Fischer-Tropsch process design package
A Fischer-Tropsch process design package defines the full engineering scope of the FT island, translating feasibility study outputs into a structured design ready for detailed engineering and project execution
Velocys process design packages provide the technical documentation required for EPC contractors and project developers to design, procure, and construct the synthesis section of a renewable fuel plant.
This includes process design, equipment definition, control philosophy, and integration requirements for the FT island.
What is a Fischer–Tropsch process design package?
A process design package (PDP) is the complete set of engineering deliverables required to define how the FT island will be implemented within a project.
It builds on feasibility study outputs and expands them into:
- detailed process design
- equipment definition
- control and safety frameworks
- integration with surrounding plant systems
The PDP becomes the primary reference for detailed engineering and procurement.
What is the FT island?
The FT island refers to all equipment, systems, and process elements required to convert cleaned synthesis gas into liquid hydrocarbons.
This typically includes:
- AlphaCore™ reactor systems
- SQRCAT™ catalyst systems
- heat exchange and thermal control
- separation and product handling
- gas recycle and compression systems
- control and instrumentation systems
The FT island is defined as a complete, integrated Fischer-Tropsch synthesis block within the larger plant.
What does a process design package include?
A Velocys PDP provides a complete technical definition of the FT island across process, mechanical, and operational disciplines.
FT general documentation
- FT unit basis of design
- process description
- control philosophy
- operating guidelines
- plot plan and critical instrument requirements
- notes to detailed engineering contractor
- operating manual
FT balances and summaries
- heat and material balance
- utility and battery limits summaries
- effluent and emissions summary
- catalyst and chemical summary
FT drawings
- block flow diagram (BFD)
- process flow diagrams (PFDs)
- material selection diagrams (MSD)
- piping and instrumentation diagrams (P&IDs)
- module layout plan and module split drawings
FT lists
- equipment and line lists
- instrument index and I/O count
- preliminary electrical load list
FT datasheets
- process datasheets
- mechanical datasheets
- safety datasheets (SDS)
How long does a process design package take?
A typical Fischer–Tropsch process design package is completed in approximately 10 to 12 weeks.
This timeframe allows for:
- expansion of feasibility-level design into a fully defined FT island
- development of engineering documentation across process, mechanical, and control disciplines
- coordination between Velocys and project stakeholders
- iteration based on project-specific inputs and design reviews
The schedule may vary depending on project complexity, scope, and integration requirements.
How is a PDP used in project development?
The process design package provides the technical foundation required for detailed engineering, procurement, and construction.
It enables:
- EPC contractor alignment
- equipment specification and procurement
- plant layout development
- control system design
- safety system definition
Without a PDP, downstream engineering lacks a consistent technical reference.
How does a PDP build on the feasibility study?
The PDP expands feasibility-level design into a fully defined FT island ready for execution.
Where feasibility studies provide:
- conceptual process definition
- early material balances
- preliminary sizing
The PDP provides:
- detailed process definition
- complete equipment specifications
- full drawing set
- operational and control frameworks
This progression reduces uncertainty as projects move toward execution.
How does Velocys approach process design?
Velocys process design packages are built around real reactor and catalyst performance, informed by operating experience.
This includes:
- integration of microFTL™ technology
- application of AlphaCore reactor configurations
- alignment with SQRCAT catalyst behavior
- incorporation of operating and commissioning lessons
The result is a design grounded in actual deployment experience, not theoretical assumptions.
Where does the PDP fit in the project lifecycle?
The process design package sits between feasibility and detailed engineering.
A typical progression includes:
- feasibility study
- process design package
- FEED and detailed engineering
- procurement and construction
The PDP ensures continuity between concept and execution.
Why does defining the FT island matter?
Clearly defining the FT island reduces integration risk across the broader project.
This matters because:
- upstream and downstream systems depend on stable synthesis assumptions
- equipment interfaces must be clearly defined
- control and safety systems must align across plant boundaries
A well-defined FT island improves coordination between licensors, EPC contractors, and project developers.
Typical next step -> COMMISSIONING AND STARTUP
Frequently asked questions
Does the PDP include detailed engineering drawings?
It includes process and system-level drawings, but detailed engineering is typically completed by the EPC contractor.
Is the PDP required before procurement?
Yes. It provides the specifications needed for equipment selection and procurement.
Does the PDP define the full plant?
No. It defines the FT island and its integration within the broader plant.
Can the PDP be adapted during engineering?
Yes. It provides the baseline design but may be refined during detailed engineering.