Methane-rich gas to gasoline

Synthetic fuels: a drop-in solutions for modern energy needs

After the 1973 oil crisis sparked a surge of interest in synthetic fuels, that interest soon waned as oil prices began to fall. However, today’s high energy prices and a volatile energy supply have rejuvenated interest in synthetic fuels. And, as gasoline specifications reach new levels of stringency, Topsoe has responded to the needs of the market with TIGAS™ – Topsoe Improved Gasoline Synthesis.

Synthetic gasoline is a competitive alternative to refinery gasoline and new energy carriers. Unlike DME, methanol and ethanol, synthetic gasoline meets existing gasoline standards so it can be used as a ‘drop-in’ fuel. This means that production can take place far from refineries, the existing infrastructure can be used for distribution and car engines can use it as fuel without modification.

Suitable for diluting highly viscous oil, or blending into the refinery gasoline pool, or simply as a ‘drop-in’ fuel, TIGAS™ is today’s technology for the fuel of tomorrow.

Two options for gasoline production

We offer you two processes for producing gasoline:

MTG (Methanol to Gasoline) – an efficient route which uses methanol as an intermediate
STG (Syngas to Gasoline) – the route from synthesis gas

MTG is the logical choice if you already have a methanol plant. For new plants, however, your choice will depend on the type of feedstock your plant uses, local energy costs and your investment philosophy. We will work closely with you, looking into your plant and processes in detail to arrive at a solution that will best help you achieve your business goals.

Gasoline from methanol (MTG)

Not only is the MTG process often the first choice for new plants, it also provides you with a way of adding value to your methanol production. With methanol as an intermediate product, the MTG process is ideal for a feedstock of natural gas using our steam reforming technologies, including our proprietary SynCOR™ technology to produce the synthesis gas.

Gasoline from synthesis gas (STG)

In the STG process, the synthesis of methanol, dimethyl ether (DME), and gasoline are integrated into one synthesis loop by first passing synthesis gas to the oxygenate (methanol/DME) reactor and then converting the oxygenates into gasoline in the gasoline reactors. The STG process is particularly suitable for a feedstock like coal, pet-coke or biomass, all of which use a process based on gasification to prepare the synthesis gas (a mixture of H2, CO and CO2) with a H2:CO ratio close to one.

Two highly efficient processes

Preparing for gasoline synthesis

Having designed and delivered catalysts to more than 100 of our customers’ methanol plants worldwide, we have not only pushed the processes to the limits of efficiency, we have also gained deep insight into the needs of our customers, and how we can add value to their businesses. The final product is of essence, however the technology choices when converting the carbon source will determine the overall economics of the TIGAS™ plant, as the synthesis gas preparation step typically constitutes the most capital-intensive part of the plant. All of the reforming technologies are within the core of Topsoe technologies and part of the reason why we will always find the most efficient process lay-out to meet all your needs. In both the MTG and STG processes, gasoline production makes up more than 85 percent of the total product stream. In addition to gasoline, another valuable product is liquefied petroleum gas (LPG), which accounts for about 11–13 percent of the total product stream. This leaves only a fraction of fuel gas, ensuring that the carbon efficiency of your plant is very high.

Following synthesis gas preparation by gasification or steam reforming, the synthesis gas undergoes oxygenate synthesis based on either methanol synthesis (MTG) or the integrated methanol/DME synthesis (STG) according to the following reactions:

CO + 2H2 ↔ CH3OH (1)
CO + H2O ↔ CO2+ H2 (2)
2CH3OH ↔ CH3OCH3+ H2O (3)

Gasoline from methanol or DME

The product stream from methanol/DME synthesis is diluted with recycled gas and fed directly into the next step: gasoline synthesis. This step takes place in parallel adiabatic gasoline reactors which allow for intermittent catalyst regeneration. Methanol and DME are converted to gasoline according to the reactions:

n CH3OH ↔ n (CH2) + n H2O (4)
n CH3OCH3 ↔ n 2(CH2) + n H2O (5)

where (CH2) denotes the hydrocarbon product. The net reaction may be formulated as:

Oxygenates (MeOH/DME) → C 1-2 + C3-4 (LPG) + C5+ (Gasoline) + H20 + Heat (6)

The all-new Gasoline Upgrade Unit (GUU) comprises an additional catalytic step in which the heavy fraction gasoline is isomerized to produce a high-octane gasoline fraction. Blending this with the remaining gasoline results in high-value gasoline such as the Euro V gasoline.

