Microchannel FT reactors, yields, and the Velocys advantage
Learn how Fischer-Tropsch technology works, why microchannel FT reactors matter, and how Velocys leads in SAF, e-fuels, and waste-to-fuel solutions.
Understanding Fischer Tropsch technology
What is the Fischer Tropsch process?
The FT process is a chemical reaction that converts synthesis gas (a mixture of carbon monoxide and hydrogen, often called syngas) into liquid hydrocarbons such as jet fuel, diesel, naphtha, and waxes. The process uses a catalyst (typically iron or cobalt-based) to facilitate the conversion at elevated temperatures and pressures. FT synthesis plays a foundational role in the production of synthetic fuels and chemicals from non-petroleum feedstocks like natural gas, biomass, biogas, municipal solid waste, or captured CO2.
What feedstocks are suitable for FT conversion?
FT technology is feedstock-agnostic after syngas is produced. Suitable inputs include:
Biomass (wood chips, agricultural residues)
Municipal solid waste (MSW)
Natural gas
Biogas and landfill gas
Captured CO2 combined with low-carbon hydrogen (for e-fuels)
Composition of the syngas and the ratio of carbon-monoxide to hydrogen play a crucial role in FT synthesis. Syngas production and clean-up technologies are critical for high FT yield.
What are common challenges in FT reactor design?
Traditional Fischer-Tropsch reactors (slurry bed and conventional tubular reactors) face challenges such as:
Hotspot formation due to exothermic reactions
Poor heat transfer, leading to catalyst deactivation
Catalyst fouling and catalyst-wax separation difficulties
Large footprint and complexity at commercial scale
Modern advancements, such as microchannel reactor design, aim to address these issues.
How does FT differ from methanol-to-gasoline (MTG), methanol-to-jet (MTJ) or HEFA processes?
FT: Converts syngas into a range of hydrocarbons; feedstock flexible.
MTG/MTJ: Converts methanol into gasoline-range fuels; less mature technology that is not commercially proven and has not yet passed ASTM process requirements.
HEFA: Uses fats, oils, and greases to produce hydroprocessed esters and fatty acids; dependent on lipid feedstocks, which are limited in supply and will not be enough to produce the anticipated volume of renewable fuels
Microchannel Fischer-Tropsch reactors
What is a microchannel reactor?
A microchannel reactor contains thousands of small, parallel flow channels—each typically less than 1 mm in diameter—embedded within a metal block. These microchannels significantly enhance heat and mass transfer, which is critical in controlling the highly exothermic FT reaction.
How do microchannel FT reactors differ from conventional fixed-bed or slurry-phase reactors?
Size: Microchannel reactors are significantly smaller for the same throughput.
Heat management: Superior to fixed-bed reactors due to small channel dimensions.
Modularity: Easier to scale by numbering up reactor units.
Selectivity: Enables more controlled reaction environment, improving yield of desired hydrocarbons.
What are the benefits of microchannel reactors in FT synthesis?
FT microchannel compared to tubular fixed-bed FT reactors
6–10x higher volumetric productivity
Better temperature uniformity, minimizing hotspots
Faster ramp-up and shutdown times
Smaller plant footprint
Higher CO conversion rates (70% per pass, 90–95% overall with recycling)
Higher C5+ selectivity (produces less methane)
Note: Velocys microchannel reactors and Oxford-engineered catalysts can achieve up to 98% conversion with recycling.
FT microchannel compared to slurry bubble column/ slurry-bed FT reactors
6–10x higher volumetric productivity
Faster ramp-up and shutdown times
Smaller plant footprint
Higher CO conversion rates (70% per pass, 90–95% overall with recycling)
Simplified processing with no need for separation and removal of catalyst powder from the FT wax
Easier catalyst regeneration that avoids mutli-step batch processing
Note: Velocys microchannel reactors and Oxford-engineered FT catalysts can achieve up to 98% conversion rates
How does microchannel design impact heat transfer and selectivity?
Microchannel reactors offer superior heat control, reducing thermal gradients and hot spots, which prevents catalyst degradation and maintains optimal reaction conditions. This improves selectivity for C5+ hydrocarbons (e.g., jet fuel range) and reduces the formation of low-value byproducts. Note that final improved jet yields are directly related to crude upgrading, which occurs after FT synthesis.
What kind of yield improvements can microchannel reactors offer?
