Integrated Fischer-Tropsch module
The integrated Fischer-Tropsch module packages Velocys microFTL™ technology into a deployable unit built around AlphaCore™ reactors, SQRCAT™ catalyst, and core process equipment.
It provides the hydrocarbon synthesis section of a renewable fuel project as a defined process block that can be delivered using modular or site-integrated execution strategies depending on project requirements.
Built around compact, repeatable reactor geometry, the module simplifies Fischer-Tropsch deployment while preserving flexibility in project design.
What is an integrated Fischer-Tropsch module?
An integrated Fischer-Tropsch module is a packaged synthesis section that converts cleaned synthesis gas into liquid hydrocarbons.
The module typically includes:
- AlphaCore reactor systems
- SQRCAT catalyst
- feed heating and thermal control equipment
- product separation systems
- gas recycle equipment
- piping and instrumentation
This creates a defined FT synthesis package within the broader plant.
How does modular delivery improve project execution?
Modular delivery can reduce capital cost, lower execution risk, and shorten construction schedules by concentrating FT island equipment into repeatable fabrication packages.
Advantages typically include:
- up to 30% reduction in capex
- reduced field construction hours
- standardized reactor manufacturing
- improved fabrication quality control
- shorter installation windows
Modular design lowers cost and reduces the likelihood of Fischer-Tropsch related delays.
Why does standardization matter?
Reduce risk and improve predictability with standardized reactor geometry and repeatable module design.
Velocys applies standardization through:
- repeatable AlphaCore reactor designs
- consistent module boundaries
- fabrication strategies aligned with experienced manufacturing partners
This helps reduce repetition in engineering while supporting faster deployment.
What role do AlphaCore reactors play inside the module?
AlphaCore reactors provide the FT synthesis core inside the integrated module.
Current reactor family designations include:
- AlphaCore 10
- AlphaCore 50
- AlphaCore 200
- AlphaCore 400
These designations correspond to approximate daily Fischer-Tropsch liquid production capacity.
Example:
A microFTL package for NovaSAF 1 includes an AlphaCore 50 reactor loaded with SQRCAT catalyst for production capacities up to 50 barrels of FT liquids per day.
What happens inside the integrated module?
The module performs the core hydrocarbon synthesis sequence between syngas entry and hydrocarbon discharge.
Syngas distribution
Cleaned synthesis gas enters the module.
Fischer-Tropsch synthesis
Hydrogen and carbon monoxide react over SQRCAT catalyst inside AlphaCore reactors.
Product separation
Hydrocarbon liquids and water are separated.
Tail gas handling
Tail gas is recycled within the FT unit or back to the syngas generation unit with a small portion being purged to flare.
The result is a stream of synthetic hydrocarbons ready for upgrading.
Does every project require modular delivery?
No. Module design and project execution strategy should match project conditions.
Some projects benefit strongly from skid-based delivery.
Others may favor a stick-built approach or greater site integration where project developers choose different risk-sharing approaches.
The goal is not identical delivery in every case, but the right FT deployment strategy for each project.
How does this connect to microFTL technology?
The integrated Fischer-Tropsch module is the physical deployment of microFTL technology.
microFTL license packages include:
- AlphaCore reactors
- SQRCAT catalyst
- Fischer-Tropsch licensing
- process know-how
- operating experience
The module packages these into deployable FT island hardware.
Why does operating experience matter here?
Module design benefits from lessons developed through commercial and demonstration deployment.
This includes:
- startup learning
- product separation behavior
- catalyst handling
- gas recycle performance
- Piping layout
Velocys’ earlier GTL deployment at Envia demonstrated modular Fischer-Tropsch operation under commercial conditions, helping define practical FT synthesis integration for later renewable fuel projects.
FAQ
Is the integrated Fischer-Tropsch module always skid-mounted?
Not always. Delivery strategy depends on project requirements.
Does the module include AlphaCore reactors?
Yes. AlphaCore reactors form the core of the FT island.
Does the module include catalyst?
Yes. SQRCAT catalyst is included as part of FT island deployment.
Is this the full fuel plant?
No. It provides the Fischer-Tropsch synthesis island inside a broader fuel production system.