Velocys1

Velocys Product/Process Velocys Product/Process DevelopmentDevelopment

John GlenningJohn GlenningJuly 23, 2009July 23, 2009

Velocys Micro-Channel Process Velocys Micro-Channel Process DevelopmentDevelopmentFischer-Tropsch Project: Micro-channel Reactors

Reactor Block Metal1. 304L Stainless Steel

• Low Metal Cost• Poor Thermal Conductivity (16.2 W/M°K)

2. Copper• High Metal Cost• Great Thermal Conductivity (401 W/M°K)

3. Aluminum• High Metal Cost• Great Thermal Conductivity (250 W/M°K)• Low melting point

Thermal Coefficient of Expansion was within 10% to 15% of each other


Manufacturing Costs• Sale Price based on Market Analysis: $225K to $250K


Manufacturing Costs• Sale Price based on Market Analysis: $225K to $250K• Manufacturing cost: $270K/Reactor

Measure 20% of the shims & 3% of the features/shim



Measure 20% of the shims & 3% of the features/shim• Measure 100% of the shims & 3% of the features/shim

Cost: $340K/Reactor




Cost: $340K/Reactor• Measure 100% of the shims & 100% of the features/shim

Cost: $1,700K/Reactor




Cost: $340K/Reactor• Measure 100% of the shims & 100% of the features/shim

Cost: $1,700K/Reactor• Shipping Costs: $95K/Reactor


Plan of Record Manufacturing Process• Photochemical Machining (PCM) of patterns into the Shims• Plating Shims with brazing material• Clean Shims• Stack Shims• Braze Reactor



Photochemical Machining industry is consolidating in the US• Projecting increase manufacturing costs



Photochemical Machining industry is consolidating in the US• Projecting increase manufacturing costs

Photochemical Machining in Asia• Reduced PCM Cost• Offset by Trans-Pacific Shipping Costs


Manufacturing Capability• 5 reactors builds using 3 PCM companies


Manufacturing Capability• 5 reactors builds using 3 PCM companies• If design specification became manufacturing specification: 0%

yield



yield• Manufacturing process was “Not Capable”

• Over 80% of specified features had Cp/Cpk significantly less than 1.00 on a consistent basis

• Processing variability was well within the norm for the PCM industry

• To eliminate the need for mass inspect, all the Cp/Cpk had to be greater than 2.00







• Initial product testing showed Reactor productivity 60% to 80% higher than anticipated based on modeling








• Reviewed results and proposed specification relief


Manufacturing Capability• 5 reactors builds using 3 PCM companies• If design specification became manufacturing specification: 0% yield• Manufacturing process was “Not Capable”





• Reviewed results and proposed specification relief• With specification relief, the manufacturing process was still “Not

Capable” and still had 0% yield


Product Design Review:• Identify potential alternative manufacturing processes


Product Design Review:• Identify potential alternative manufacturing processes• Reduce manufacturing cost


Product Design Review:• Identify potential alternative manufacturing processes• Reduce manufacturing cost • Improve manufacturing capability


Product Design Review:• Identify potential alternative manufacturing processes• Reduce manufacturing cost • Improve manufacturing capability • Improve reactor productivity


Reactor Productivity• Limiting Factor for Reactor Productivity: Heat generated

in the catalyst bed



in the catalyst bed• Limits Syn Gas injection rate



in the catalyst bed• Limits Syn Gas injection rate• Limiting Factor for removing heat: Thermal Conductivity

of the stainless steel




of the stainless steel• Current design of the reactor is cross-current cooling




of the stainless steel• Current design of the reactor is cross-current cooling• Created a temperature gradient across the diagonal of

the reactor




of the stainless steel• Current design of the reactor is cross-current cooling• Created a temperature gradient across the diagonal of

the reactor• Limited productivity and selectivity from the reactor


Reactor Redesign for Manufacturability• Counter-Current Cooling: Design minimizes temperature gradient in

the catalyst bed improving productivity and selectivity due to uniform temperature




• Improve reactor productivity and selectivity due to better heat transfer





• Coolant channel flow with no eddy currents





• Coolant channel flow with no eddy currents• Manufacturing Process: Electro-Chemical Machine (ECM) reactor with

alternative design




• Improve reactor productivity and selectivity due to better heat transfer• Coolant channel flow with no eddy currents• Manufacturing Process: Electro-Chemical Machine (ECM) reactor with

alternative design• Eliminates:

• Plating Brazing material• Cleaning• Stacking• Brazing


Electro-Chemical Machining (ECM)• ECM is a method of removing metal by an electrochemical process


Electro-Chemical Machining (ECM)• ECM is a method of removing metal by an electrochemical process• ECM’s use is limited to electrically conductive materials


Electro-Chemical Machining (ECM)• ECM is a method of removing metal by an electrochemical process• ECM’s use is limited to electrically conductive materials• ECM can cut small or odd-shaped angles, intricate contours or cavities

in extremely hard metals


Electro-Chemical Machining (ECM)• ECM is a method of removing metal by an electrochemical process• ECM’s use is limited to electrically conductive materials• ECM can cut small or odd-shaped angles, intricate contours or cavities

in extremely hard metals• Current is passed between the tool (cathode) and the part (anode)

through an electrolyte material, which conducts current, removes the etched metal and heat


Electro-Chemical Machining (ECM)• ECM is a method of removing metal by an electrochemical process• ECM’s use is limited to electrically conductive materials• ECM can cut small or odd-shaped angles, intricate contours or cavities in

extremely hard metals• Current is passed between the tool (cathode) and the part (anode)

through an electrolyte material, which conducts current, removes the etched metal and heat

• The pressurized electrolyte is injected into the area being etched


ECM Process Cost Reductions• Metal Costs Reduction: $40K to $36K• Shipping Costs Reduction: $95K to $15K• Eliminate Plating, Clean, Stacking and Brazing:

$100K cost reduction• Eliminate $184K in manufacturing costs


ECM Process Cost Reductions• Metal Costs Reduction: $40 to $36K• Shipping Costs Reduction: $95K to $15K• Eliminate Plating, Clean, Stacking and Brazing:

$100K cost reduction• Eliminate $184K in manufacturing costs

Eliminate metal-brazing interfaces (240/reactor)• Eliminate fatigue failures to the CTE mismatch• Operate at higher pressures• Increase conversion rates• Increase formation of long chain liquid hydrocarbons


ECM Manufacturing• 5 ECM companies in the US


ECM Manufacturing• 5 ECM companies in the US• ECM lines were built for the Raptor and Joint Strike

Fighter projects



Fighter projects• Capacity utilization was between 5% and 20%,

depending on the ECM company



Fighter projects• Capacity utilization was between 5% and 20%,

depending on the ECM company• Worked with ECM companies to determine process

limitations and manufacturing variability


ECM Manufacturing Costs• Tooling Costs

• Design & Build of initial tooling: $50K to $150K• Back-up Tooling Build: $25K to $50K• Prorated tooling costs/Reactor over 7 years: $45

to $115




to $115• ECM manufacturing time: 4 to 8 hours per reactor

block




to $115• ECM manufacturing time: 4 to 8 hours per reactor

block• ECM costs were not determined due to Velocys’

acquisition by Oxford Catalyst


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed• Thermal conductivity of 304L Stainless Steel: 16.2 W/M°K


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed• Thermal conductivity of 304L Stainless Steel: 16.2 W/M°K• Researched coating options to improve heat transfer


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed• Thermal conductivity of 304L Stainless Steel: 16.2 W/M°K• Researched coating options to improve heat transfer• Thermal conductivity of Diamond: 1800 W/M°K


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed• Thermal conductivity of 304L Stainless Steel: 16.2 W/M°K• Researched coating options to improve heat transfer• Thermal conductivity of Diamond: 1800 W/M°K• Consulting with CVD company in California


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed• Thermal conductivity of 304L Stainless Steel: 16.2 W/M°K• Researched coating options to improve heat transfer• Thermal conductivity of Diamond: 1800 W/M°K• Consulting with CVD company in California• 50 microns of diamond on the catalyst channel walls


Productivity Improvement Opportunity• Limiting Factor: Removing the heat from the catalyst bed• Thermal conductivity of 304L Stainless Steel: 16.2 W/M°K• Researched coating options to improve heat transfer• Thermal conductivity of Diamond: 1800 W/M°K• Consulting with CVD company in California• 50 microns of diamond on the catalyst channel walls• Significantly increase Syn gas injection rate while being

able to remove heat from the catalyst bed



able to remove heat from the catalyst bed• Increase liquid hydrocarbon productivity



able to remove heat from the catalyst bed• Increase liquid hydrocarbon productivity• Cost and feasibility were not determined due to Velocys’

acquisition by Oxford Catalyst


End of Fischer-Tropsch Presentation

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