Microchannel FT reactors like those developed by Velocys provide optimal reaction conditions across the operational life of the plant. This translates into:
Greater fuel yields per tonne of syngas, enabled during the upgrade process by a higher yield of C5+ hydrocarbons
Improved downstream processing enabled by greater consistency of the produced synthetic crude
How does Velocys FT reactor performance compare to that of competing systems?
Catalyst and reactor productivity levels are 6-10x higher than most commercially available FT technologies
Syngas conversion rates are as high as 98% with recycling, greater even than competing microchannel reactor technologies that haven’t been shown to achieve more than 90-95% conversion with full recycling designs
>70% single-pass syngas conversion rates, the highest on the market
Compact, modular reactor designs lower installation costs and significantly reduce the footprint required for slurry-bed and fixed-bed FT reactors
What are the scale-up advantages of microchannel systems?
Instead of scaling a single large reactor, microchannel systems scale through replication (numbering up). This modular approach:
Is based on the proven operation of commercial-scale reactors
Reduces project risk
Enables distributed and smaller-scale production sites
Allows for phased project development
Are microchannel reactors modular or custom-built?
Microchannel reactors are typically standardized units manufactured offsite and assembled into modules. This standardization enables repeatability, quality control, and faster deployment, especially important in SAF and e-fuels projects aiming for commercial-scale rollouts.
CO conversion, selectivity, and yield
What does CO conversion mean in FT synthesis?
CO conversion refers to the percentage of carbon monoxide in syngas that is converted into hydrocarbons during the FT process. It is typically expressed in two ways:
Per-pass conversion: How much CO is converted in a single flow through the reactor (e.g., 60%)
Overall conversion: Total conversion after recycling unconverted gases (can exceed 90–95%)
What is the significance of high CO conversion rates?
High CO conversion improves reactor efficiency, reduces recycle loop requirements, and boosts overall fuel yield. It also means better utilization of feedstock, which is critical in commercial operations with cost or carbon intensity constraints.
How does catalyst performance impact selectivity and yield?
Catalyst formulation directly affects how selectively CO and H2 are transformed into target products. High-performing catalysts:
Minimize the production of unwanted methane and light gases
Favor jet- and diesel-range hydrocarbons (C5+)
Extend catalyst life and reduce regeneration frequency
How do reactor conditions influence product distribution?
Temperature, pressure, and reactor geometry determine the range of hydrocarbons produced. Higher temperatures often increase light gas formation, while optimized temperature control (as enabled by microchannels) enhances selectivity for the desired longer-chain hydrocarbons.
What are realistic fuel yields from syngas using modern FT systems?
Fuel yields depend on feedstock, catalyst, and reactor design, but advanced microchannel FT systems can deliver up to 85% liquid fuel yield from syngas with optimized integration and gas recycling.
Velocys-specific implementations
Who is Velocys, and what do they do?
Velocys is a technology company that develops and licenses microchannel Fischer-Tropsch reactor systems and catalysts for the production of low-carbon synthetic fuels. They offer fully constructed FT modules, standard product packages, and fit-for-purpose designs. The technology has been demonstrated at commercial scale and is used in projects targeting SAF and renewable diesel, both biofuels and e-fuels.
What makes Velocys’ FT reactors unique?
Velocys reactors use microchannel architecture with Oxford-engineered high-performance catalysts to enable high productivity, excellent heat management, and modular scale-up.
They offer:
6–10x volumetric productivity over conventional FT reactors, reducing footprint and required capex
High syngas conversion rates up to 98% with recycling, reducing the cost to produce the same volume of final fuel
85% yield of high-value C5+ hydrocarbons, making FT synthesis more efficient and lowering the cost of fuel production
Per-pass CO conversion of more than 70%
Compact, factory-built reactor cores for rapid deployment
Demonstrations (USA, Brazil, Austria, Australia): 13,000 cumulative hours across five demo units worldwide
Pilot plant (Ohio, USA): 11,000+ cumulative hours of runtime, testing, and optimization
What role does Velocys’ catalyst play in performance?
Velocys’ proprietary catalyst was engineered at Oxford for high activity and selectivity. It supports stable operation and high fuel yields without requiring complex reactor solids removal.
Is Velocys Fischer Tropsch technology ASTM-compliant for SAF production?
Yes. Velocys technology follows the ASTM D7566-certified FT-SPK pathway, allowing the SAF it produces to be blended into conventional jet fuel up to 50%.
