Abstract:
Disclosed are hybrid Fischer-Tropsch catalysts containing cobalt deposited on hybrid supports. The hybrid supports contain an acidic zeolite component and a silica-containing material. It has been found that the use of the hybrid Fischer-Tropsch catalysts in synthesis gas conversion reactions results in high C5+ productivity, high CO conversion rates and low olefin formation.
Abstract:
Disclosed are hybrid Fischer-Tropsch catalysts containing cobalt and ZSM-48 zeolite. The hybrid Fischer-Tropsch catalysts can contain cobalt deposited on ZSM-48 extrudate supports. Alternatively, the Fischer-Tropsch catalysts can contain cobalt deposited on supports mixed with ZSM-48 particles. It has surprisingly been found that the use of hybrid Fischer-Tropsch catalysts containing ZSM-48 zeolite in synthesis gas conversion reactions results in improved C5+ productivity and catalyst activity, as well as a desirable product distribution including low formation of methane and C21+.
Abstract:
Methods for preparing integral synthesis gas conversion catalyst extrudates including an oxide of a Fischer-Tropsch (FT) metal component and a zeolite component are disclosed. The oxide of the FT metal component is precipitated from a solution into crystallites having a particle size between about 2 nm and about 30 nm. The oxide of the FT metal component is combined with a zeolite powder and a binder material, and the combination is extruded to form integral catalyst extrudates. The oxide of the FT metal component in the resulting catalyst is in the form of reduced crystallites located outside the zeolite channels. No appreciable ion exchange of FT metal occurs within the zeolite channels. The acid site density of the integral catalyst extrudate is at least about 80% of the zeolite acid site density.
Abstract:
Processes and systems are provided for converting synthesis gas containing a mixture of H2 and CO to liquid hydrocarbon products having a cloud point less than about 15° C. The systems utilize at least one Fischer-Tropsch reactor containing hybrid Fischer-Tropsch catalyst with cooling and separation of reactor effluent following each reactor. The low cloud point indicates that the amount of wax in the hydrocarbon products is minimized relative to conventional Fischer-Tropsch conversion. Accordingly, more economical systems can be built and operated because equipment associated with wax removal or wax treatment can be reduced or eliminated.
Abstract:
The disclosure relates to a method of performing a synthesis gas conversion reaction in which synthesis gas contacts a catalyst system including a mixture of ruthenium loaded Fischer-Tropsch catalyst particles and at least one set of catalyst particles including an acidic component promoted with a noble metal, e.g., Pt or Pd. The reaction occurs at conditions resulting in a hydrocarbons product containing 1-15 weight % CH4, 1-15 weight % C2-C4, 70-95 weight % C5+, 0-5 weight % C21+ normal paraffins, and 0-10 weight % aromatic hydrocarbons.
Abstract:
Disclosed is a method of forming a hybrid Fischer-Tropsch catalyst extrudate for use in synthesis gas conversion reactions. The method includes extruding a mixture of ruthenium loaded metal oxide support particles, particles of an acidic component and a binder sol to form an extrudate. The resulting extrudate contains from about 0.1 to about 15 weight percent ruthenium based on the weight of the extrudate. In a synthesis gas conversion reaction, the extrudate is contacted with a synthesis gas having a H2 to CO molar ratio of 0.5 to 3.0 at a reaction temperature of 160° C. to 300° C., a total pressure of 3 to 35 atmospheres, and an hourly space velocity of 5 to 10,000 v/v/hour, resulting in hydrocarbon products containing 1-15 weight % CH4; 1-15 weight % C2-C4; 70-95 weight % C5+; 0-5 weight % C21+ normal paraffins; and 0-10 weight % aromatic hydrocarbons.
Abstract:
A process is disclosed for converting a feed comprising synthesis gas to liquid hydrocarbons within a single reactor at essentially common reaction conditions. The synthesis gas contacts a catalyst bed comprising a mixture of a synthesis gas conversion catalyst on a support containing an acidic component and a dual functionality catalyst including a hydrogenation component and a solid acid component. The hydrocarbons produced are liquid at about 0° C., contain at least 25% by volume C10+ and are substantially free of solid wax.
Abstract:
A process is disclosed for converting synthesis gas to a liquid hydrocarbon mixture useful as distillate fuel and/or lube base oil which is substantially free of solid wax. A synthesis gas feed is contacted with a synthesis gas conversion catalyst in an upstream bed and a hydroisomerization catalyst containing a metal promoter and an acidic component in a downstream bed within a single reactor at essentially common reaction conditions. A Fischer-Tropsch wax is formed over the synthesis gas conversion catalyst and said wax is subsequently hydroisomerized over the hydroisomerization catalyst, thereby resulting in a liquid hydrocarbon mixture having a desirable product distribution.
Abstract:
A method for performing synthesis gas conversion is disclosed which comprises contacting synthesis gas with a hybrid Fischer-Tropsch catalyst formed by impregnating a ZSM-12 zeolite extrudate using a solution, for example, a substantially non-aqueous solution, comprising a cobalt salt and activating the impregnated zeolite extrudate by a reduction-oxidation-reduction cycle. The method results in reduced methane yield and increased yield of liquid hydrocarbons substantially free of solid wax.
Abstract:
A process is disclosed for converting a feed comprising synthesis gas to liquid hydrocarbons within a single reactor at essentially common reaction conditions. The synthesis gas contacts a first catalyst bed comprising a synthesis gas conversion catalyst, and a second catalyst bed comprising a mixture of a hydrogenation catalyst and a solid acid catalyst. A Fischer-Tropsch wax is formed over the first catalyst bed and the wax is then hydrocracked and hydroisomerized over the second catalyst bed, resulting in liquid hydrocarbons substantially free of solid wax.