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.
Abstract:
A method for forming a catalyst for synthesis gas conversion comprises impregnating a zeolite extrudate using a solution, for example, a substantially non-aqueous solution, comprising a cobalt salt to provide an impregnated zeolite extrudate and activating the impregnated zeolite extrudate by a reduction-oxidation-reduction cycle.
Abstract:
The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions to prepare synthesis gas and ultimately C5+ hydrocarbons. In particular, preferred embodiments of the present invention comprise catalyst systems comprising a core and an outer region disposed on said core, wherein a substantial amount of the catalytic metal is located in the outer region of the catalyst support matrix. In addition, the catalyst systems are able to maintain high conversion and selectivity values with very low catalytically active metal loadings. The catalyst systems are appropriate for improved syngas, oxidative dehydrogenation and other partial oxidation reactions, including improved reaction schemes for the conversion of hydrocarbon gas to C5+ hydrocarbons.
Abstract:
A catalyst and method for producing hydrocarbons using a catalyst support having an improved hydrothermal stability, such as under Fischer-Tropsch synthesis conditions. The stabilized support is made by a method comprising treating a boehmite material in contact with at least one structural stabilizer. Contacting the boehmite with at least one structural stabilizer can include forming a mixture comprising the boehmite material and at the least one structural stabilizer. The mixture can be a sol or a slurry. The treating preferably includes drying or spray drying the mixture, and calcining in an oxidizing atmosphere to obtain the stabilized support. Preferred structural stabilizers can include an element, such as cobalt, magnesium, zirconium, boron, aluminum, barium, silicon, lanthanum, oxides thereof, or combinations thereof; or can include precipitated oxides, such as a co-precipitated silica-alumina.
Abstract:
The invention generally relates to methods for modifying a porous amorphous material comprising micropores to reduce its micropore volume and to form a support for a hydroprocessing catalyst, to methods of making said catalyst, as well as to methods for hydrocracking employing said hydroprocessing catalyst characterized by a lower selectivity towards undesirable gaseous hydrocarbon products. In one embodiment, the method for modifying the amorphous material comprises depositing an inorganic oxide or inorganic oxide precursor to the amorphous material; and treating the deposited amorphous material so as to reduce its micropore volume by at least about 5 percent, while its mean pore diameter is substantially unchanged or changed by not more than about 10 percent. Further embodiments include the amorphous material comprising silica-alumina, and the deposited inorganic oxide or inorganic oxide precursor comprising silicon.
Abstract:
A process has been developed for preparing a Fischer-Tropsch catalyst precursor and a Fischer-Tropsch catalyst made from the precursor. The process includes contacting a gamma alumina catalyst support material with a first solution containing a compound containing an element selected from the group consisting of yttrium (Y), niobium (Nb), molybdenum (Mo), tin (Sn), antimony (Sb) and mixtures thereof to obtain a modified catalyst support material. The modified catalyst support material is calcined at a temperature of at least 700° C. The calcined modified catalyst support has a pore volume of at least 0.4 cc/g. The modified catalyst support is less soluble in acid solutions than an equivalent unmodified catalyst support. The modified catalyst support is contacted with a second solution which includes a precursor compound of an active cobalt catalyst component to obtain a catalyst precursor. The catalyst precursor is reduced to activate the catalyst precursor to obtain the Fischer-Tropsch catalyst. The catalyst has enhanced hydrothermal stability as measured by losing no more than 25% of its pore volume when exposed to water vapor.
Abstract:
A process has been developed for preparing a Fischer-Tropsch catalyst precursor and a Fischer-Tropsch catalyst made from the precursor. The process includes contacting a gamma alumina catalyst support material with a first solution containing a compound containing zinc and optionally containing P, Ti, V, Co, Ga, Ge, Mo, W and/or Pr to obtain a modified catalyst support material. The modified catalyst support material is calcined at a temperature of at least 500° C. The calcined modified catalyst support has a pore volume of at least 0.4 cc/g. The modified catalyst support is less soluble in acid solutions than an equivalent unmodified catalyst support. The modified catalyst support is contacted with a second solution which includes a precursor compound of an active cobalt catalyst component to obtain a catalyst precursor. The catalyst precursor is reduced to activate the catalyst precursor to obtain the Fischer-Tropsch catalyst. The catalyst has enhanced hydrothermal stability as measured by losing no more than 20% of its pore volume when exposed to water vapor.
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.