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5 Things You Need to Know About The Fischer-Tropsch Process
By Bill Siuru
Why Fischer-Tropsch Synthetic Fuel?
Synthetic fuels represent an interesting alternative to petroleum, which can sometimes be in short supply and, as is the case today, also quite expensive. One of the most high-profile ways to create synthetic fuel is through what's known as the Fischer-Tropsch (F-T) process. It was invented in the 1920s by Franz Fischer and Hans Tropsch, scientists at Kaiser Wilhelm Institute. The F-T process was initially used to help solve Germany's need for fuel in the midst of a petroleum shortage by converting coal, which was abundant in Germany, into synthetic fuels. Both Germany and Japan used this ersatz fuel during World War II. By 1944, Germany was producing 124,000 barrels of synthetic fuels daily at 25 F-T plants. After the war, research was continued in the U.S. by German scientists as part of Operation Paperclip. During South Africa's economic isolation because of Apartheid, Sasol used the process to meet the country's energy needs using both natural gas and coal as feedstocks.
How the F-T Process Produces Fuel
The Fischer-Tropsch process converts carbon monoxide and hydrogen, called synthesis gas or syngas, into liquid hydrocarbon fuels like synthetic diesel and jet fuel. Prior to the T-F process, the coal, gas, or biomass is gasified to produce this syngas using intense heat and pressure, turning these feedstocks into hydrogen and carbon monoxide. Synthetic fuels burn cleanly so they offer improved environmental performance along with addressing energy diversity.
Many Raw Materials can be Used
Some of the more promising applications for the F-T process include coal-to-liquid (CTL), gas-to-liquid (GTL), and bio-to-liquid (BTL) technologies. The latter would mean a less carbon-intensive alternative that could not only use agricultural feedstocks but also waste biomass materials.
Alternatives Become Attractive as Fuel Prices Climb
While the Fischer-Tropsch process is a well proven technology, it requires a large capital investment in equipment followed by high operation and maintenance costs. Also, the gasification to create carbon monoxide and hydrogen is very energy intensive. However, as petroleum prices spiral upward, making synfuels from coal, natural gas, and biomass become more economically competitive. Along with advanced energy companies focusing exclusively on alternative fuels, many oil companies also have dedicated synthetic fuel development programs in place. Shown here is traditional diesel (left) and clean F-T diesel produced by Shell.
Diverse Use of Synthetic Fuels
Audi has used Shell's GTL diesel in the R10 TDI Le Mans racers for the past two seasons. In fact, many automakers have explored using synthetic GTL fuels in their quest to decrease future environmental impact. Since jet fuel and diesel are both kerosene based and quite similar, GTL fuel can also be used in civilian and military aircraft. For example, the USAF has already flown a B-52H bomber and C-17 Globemaster III transport on a 50-50 blend of JP-8 jet fuel and F-T fuel produced in a natural gas-to-liquid process by Syntroleum. The USAF intends to certify every one of its aircraft models for the fuel by 2011. This is a major step in the U.S. military's goal of obtaining about half of its aviation fuel from alternative sources by 2016 to reduce its dependence on foreign-sourced crude oil.
Bill Siuru is a retired USAF colonel who has been writing about automotive technology for nearly 40 years. He has a bachelor's degree in automotive engineering, a PhD in mechanical engineering and has taught engineering at West Point and the U.S. Air Force Academy.
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