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Power Play: In Qatar, Oil Firms Make Huge Bet On Alternative Fuel --- Supporters Say New Diesel IsCleaner, More Efficient; Untested on Large Scale --- `It Was Just Like Water'
 By
Russell Gold
2,321 words15 February 2005The Wall Street JournalJ A1English(Copyright (c) 2005, Dow Jones & Company, Inc.) RAS LAFFAN, Qatar -- Here in the Persian Gulf, hundreds of workers are piecing together a coiled labyrinthof pipes that they hope will turn natural gas into an ultraclean automotive fuel -- and challenge the oilindustry.
 
These plants will produce a clear liquid that operators say will have the high efficiency of diesel fuel, butvirtually none of the sooty pollutants. Millions of diesel cars and trucks around the world could run on thisfuel.
 
The gas-to-liquids, or GTL, plants under way here are part of a big bet by a small nation to reshape globalenergy markets. Some of the world's biggest energy companies, including Exxon Mobil Corp., RoyalDutch/Shell Group and ChevronTexaco Corp., have committed $20 billion to build GTL facilities in anindustrial park here that's twice the size of Manhattan. They are using an unusual technology whose lineagetraces back to Nazi Germany and apartheid South Africa. The projects are one of the largest and riskiestgambles by the industry in years.
 
"Qatar is going to become in the gas business what Saudi Arabia is in the oil business," says Wayne Harms,Exxon Mobil's top official in Qatar. Largely blocked from doing business in Saudi Arabia, Exxon is investingin Qatar's natural gas. It expects to spend $15 billion to $17 billion in coming years building facilities in thegiant industrial park, including $7 billion for a GTL plant, the largest single investment in the company'shistory.
 
The companies say these GTL facilities -- unlike some earlier, smaller efforts -- make economic sense because of technological advances and the lower costs from building on such a large scale. They say theresult will be an alternative fuel that should be priced competitively with crude oil.
 
The challenges are also huge. Only small amounts of GTL fuel are sold in the world today. The process tomake it gobbles up a lot of energy, and no one has ever built a GTL plant of the size of those here. If thecosts of producing GTL on this gargantuan scale run higher than expected, or if the price of competing crudeoil tumbles, the investments could be at risk.
 
Qatar has championed GTL in the hope it will provide a new market for its huge natural-gas reserves. If GTLcatches on, natural gas could loosen crude oil's grip on one of the biggest energy markets of all -- poweringthe world's vehicles, which accounts for 26% of all energy use. Home to some 900 trillion cubic feet of natural gas -- more than 14% of world gas reserves and enough to meet current global demand for naturalgas for 10 years -- Qatar would be a leading beneficiary in such a sea change.
 
"We want to be a big part of bringing this fuel to the world," says Qatar's energy minister Abdullah binHamad al Attiyah, as he sits in his wood-paneled office, decorated with gold-plated miniatures of offshore-drilling rigs. He calls GTL "the fuel of the 21st century."
 
Whether or not Qatar's natural-gas bet pays off could be important to the West. Unlike Saudi Arabia, whichhas long resented Western influences in its closed society, Qatar is courting the U.S. and other industrializedcountries. The current emir, Sheik Hamad bin Khalifa al Thani, who ousted his father in a bloodless coup in1995, has radically reshaped Qatar in ways that ruffle Saudi Arabia's feathers.
 
Unlike Saudi Arabia, Qatar has a largely free media. When Saudi Arabia refused to allow U.S. warplanes inthe kingdom to fly missions against Iraq in the late 1990s, Qatar opened its airspace. The U.S. military ran itswar to oust Saddam Hussein from Iraq from Qatar.
 
Page 1 of 4 © 2011 Factiva, Inc. All rights reserved.
 
The promise of GTL fuel is alluring. Diesel engines tend to get about one-third better fuel economy thangasoline engines. The problem is that conventional diesel -- which is made from crude oil -- is much higher in pollutants that cause smog than is gasoline. By contrast, GTL diesel, because it comes from natural gas,one of the cleanest fossil fuels, has just a fraction of the pollutants found in crude oil. And current dieselengines can run on it without modification.
 
