SBIR Phase I: Internal Combustion Engines as Small Scale Chemical Plants for Compact, Low Cost Gas to Liquids to Reduce Flaring

这个小企业创新研究（SBIR）项目的更广泛的影响/商业潜力是消除石油和天然气生产的燃烧。全球估计有1500亿立方米（5.3万亿立方英尺），2016年约100亿立方米（3530亿立方英尺）在美国每千立方英尺（MCF）2美元（井口天然气价格），全球每年燃烧的气体价值相当于106亿B美元，在美国燃烧的气体价值为7.06亿美元，因为将它们转化为液体用于运输（GTL）的过程是昂贵的，并且难以在较小规模上执行。用大规模生产的发动机取代定制的工艺设备可以显著降低成本和尺寸。一台8升柴油发动机的成本约为10，000美元，可以将40万标准立方英尺（MSCF）/天的天然气转化为液体，而不是成本约为15，000美元/MSCF/天的大规模GTL工厂。 该项目将开发一种新型、超紧凑和低成本的气转液小型工厂。 该工厂将在井口附近将甲烷，乙烷和丙烷（目前将被燃烧和浪费）加工成甲醇，这是一种可以运输到市场的高价值化学品。如果以432美元/吨的价格转化为甲醇，这些燃烧的气体量在美国市场的价值为2 B美元/年，在全球市场的价值为近30 B美元/年。反应所需的压力和温度是通过活塞压缩作用和部分燃烧在气缸内产生的。该项目将开发一个分阶段的发动机系统：第一个将甲烷，乙烷和丙烷转化为一氧化碳和氢气;随后，产生的气体将在第二个发动机中压缩并转化为甲醇。这将通过将浸渍有催化剂的高表面积金属泡沫放置在第二发动机的活塞碗内来实现。项目第一阶段将：1）展示一种概念验证发动机，可以从一氧化碳和氢气合成甲醇，和2）进行系统工程研究，描述将发动机反应堆集成到位于井口附近的紧凑型GTL工厂中。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响进行评估，被认为值得支持审查标准。

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) project is the elimination of flaring from oil and gas production. Globally, there were an estimated 150 billion cubic meters (5.3 trillion cubic feet) of flared produced gases in 2016 and around 10 billion cubic meters (353 billion cubic feet) in the U.S. At $2 per thousand cubic feet (MCF) (wellhead natural gas price), the value of flared gases is equivalent to $10.6 B per year globally and $706 M in the U.S. Gases are flared because processes converting them to liquids for transportation (GTL) are expensive and are difficult to execute at a smaller scale. Replacing customized process equipment with mass-produced engines enables significant cost and size reductions. An 8-liter diesel engine that costs ~$10,000 can convert 400 thousand standard cubic feet (MSCF)/day of gas to liquids, rather than a large-scale GTL plant costing ~$15,000/MSCF/day. This project will develop a novel, ultra-compact and low-cost gas to liquids mini-plant. The plant will process methane, ethane and propane near the wellhead (which currently would be flared and wasted) into methanol, a high value chemical that can be transported to market. If converted to methanol at a value of $432/ton, these otherwise flared gas volumes would be valued at $2 B/year for the US market and nearly $30 B/year globally.This SBIR Phase I project proposes to use modified automotive internal combustion engines as small scale chemical reactors and compressors. The necessary pressure and temperature for the reaction is created in-cylinder by piston compression action and partial combustion. This project will develop a staged system of engines: The first converts methane, ethane and propane into carbon monoxide and hydrogen; subsequently, produced gases will be processed in a second engine compressing them and converting them into methanol. This will be accomplished with a high surface area metal foam impregnated with a catalyst placed inside the piston bowl of the second engine. Phase I of the project will: 1) demonstrate a proof-of-concept engine that can synthesize methanol from carbon monoxide and hydrogen, and 2) conduct the systems engineering studies describing integration of the engine reactor into a compact GTL plant to be placed near the wellhead.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.