Velocys Launches AlphaCore 800 Microchannel Fischer-Tropsch Reactor

Velocys has launched its new AlphaCore™ 800 microchannel Fischer-Tropsch (FT) reactor, expanding its technology portfolio for larger-scale sustainable aviation fuel (SAF) and e-fuels projects.

The new reactor is designed to produce up to 800 barrels per day (bpd), or approximately 30,000 tonnes per year, of Fischer-Tropsch liquids from a single reactor. Velocys says the higher-capacity design can allow larger fuel projects to use fewer reactors while simplifying the overall Fischer-Tropsch configuration.

AlphaCore 800 Doubles Reactor Capacity

AlphaCore 800 doubles the capacity of Velocys' previous AlphaCore 400 reactor. It extends the company's reactor portfolio from approximately 50 to 800 bpd per reactor, with AlphaCore 50, 200, 400 and 800 now forming the main throughput-based product family.

Fewer Reactors for Larger FT Plants

One of the main objectives behind AlphaCore 800 is to increase production capacity per reactor.

For example, Velocys says an FT plant requiring approximately 1,600 bpd, or 60,000 tonnes per year, of FT liquids could use two AlphaCore 800 reactors instead of eight AlphaCore 200 units.

This configuration would reduce the number of reactors by 75% while maintaining the same overall FT liquid capacity. According to Velocys, fewer reactors can simplify the FT island, reduce associated equipment requirements and potentially lower FT unit costs.

Microchannel Technology for Fischer-Tropsch Synthesis

AlphaCore reactors use microchannel Fischer-Tropsch technology to convert cleaned synthesis gas into liquid hydrocarbons.

Within the reactor, synthesis gas passes through compact reaction channels containing catalyst, while adjacent cooling channels help remove the heat generated during the highly exothermic Fischer-Tropsch reaction.

Velocys says its microchannel architecture is designed to provide controlled heat removal and stable reaction conditions while supporting compact and modular plant configurations.

Supporting Sustainable Aviation Fuel Production

The AlphaCore 800 has been introduced as the sustainable fuels industry moves toward larger commercial-scale SAF projects.

Fischer-Tropsch technology can convert synthesis gas containing hydrogen and carbon monoxide into liquid hydrocarbons. These FT liquids can subsequently be upgraded into products such as sustainable aviation fuel, renewable diesel, naphtha and other synthetic hydrocarbons, depending on the downstream process configuration.

Velocys integrates its AlphaCore reactors with its SQRCAT™ catalyst and wider microFTL™ technology platform. The company provides reactor technology, catalyst, process know-how and related support for Fischer-Tropsch fuel projects.

AlphaCore 800 Expands Velocys' Reactor Portfolio

The new reactor joins AlphaCore 50, AlphaCore 200 and AlphaCore 400, giving developers a range of reactor capacities for different project scales.

According to Velocys, the same core technology platform can be applied across multiple project sizes and syngas pathways. Larger reactors such as AlphaCore 800 are intended to help developers scale FT facilities while limiting the number of individual reactor units required.

This modular approach can also allow multiple reactors to be arranged into parallel trains within an FT plant, providing flexibility as project capacity increases.

Enabling Larger E-Fuels Projects

Beyond SAF, AlphaCore 800 is designed for broader e-fuels and synthetic-fuel applications.

The technology can be incorporated into projects where synthesis gas is generated from different feedstock pathways and subsequently converted into liquid hydrocarbons through Fischer-Tropsch synthesis.

Velocys describes AlphaCore 800 as part of its strategy to provide scalable FT technology for projects that require higher production capacity while maintaining a modular plant configuration.

AlphaCore 800 at a Glance

Scaling Fischer-Tropsch Technology

The launch of AlphaCore 800 gives Velocys a higher-capacity reactor option for the growing number of larger SAF and e-fuels projects being developed worldwide.

By increasing FT liquids capacity per reactor, the company aims to reduce reactor counts and simplify plant configurations as projects scale. The new reactor therefore represents an expansion of Velocys' microchannel FT technology toward larger commercial fuel-production facilities.