Despite such benefits, few cars use GTL diesel today. Only a tiny amount is manufactured right now, mostlyat small plants in Malaysia and South Africa. Few drivers have ever heard of GTL or are even aware of thepossibility of a cleaner diesel fuel.
 
Even the energy companies say they aren't yet sure exactly how they'll market it. They might try to sell itdirectly to consumers, or initially to refiners, who may blend it with diesel fuel they already manufacture."We'll put our product where it makes us the most money," says Exxon's Mr. Harms.
 
Western energy companies are taking the gamble because GTL plants in Qatar offer a rare opportunity: achance to make a big investment in a place where there are a lot of undeveloped resources. Despite runningup record profits, the oil giants are locked out of much of the Middle East, home to some 65% of the world'soil reserves. Most of the known oil reserves are in a handful of Persian Gulf countries -- Saudi Arabia, Iraq,Iran and Kuwait -- that are either unstable or closed to Western development.
 
Qatar, however, is far more open. In the capital's bustling City Centre mall, a four-story behemoth with anindoor ice-skating rink, women browse in chic shops for Western clothes, although many wear black chadorsin public. Women can vote, work and drive in Qatar, none of which is permitted in Saudi Arabia. Severalyears ago, the energy ministry even abandoned the Middle East's traditional Thursday-Friday weekend infavor of a Friday-Saturday break that kept it more in step with the rest of the globe. The government later followed suit.
 
Natural gas is more broadly dispersed around the world than oil. Much of it is in less-insular nations such asRussia, Qatar, Norway and Australia. So hopping into the gas-to-liquid business allows the Western energycompanies back in the game, in a big way.
 
Even before GTL, natural gas was chipping away at oil's position as the world's primary fuel. Natural gasprovides 23% of global energy today, up from 17% in 1970, thanks largely to a recent spree of buildingnatural-gas-fired electricity-power plants. If natural-gas use continues to grow, it could pass coal as theworld's second-most-used fuel by the end of the decade and catch oil as the top fuel by 2025, according toforecasters for Royal Dutch/Shell Group. Oil now accounts for 39% of global energy use.
 
The first GTL diesel fuel from Qatar is expected to hit the market later this year. By 2010, Qatar and itspartners plan to produce up to 750,000 barrels a day -- about 6% of current global consumption.
 
Diesel usage is expected to grow quickly in industrialized economies, although it isn't widespread in the U.S.While some trucks use the fuel, less than one percent of new cars in the U.S. run on diesel. By contrast,about half the new passenger cars in Europe run on conventional diesel.
 
Shell discovered the North Field, the world's biggest natural-gas field, off the coast of Qatar in 1971. Theproblem was that the gas was too far away from potential markets for a pipeline. In essence, the field waslike an enormous bank, but Qatar had no way of getting the money out.
 
In the mid-1990s, Qatar began building expensive facilities to chill natural gas into a liquid and ship it toWestern markets on giant thermos-like ships. The natural gas is chilled, shipped, and then reheated into gasform, mostly for industrial use or for electrical-power generation. GTL, on the other hand, transforms thenatural gas into automotive fuel.
 
The chemical process at the heart of modern GTL plants was developed in 1923 Germany. That countrywas rich in coal, but had little petroleum, so two scientists decided to figure out how to turn coal into a liquidfuel. They flooded coal with steam to turn it into a gas, and then ran it through pipes lined with cobalt tocreate a liquid fuel. The Nazi government subsidized the nascent industry as it geared up its war machine.Germany got as much as 15% of its motor fuel from coal-to-liquids plants, according to Texas A&MUniversity history professor Anthony Stranges.
 
 After the end of the war, the U.S. government experimented with the German technology because it feareddomestic crude-oil supplies were running out. But gigantic discoveries of oil in the Middle East soon led to anabundance of global crude, and the experiments were dropped.
 
Interest in coal-to-liquids research dried up world-wide -- except in South Africa. Like Germany, South Africahas a lot of coal, but little crude oil. The state oil company acquired the rights from Germany to key parts of the technology and developed its own coal-to-liquids plants.
Page 2 of 4 © 2011 Factiva, Inc. All rights reserved.
 
