Abstract: A process for enhancing metal catalysts for carbon monoxide hydrogenation comprising reducing the catalyst so that at least a portion is in the metallic state, impregnating under a non-oxidative atmosphere with a solution of a salt of at least one metal, optionally in combination with at least one of an ammonium salt, an alkyl ammonium salt, a weak organic acid and ammonia, oxidizing with a gaseous oxidant in the presence of the impregnating solution, and reducing to form an active catalyst. Used catalysts enhanced by the process are initially treated to decrease their hydrocarbon content. The treatment may be carried out in a single reactor, or by carrying out up to all steps after catalyst may be withdrawn from a reactor and returned to at least one reactor, both preferably during operations. Up to all steps may be effected in a subsequent reactor, or in specialized apparatus.

Abstract: A process for enhancing metal catalysts for carbon monoxide hydrogenation comprising reducing the catalyst so that at least a portion is in the metallic state, impregnating under a non-oxidative atmosphere with a solution of a salt of at least one metal, optionally in combination with at least one of an ammonium salt, an alkyl ammonium salt, a weak organic acid and ammonia, oxidizing with a gaseous oxidant in the presence of the impregnating solution, and reducing to form an active catalyst. Used catalysts enhanced by the process are initially treated to decrease their hydrocarbon content. The treatment may be carried out in a single reactor, or by carrying out up to all steps after catalyst may be withdrawn from a reactor and returned to at least one reactor, both preferably during operations. Up to all steps may be effected in a subsequent reactor, or in specialized apparatus.

Abstract: A hydrocarbon wax product from a HCS slurry comprising liquid synthesis product and catalyst particles is purified by circulating the slurry from a synthesis zone with a first temperature through a treatment zone with a second temperature in which a hydrogen-containing treatment gas contacts the slurry. The gas treatment removes impurities from the hydrocarbon wax product and also removes catalyst de-activating species which may be present in the slurry. Purified wax product is separated and removed from the treated slurry via wax withdrawal means. This avoids or minimizes the need for further treating the wax product. Remaining treated slurry may be returned to the synthesis zone.

Abstract: A process for increasing the hydrogenation activity, particularly the carbon monoxide hydrogenation activity, of a catalyst or catalyst precursor comprised of a particulate solids support component and a catalytic metal, or metals component, preferably cobalt; cobalt alone or cobalt and an additional metal, or metals added to promote or modify the reaction produced by the cobalt. Treatment of the catalyst, or catalyst precursor is conducted at low temperature ranging from ambient to about 275° C. sufficient to form on the surface of a catalyst precursor, e.g., a cobalt catalyst precursor, a cobalt metal hydroxide, low valence cobalt metal oxide, or mixture of cobalt metal hydroxide and low valence cobalt metal oxide. Sometimes also metallic metal, e.g., cobalt, is also formed, and dispersed on the surface of the support.

Abstract: A catalyst precursor comprising a composite of a solids support, or powder component, and a compound or salt of a metal, or metals component, inclusive of cobalt, is upon reduction rendered catalytically active for conducting hydrogenation reactions, especially carbon monoxide hydrogenation reactions by contact at low temperature with liquid water, or steam, or a mixture of liquid water and steam, sufficient to oxidize and convert the metal, or metals component of the catalyst precursor to a metal hydroxide, low oxygen-containing metal oxide, or mixture of metal hydroxide and low oxygen-containing metal oxide. On reduction, as may be produced by contact and treatment of the oxidized catalyst precursor with hydrogen, the now well dispersed oxide or hydroxylated catalytic metal, or metals component of the catalyst, is reduced to metallic metal, e.g., Co, and the catalyst thereby activated.

Abstract: A hydrocarbon wax product from a HCS slurry comprising liquid synthesis product and catalyst particles is purified by circulating the slurry from a synthesis zone with a first temperature through a treatment zone with a second temperature in which a hydrogen-containing treatment gas contacts the slurry. The gas treatment removes impurities from the hydrocarbon wax product and also removes catalyst de-activating species which may be present in the slurry. Purified wax product is separated and removed from the treated slurry via wax withdrawal means. This avoids or minimizes the need for further treating the wax product. Remaining treated slurry may be returned to the synthesis zone.