Update on STF technology Freiberg test plant for the production of high octane gasoline from synthesis gas. Dr. Mario Kuschel, May 2012

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1 Update on STF technology Freiberg test plant for the production of high octane gasoline from synthesis gas Dr. Mario Kuschel, May 2012

2 1 Review STF technology 2 First Results 3 Outlook

3 Raw Material Synthesis gas generation Production of gasoline Natural gas Crude oil associated gas Coal Biomass Partial non catalytic oxidation Catalytic auto thermal reforming Syngas to Methanol Methanol to Fuel Gasoline

4 Fresh synthesis gas Steam Methanol synthesis reactor Steam condensate system Steam Boiler feed water Fuel synthesis reactor Electric energy Instrument & compressed air Circulation compressor Power supply Instrument and compressed air supply Control room Analytics Methanol Recycle gas Overhead product Flare Circulation compressor Recycle gas Cooling and separation Cooling and separation Instable fuel Fuel stabilization column Heavy fuel Absorption refrigerating machine Recooling plant Nitrogen supply Feed water buffer vessel Feed water Methanol separation column Process waste water CO + H2 gas Purifed water Stable fuel Produkt - Lager Catalytic waste water purification

5 Technical University Bergakademie Freiberg, Department of Energy Process Engineering and Chemical Engineering, Reiche Zeche STF plant Synthesis gas plant

6 Novelties of Technology: Employment of new isothermal reactors Advantage: more stabile and better product quality Employment of new developed catalysts in section of gasoline production and treatment of process water (formed in process) Advantage: higher product yields and better product quality Lower rate of circulation gases in combination with isothermal plant operation Advantage: Lower rates of circulation gases are necessary in comparison to adiabatic operation mode.

7 11 Die Review Chemieanlagenbau STF technologychemnitz GmbH stellt sich vor 2 First results 2.1 Test campaigns 2.2 Results of full load mode 2.3 Results of partial load mode 3 Outlook

8 Test campaigns: 1. June weeks 2.1 December weeks 2.2 Feb./March weeks 3. Aug./Sept weeks total 12 weeks forecast: 5. May/June weeks

9 1 st campaign: Feed of synthesis gas and Start-up of main process units in test mode Sampling of first STF fuel produced in test facility 2 nd campaign: (Febr./March 2011) Supply Syngas Methanol, pure Gasoline, instable 3 rd campaign: (Aug./Sept. 2011) Supply Syngas Methanol, pure Gasoline, instable 95 h 9,170 kg 4,000 kg 240 h 12,850 kg 8,800 kg

10 Properties of STF fuel Density (15 C) Molecular mass Paraffins Olefins Naphthenes STF fuel DIN EN 228: gasoline, regular max. 18 kg/m³ kg/kmol wt% wt% wt% Aromatic compounds Benzene Durene ,2 0,4 max. 3 max. 35 max. 1 wt% % vol. % vol. Research octane number Motor octane number Steam pressure Boiling range , min. 91 min. 82,5 max kpa C

11 First results of full load mode: tests with a modern fuel injection motor (Downsizing Concept) Comparative fuel: Gasoline RON 95 ( Super E10 with 5.1% Ethanol) p me [bar] STF Benzin Charge 2 Basis Benzin ROZ95 16 Valuation of Results: With STF gasoline nearly same results under full load at constant charging pressure Ignition angle with STF gasoline minimal later (ca. 1 KW), this means knocking behavior slightly higher Specific fuel demand Beff until /min for both fuels identical, at higher speed (number of revolutions) slightly higher Beff [g/kwh] Ignition Angle [-] Zündwinkel [-] in cooperation with: Drehzahl [1/min] Speed [1/min]

12 First results of partial load mode: fuel consumption for STF similar to commercial gasoline, with ethanol addition increasing value due to decreasing cross value with STF increased HC emissions at higher loads, slight decrease through E10 NO x with STF at level of commercial gasoline, STF E20 as expected at lowest level ROZ 95 ROZ98 STF1 STF3 STF3 E10 STF3 E20 in cooperation with: HC [ppm] pme [bar] Beff [g/kwh] NOx [ppm]

13 1 Review STF technology 2 First Results 3 Outlook

14 Open points: Constant operation with all units Optimization of process parameters of gasoline synthesis especially heat transfer Development of improved reactor for gasoline synthesis Variation in methanol quality and investigation of impurities due to different sources of methanol Improvement of sampling e.g. Sampling under high pressure Target: First commercial plant in Engineering Phase latest end of 2013

15 Acknowledgement The project is supported with public funding by the Saxon State Ministry for Economic Affairs and Labour (SMWA) represented by the Sächsische AufbauBank (SAB) financed by the European Regional Development Fund (ERDF) as well as by private investors. European Union European Regional Development Fund

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17 Chemieanlagenbau Chemnitz GmbH Augustusburger Str Chemnitz Germany Phone: Fax: Internet: info@cac-chem.de