Non-catalytic methane conversion in the microwave plasma torch

1. 1
Innovation project name:
Non-catalytic methane conversion
in the microwave plasma torch
Sk
Skolkovo Name of organization:
Plazma-conversion Ltd.
Moscow, 2015

2. The known technologies of production of synthetic liquid hydrocarbons (SLH) from
natural gas (GTL-productions) are not profitable in the small-scale sector. The
main reason is: the high cost of methane conversion to synthesis gas, as a key
stage of GTL-process (occupying from 50 to 70% of the cost of SLH production).
Significant volumes of associated petroleum gas (APG) and natural gas of distant,
hard to reach and small deposits are not involved into the processing.
For oil&gas and gas-chemical companies interested in processing of APG and
natural gas of distant deposits in the place of extraction, our solution is able to
provide an additional source of profit.
At the current moment cost-effective profitable small-scale technologies for
producing of syngas from natural gas are absent on the market.
Our project is able to ensure the profitability of small-scale GTL-productions and
solution of a largest problems: APG processing and the problem of "northern
delivery" (in the part of liquid motor fuels) (for Russia).
2
1. The description of the problem on which decision the project is
aimed to:

3. The proposed technology of methane conversion in the microwave plasma torch ensures the possibility of
highly efficient and cost-effective small-scale production of synthesis gas - as a key stage of GTL production.
2. The description of proposed problem solution and its advantages:
Experimental confirmation of the effectiveness of the method:
Conducted experiments have confirmed the efficiency of method:
 The conversion of methane to syngas (the proportion of methane flow
transformed into synthesis gas):
α = 0,45 ± 0,11 (45±11)%;
 The energy cost of production of syngas (Referred to 1 liter of methane) :
ηСH4 = (3,7 ± 0,7) 10-2
kWh / liter;
 Energy cost of production, referred to 1 liter of syngas:
ηsg ≅ (0,92 ± 0,2) 10-2
kWh / liter;
The photography of
microwave plasma torch in the
zone of which the conversion
reaction takes place
Consumer benefits as a result of application of Project solution:
Profitable processing of today unused resources of APG and natural gas of small-debit and hard to reach
deposits. Source of additional profit.
Reducing by 2 times the energy consumption for a process of conversion of natural gas to syngas in
comparison with the traditional method of steam conversion.
Reduction by several times the capital costs at the stage of syngas production.
Source of additional profit for equipment manufacturers by reducing the prime cost.

4. Gas is supplied through the central coaxial electrode. After the
launch of magnetron the microwave radiation starts to accumulate
in a system of “rectangular resonator – coaxial tract”. During the
operation of the magnetron and the accumulation of microwave
energy the field strength at the end of the nozzle increases, and at
some point in time, reaches the breakdown magnitude. In this case
at the end of the nozzle in the jet of the working gas the breakdown
occurs and the field of gas discharge plasma is formed. This
plasma, because of its high conductivity, actually becomes an
extension of the inner electrode of the coaxial line, and the
electromagnetic wave can now spread further to coaxial, to the end
of the area occupied by the plasma, where the breakdown
conditions for adjacent area are provided again. Thus, in a working
gas jet the plasma torch is formed, the length of which can reach
tens of centimeters. Because of the electric field strength at the
nozzle end due to the accumulation of microwave energy in a
coaxial resonator can reach a significant value even at a not very
powerful magnetrons, the device can operate in a wide range of
gases and their mixtures.
It is revealed that the energy cost of producing synthesis gas
(referred to 1 liter of methane) is (3,7 ± 0,7) 10-2
kWh / liter.
3. The description of the basic Project technology:
Scheme of layout of plasma
chemical methane
conversion reactor
1 - rectangular resonator 2 -
coaxial resonator 3 -
continuation of outer electrode
of coaxial waveguide (grid), 4
- working chamber of 5 -
viewing window 6 - microwave
discharge plasma 7 -
magnetron 8 - water supply
unit.

5. High energy efficiency of the conversion process due to
maximally complete transfer of microwave energy into the
working gas
Reduction by 2 times the level of the energy consumption
for the production of synthesis gas as compared to existing
solutions (up to ≈2 kWh/m3
)
Process is non-catalytic
Process does not require the preliminary heating and
compression of the working gas
Space-saving, mobility
Periodicity of the process - instant start-up of device, the
insensitivity to the number of starts / stops
Relatively low capital costs
4. Competitive advantages:
Acting model of the
reactor of plasma chemical
methane conversion
Power: 1 kW
Productivity: 2*103
m3
/year

6. Target market of Project (segments):
Russian market: $2,1 - $2,7 billion. Planned market share: 25-30%.
Global market: $6 – $9,4 billion. Planned market share: 5-10%.
Directions of Project commercialization:
Sale of licenses
Research contracts related with the introduction and development of technology
5. Market / Business model:

