The CTO conversion process is a thermal treatment followed by pyrolysis that produces synthetic petroleum at 43 API or higher (lighter). This molecular weight compound is essentially blending stock for gasoline and diesel fuels for all commonly used aircraft, automotive and truck engines. CTO also generates a synthesis gas rich in methane that can be used directly or converted into electricity. It also generates a carbon residual with a high BTU content (14,500 BTU/lb) similar to metallurgical coke.
Key to the New Range CTO hybrid processing is that we use high temperature and moderate pressure in a pretreatment design to drive a hydrolysis of the organic material including coal to change in a way that encourages a much easier (hence more efficient) breakdown under the second phase of the process (gasification) into small chain hydrocarbons.
The CTO Process represents 4 modules that are integrated to provide a system that produces clean gas that can be used by a natural gas power plant to produce electricity. This allows the power plant to have a low carbon foot print. The water used to operate the process is continually recycled so that there is little to no water usage. Any excess water required to be discharged is completely treated in the recycle water system prior to discharge.

CTO Plant Performance:

The commercial CLFPP plant is expected to be operating for approximately 350 days per year or at 95% of its capacity. The inclusion of redundant components such as screw press, pumps and valves to insure continuous operation plus the ability to run the plant manually will be part of the design process and implemented upon fabrication and construction of the equipment.

Summary of products produced via New Range Power, Corp’s advanced CTO carbon conversion technology.

Coal to Oil, Met Coke and Natural Gas

Each 1000 ton per day (tpd) coal system will convert to approximately 1000 barrels/day of 44 API light sweet crude oil, 420 tons per day (tpd) of metallurgical quality coke (14,500 BTU/lb) and sufficient natural gas (6,413,142 scf/d) to produce 54 MW/h of electricity in a natural gas fired generator unit, should this be selected as the best use of the gas. The coal to oil system is designed to operate at 95.9% efficiency or 350 days per year.

MSW to Oil, Carbon and Natural Gas

Each 1000 tpd MSW conversion system will produce approximately 450 barrels/day of 44 API light sweet crude oil and enough gas sufficient to produce 65 MW/h of electricity. Approximately 200 tpd of high BTU carbon will be produced (14,500 BTU/lb). 5% - 8% ash or mineral content can be expected as well.

Tires to Oil, Carbon and Natural Gas

A 100 tpd tire conversion facility will produce approximately 288 barrels/day of 50 API light sweet crude oil, 121,000 scf/day of natural gas at 1,000 BTU/scf and 46 tons per day of 14,500 BTU/lb of high grade carbon per day. 10 tons of steel per day will also be recovered.


Rubber converts to 48% oil, 48% high grade (14,500 BTU/lb) carbon and 4% syngas at 1,000 BTU/scf.


A 100 tpd of wood CTO facility will produce approximately 1,247,000 CuFt/day of syngas at 1000 Btu/CuFt equivalent to 10 MWh electricity, 15 TPD/day of metallurgical coke @14,500 BTU/lb and 50 Bbls/day of 45 API (or higher/lighter) synthetic oil.

Plastics to Oil, Carbon and Natural Gas


HDPE converts to 80% synthetic petroleum oil, 1% carbon and 19% syngas. For Syngas composition, expect 4%-5% light hydrocarbon compounds like propane butane, methylene, ethylene, propylene and butylene with the balance of syngas being methane.

Mixed Plastic

Mixed Plastic will convert to 65% synthetic oil, 11% high grade coke/carbon and 24% syngas at 1,000 BTU/lb similar to above components. Results will vary depending on your projects mix of plastic.

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