 
When the United Nations led an oil embargo against South Africa's government, the country was forced tokeep refining its technology. It eventually determined that it was more cost-effective to use natural gas, notcoal, as the main ingredient.
 
But South Africa doesn't have a lot of natural gas. In the mid-1990s, its former state oil company, privatizedand renamed
Sasol
Ltd., went looking for a large supply of natural gas. It set its sights on Qatar. At first, thereaction was lukewarm. "It was like selling encyclopedias. You knocked on doors and tried to get peopleinterested," Cavan Hill, then
Sasol
's manager of business development, says of the first cold calls to Qatariofficials. "There was a lot of skepticism about whether this was an academic curiosity or whether it could bea commercial process."
 
The Qataris brought in an outside energy consultant to analyze the economics of a GTL plant. The resultswere good enough that Mr. Hill was able to secure meetings with Qatar's top officials. Finance minister Youssef Kamal, also the vice chairman of the state-run Qatar Petroleum, recalls being intrigued when hesaw his first vial of natural gas-derived diesel. Crude oil is generally black because it's full of impurities suchas sulfur. "They showed me this liquid and it was just like water," he says.
 
(MORE)
 
In July 2001,
Sasol
and Qatar officials signed an agreement to jointly build the first commercial-scale GTLplant. Then Qatar started leaning on Western energy giants. Mr. Attiyah, the energy minister, sent them amessage: If they wanted additional access to Qatar's natural gas, they would have to build GTL plants. He"had to work pretty hard to cajole the companies, to get everyone where he wants them to be, to do GTLprojects," says Exxon's Mr. Harms.
 
In 2003, Qatar and Shell signed an agreement to build a $6 billion GTL plant. Exxon finalized a deal lastyear. There are ongoing talks with ConocoPhillips and a joint-venture between
Sasol
and ChevronTexaco toexpand GTL plants.
 
Like all alternative fuels, the economics of GTL hinge on world oil prices. Bernard J. Picchi, an analyst for Foresight Research Solutions LLC, says it will cost about $14 to produce every barrel of GTL diesel. With oilcurrently at about $47 a barrel, that makes GTL look sweet. If world oil prices plummet to $25 a barrel, aGTL plant still could yield a 19% return on investment. Below $20 oil, however, the returns aren't attractive,Mr. Picchi says.
 
Once the first plant is operational later this year, the natural gas will be fed into a three-quarter-mile structurethat is longer and heavier -- at about 19,000 tons -- than the main span of the Brooklyn Bridge. The gas is fed through a series of four furnaces where it is mixed with oxygen and water and burned to create a carbon-monoxide gas. The gas is then fed into a 20-story-tall cylinder with 4-inch-thick steel walls. Exactly whatgoes on inside is a proprietary secret, but essentially the gas is exposed to cobalt -- a metallic-gray ore oftenfound on meteors. When the gas comes into contact with the cobalt, the interaction rearranges the molecular structure and turns the gas into a waxy petroleum. This wax is then put under high pressure to break it intodiesel, and a smaller amount of other products, including motor oil.
 
Shell built a similar, but much smaller, plant in Malaysia in 1993 to see if it could manufacture GTL. The GTLfuel from that plant has been used in small-scale tests in buses in London and Shanghai and in a fleet of water-delivery trucks in California. It's also for sale in limited quantities to the public in Germany, Greece andThailand.
 
On a recent day, Benjasook Chumhepan filled up her Toyota pickup with "Pura Diesel" at a Shell station inBangkok. The GTL diesel costs about 7% more than regular diesel -- an effort by Shell to see if drivers arewilling to pay a little more for a cleaner fuel. Ms. Chumhepan says she buys it regularly because it cuts downon the truck's emissions. "The engine runs smoothly and doesn't emit black smoke," she says.
 
---
 
Kullawee Pongpattanajit in Bangkok contributed to this article.
 
Page 3 of 4 © 2011 Factiva, Inc. All rights reserved.
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