Where are Velocys reactors manufactured?
Velocys previously operated two production facilities in the US, the largest of which was a 52,000 sq ft reactor assembly and catalyst production plant in Columbus, Ohio. Given market and customer preferences, Velocys now oversees manufacturing and assembly at various geographies around the world near project locations. This strategy boosts local content, reduces supply chain uncertainty, and helps derisk investment for customers.
Fischer Tropsch applications and integration
What are the primary applications of Fischer-Tropsch technology today?
FT technology is primarily used to convert syngas into liquid hydrocarbons for:
Sustainable aviation fuel (SAF)
Renewable diesel and naphtha
Synthetic paraffins and waxes
Specialty chemicals and lubricants
How is FT technology integrated into biomass-to-liquid (BtL) or waste-to-fuel projects?
The BtL process typically includes:
Feedstock preparation (drying, shredding, and separating)
Gasification to create syngas
Syngas cleaning and conditioning
Fischer-Tropsch synthesis
Product upgrading (hydrocracking, distillation)
How does FT support power-to-liquid (PtL) or e-fuels applications?
PtL systems use renewable electricity to generate hydrogen (via electrolysis) and combine it with CO2 (captured from air or point sources and then converted into CO) to create syngas. This syngas feeds into FT reactors to produce synthetic hydrocarbons, forming the backbone of e-fuels.
Can FT reactors be deployed in distributed or smaller-scale facilities?
Yes. Especially with microchannel reactor systems, FT plants can be modularized and downsized for:
Locally available biogas, biomass, or waste supplies
Remote or off-grid locations
Industrial co-location
What downstream processes are required after FT synthesis?
Products from FT synthesis often undergo upgrading steps such as:
Hydrocracking or hydroisomerization (to meet jet or diesel fuel specs)
Fractional distillation
Blending with conventional fuels (for ASTM SAF compliance)
What are some project examples using Fischer Tropsch technology in integrated systems?
What is the carbon intensity (CI) of FT-derived fuels?
The CI of FT-derived fuels depends on feedstock, energy input, and process configuration. Advanced FT systems using biomass or waste feedstocks can achieve very low, or even negative, CI scores. For example, Velocys’ AltAlto project reported an expected CI score of -50 gCO2e/MJ.
How can Fischer Tropsch technology support net-zero or carbon-negative goals?
By integrating carbon-neutral or carbon-negative feedstocks (e.g., biomass, biogas, captured CO2), FT plants can displace fossil fuel use and actively reduce atmospheric carbon. Combined with renewable power, FT enables power-to-liquid systems that close the carbon loop.
What are the environmental advantages of FT over other renewable fuel pathways?
Broader feedstock flexibility (including municipal solid waste)
Production of drop-in fuels with high energy density
No ILUC (Indirect Land Use Change) issues
Superior lifecycle emissions when combined with clean power and CCS (Carbon Capture and Storage)
How does the cost of FT fuel production compare to other pathways?
FT plants have historically been capital intensive, but microchannel and modular reactor designs reduce upfront costs. Operating costs are competitive, especially where low-cost feedstocks (e.g., waste, biogas, biomass) or carbon credits (LCFS, 45Q) apply.
What incentives or regulations support FT project development?
ASTM D7566 approval (SAF blending)
Low Carbon Fuel Standard (LCFS) credits
45Q tax credits (carbon capture)
Renewable Fuel Standard (RFS) credits (e.g., RINs)
Country and regional SAF mandates (EU, UK, Brazil, Singapore, Japan, India, Australia, and others)
Government grants (e.g., UK’s Advanced Fuels Fund, DOE funding)
CORSIA (SAF specifications)
What are the scalability prospects for FT-based SAF and e-fuels?
Scalability is increasingly viable due to:
Modular reactor systems
Government-backed SAF mandates
Airline and offtaker demand
Established certification pathways
Closing summary and policy resources
Fischer-Tropsch technology—especially in microchannel form—is proving to be a critical platform for the production of sustainable, drop-in fuels from diverse feedstocks. From large-scale SAF projects to decentralized e-fuel hubs, FT synthesis offers technical maturity, commercial viability, and a clear path toward net-zero emissions.
Note on Policy and Regulation: Regulations around SAF, e-fuels, and low-carbon fuels vary by region and change frequently. For the latest updates, refer to:
Contact us to learn more about license opportunities for Velocys’ microchannel FT reactor technology.
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