Meeting national gasoline standards on a global scale

Gasoline is a mixture of hydrocarbons (aromatics, olefins, naphthenes and paraffines), and for use in engines, it needs to meet particular requirements. Many countries have created their own standards to make sure these requirements are met. Even though there is some variation between, for example, the American Standard, Euro V, and GB 1730, TIGAS™ makes sure the gasoline produced will comply with the vast majority of national gasoline specifications.

Gasoline of even higher quality

The raw gasoline may be blended into the regular gasoline pool or treated to meet other specific product criteria. In the simplest case, removing dissolved gases stabilizes the liquid product.

Catalysts for synthetic gasoline

AR-401 catalyst

High-performance nickel catalyst for efficient hydrocarbon conversion.

HTZ-3 catalyst

HTZ-3 will give your plant a cost-effective, reliable means of protecting downstream catalysts from sulfur.

HTZ-31 catalyst

HTZ-31 delivers unmatched sulfur removal and protection, even during unexpected leakages of organic sulfur.

HTZ-5 catalyst

HTZ-5 reliably removes sulfur to keep your downstream catalysts protected.

HTZ-51 catalyst

HTZ-51 delivers unmatched sulfur removal and protection, even during unexpected leakages of organic sulfur.

MK-121 catalyst

MK-121 ensures a high preservation of the initial high catalyst activity as well as an improved stability.

MK-151 FENCE™ catalyst

Our MK-151 FENCE™ methanol synthesis catalyst delivers documented industry-leading performance and stability that will enable you to far exceed your initial target.

MK-417 SUSTAIN™ catalyst

MK-417 SUSTAIN™ catalyst offers excellent stability even under severe operating conditions.

RKA-02 catalyst

RKA-02 is a nickel based top layer catalyst for oxygen fired secondary and autothermal reformers.

RKS-2 catalyst

RKS-2 is a nickel based reforming catalyst that reduces the effect of ruby and dust deposition.

RKS-2-7H catalyst

The RKS-2-7H catalyst has high activity and the shape and size gives low start-of-run pressure drop.

GSK-10 catalyst

GSK-10 is a catalyst used for synthezising gasoline using methanol as a feedstock.

HTG-2 catalyst

HTG-2 is an alumina-type absorbent used for the removal of hydrogen chloride from vapor- and liquid-phase process streams.

HTG-10 catalyst

HTG-10 effectively absorbs any inorganic chloride your feedstocks might contain.

RKA-10 catalyst

RKA-10 catalyst helps you to optimize the run length of your oxygen-fired reformers, hereby improving the performance of your plant.

RKC-2-7H catalyst

RKC-2-7H is a nickel based reforming catalyst for secondary reforming.

MK-181 PRIME™ catalyst

Achieve record-breaking methanol plant performance by reducing energy consumption or increasing capacity.

Boiling water reactor

Optimize exothermic reactions with boiling water reactors – efficient cooling for methanol synthesis and more.

Convection reformer HTCR

A compact, high-efficiency heat exchange reformer that provides refinery operators with a straightforward, inexpensive way to meet the growing demand for hydrogen.

Oxygen-fired secondary reformer

One of the important pieces of equipment used in the methanol production process is the oxygen-fired secondary reformer.

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SynCOR™ - Autothermal Reformer (ATR)

SynCOR enhances economy of scale by maximizing single-line capacity while significantly reducing capital and operating costs.

SynCOR™ CTS™ burner

The CTS™ (Cool Tip Swirl) burner delivers high-performance burner design for reliable reformer operation.

HTZR™ target tiles

Boost reactor reliability with HTZR™ Target Tiles – protect catalysts, reduce wear, and extend runtimes.

Catalyst bed support structure

Optimize reformer performance with Rampart™ – strong, compact catalyst bed support system for reliable operation.

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Reactor refractory lining

Enhance reactor reliability with our refractory linings – superior protection, durability, and performance.

Applications within this area

Methane-rich gas to diesel and jet fuels

Produce synthetic fuels from methane-rich gas at an industrial scale and open up new business opportunities.

Renewable energy and CO2 to synthetic diesel and jet fuels

e-Fuels produced from renewable power and CO₂ are a viable long-term solution to decarbonize the transportation sectors.

Contact us

Do you have a question about our products or solutions? Or do you want to know how our technologies can support your business? Contact our experts today.