)
Product fractions (wt. %)
<40 °C 10 —
<160 °C >24 Flexible 30–60
160-350 °C 64 Flexible 38–68
>350 °C <5 (depends on upgrade severity) <2
Isoparaffins <5 25 (winter diesel possible)
Aromatics (wt. %) 0 0
Oxygenates (wt. %) 7 0 (no need in oxygenate rejection)
CAPEX ($ per 1 ton of annual capacity)
Large–scale (34,000 bbld) 600–900 — marketing materials 400–500
Small–scale (300 bbld) not provided by the licensors — not considered economically feasible 1,400–1,600
Catalyst reload cost ($Mln/year) 120 30