7. Comparison of Plazma-conversion Ltd’s solution with the most similar analogues:
6. Comparison with Competitors:
Key
parameters
/ Solution
Plazma-
conversio
n Ltd.
DavyProcess
Technology,
Mahler
Steam
methane
reforming
LLC
Gazohim-
Techno
Partial
oxidation of
methane
Haldor
Topso , Lurgi,ё
TEC, JFE
Partial
oxidation of
methane
ARCO, Kerr-
McGee,
Marathon,
Repsol
Autothermal
methane
reforming
Energy
consumption
≈2kW*h/
m3 ≈4kW*h/m3 Exothermal
process
Exothermal
process
≈4kW*h/m3
Necessity of
using
catalysts
NO
Requires cobalt /
nickel catalyst
Requires nickel
catalyst
Requires cobalt
catalyst
Requires a highly
active nickel
catalyst
Capital
intensity
Low High High High High
Special
conditions of
the
conversion
process
Pressure
0,2-0,3
MPa
Pressure
2 MPa
Pressure
0.8 MPa
Pressure
3-4 MPa
Pressure
2-3 MPa
Price ≈$3 mln. No data ≈$8 mln. No data No data

8. In 2014, the project received Skolkovo participant status, which provided tax
incentives in the form of exemption from the duties of the taxpayer's income tax and
VAT for a period of ten years.
On fundamental research conducted in the GPI RAS, a working model of reactor
power of 1 kW has been created.
Installation experiments of plasma chemical methane conversion have been
conducted, positive results have been obtained.
Russian patents for invention and utility model have been obtained; PCT application
for the invention has been filed.
In 2015 - 2016 it is planned to create a working prototype of plasma chemical
methane conversion reactor and adjustment of optimal parameters of stability and
controllability of the process of plasma chemical conversion of methane depending
on the types of conversion.
7. Project current status:

9. The project team has been succeeded to conduct
an experiment on microwave conversion of
methane using principally different source -
GYROTRON. According to the first results
obtained in a single experiment, the energy cost
of carbon dioxide conversion can be as small as:
η ≈ 2,5 10-3
kWh / liter
Modular configuration, placement in a standard
container (14 m2
)
8. Parameters of planned prototype:

10. Current funding sources:
• The project is supported by the venture partner - Management Company "Navigator" (Saratov).
Need for investment: $0,9 mln.
Expect to attract funding under the scheme:
50% of the required amount - Skolkovo Foundation grant.
50% of the required amount - co-investor funds.
• Purpose of investment:
Creation and testing of a prototype of reactor of plasma chemical methane conversion:
Adjustment and clarification in the laboratory parameters of the conversion process.
Adjustment of optimal operating modes of reactor depending on the composition of the feedstock.
Marketing measures on promotion of the technology to the market.
• Offer to investor:
We offer the Investor the share in the project: 10 – 25+%.
Return on investment:
On the time horizon of 3-5 years from the beginning of the commercialization the investment of the
investor is fully returned due to the share in the profit.
Exit Strategy:
Investor’s sale of its share to the company-developer;
Investor’s sale of its share to a third party;
Joint sale of Project to a profiled strategic investor.
9. The need for capital investments / Offer to investor:

11. Patenting geography:
Russia, Britain, France, Germany, Italy, China, Canada, USA, Brazil, Malaysia, South Africa,
South Korea, Japan.
10. Patenting:
Intellectual property:
Номер Название
Russian patent for utility model №124105 dated
10.01.2013, application №2012135708 dated
21.08.2012.
Microwave plasmatron.
Russian patent for invention №2486719 dated
27.06.2013, application № 2012117620.
The method of treatment, destruction
and conversion of gas.
Russian patent for invention №2513622, application
№ 2012135387, priority 17.08.2012.
The method of microwave conversion of
methane-water mixture into the
synthesis gas.
Application PCT/RU 2012/056848. priority
17.08.2012
The method of microwave conversion of
methane-water mixture into the
synthesis gas.

12. 11. Information about the project team:
Igor Cossyi – d. p/m. sciences (GPI RAS), Moscow
Scientific adviser of the project
30+ years in applied research in the field of plasma physics. Participation in
projects jointly with the Eindhoven Technical University, University of Knepper,
NWO, ISTC
Alexei Davydov – c. p/m. sciences (GPI RAS), Moscow
Leading researcher of the project
10+ years of experimental work in the field of low temperature plasma physics.
Participation in projects jointly with the IAP RAS, CNES, Chalmers University
of Technology
Renat Khabeev – General Director of the MC «Navigator» Ltd., Saratov
Venture Partner, Business Mentor of Project
15+ years of management of industrial enterprises (Plant Neftegazmash), the
establishment of partnerships with specialized companies. Creation and
management holding company LLC MC Navigator
Plazma-conversion Ltd. - was created for Project realization in 2013.

13. 12. Contact Information:
Plazma-conversion Ltd.
410005, Russia, Saratov, Bolshaya Sadovaya, 239,
office 616.
phone: (8452) 459523, 459524, 459510.
e-mail: avdvoenko@gmail.com
Alexander Dvoenko
Director