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

这项小型企业创新研究（SBIR）项目的更广泛影响和商业潜力是消除石油和天然气生产中的燃烧。全球估计有1500亿立方米(5.3万亿立方英尺)的爆发产生气体,2016年约为100亿立方米(3530亿立方英尺)在美国2美元每千立方英尺(MCF)(井口天然气价格),发生气体的价值相当于全球每年10.6美元,706美元在美国气体爆发,因为过程将他们转换为液体运输(GTL)价格昂贵,而且很难执行规模较小。用批量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1万美元，可以将40万标准立方英尺(MSCF)/天的气体转化为液体，而大型GTL工厂的成本约为1.5万美元/MSCF/天。该项目将开发一种新型的、超紧凑的、低成本的气转液小型工厂。该工厂将把井口附近的甲烷、乙烷和丙烷（目前会被燃烧和浪费）加工成甲醇，这是一种可以运往市场的高价值化学品。如果以432美元/吨的价格转化为甲醇，这些燃烧后的天然气在美国市场的价值将达到20亿美元/年，在全球市场的价值将接近300亿美元/年。SBIR一期项目拟采用改进型汽车内燃机作为小型化学反应器和压缩机。反应所需的压力和温度在气缸内由活塞压缩作用和部分燃烧产生。该项目将开发一套分段式发动机系统：第一个系统将甲烷、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台发动机中进行压缩，并将其转化为甲醇。这将通过在第二个发动机的活塞碗内放置一个浸渍有催化剂的高表面积金属泡沫来完成。项目的第一阶段将：1)展示一个可以从一氧化碳和氢气中合成甲醇的概念验证发动机，2)进行系统工程研究，描述将发动机反应器集成到靠近井口的紧凑型GTL装置中。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

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.