Abstract: Methods for discovering optimum catalysts and/or reaction conditions for performing endo-or exothermic reactions, in particular gas-to-liquid reactions, are disclosed. A combinatorial approach is used to identify optimum catalysts and/or reaction conditions for performing the reactions. The reactions are performed in the channels of a microchannel reactor. These results can be used directly to optimize large scale reactions performed in a plurality of microchannel reactors, or can be correlated to useful catalysts and reaction conditions for use in large scale reactors by taking into consideration the heat transfer effects in the microchannel reactor and the large scale reactor. The method can advantageously be used to generate a database of combinations of catalyst systems and/or reaction conditions which provide various product streams, such that as market conditions vary and/or product requirements change, conditions suitable for forming desired products can be identified with little or no downtime.

Abstract: Methods for converting of syngas to higher molecular weight products using Fischer-Tropsch synthesis, and methods for optimizing the catalyst systems in the synthesis, are disclosed. In one embodiment, the methods use cobalt/ruthenium Fischer-Tropsch catalysts in combination with an olefin isomerization catalyst, which isomerizes double bonds in C4+ olefins as they are formed. In another embodiment, the methods use Fischer-Tropsch catalysts that may or may not be cobalt/ruthenium catalysts, in combination with olefin isomerization catalysts which are acidic enough to isomerize the C4+ olefins but not too acidic to cause rapid coking. A benefit of using the relatively less acidic zeolites is that the ratio of iso-paraffins to aromatics is increased relative to when more acidic zeolites are used. Also, the relatively less acidic zeolites do not coke as readily as the relatively more acidic zeolites.

Abstract: An integrated process for producing liquid fuels from syngas via a two-stage Fischer-Tropsch reaction is disclosed. The first stage of the Fischer-Tropsch chemistry is performed using conditions in which chain growth probabilities are relatively low to moderate, and the product of the reaction includes a relatively high proportion of low molecular (C2-8) weight olefins and a relatively low proportion of high molecular weight (C30+) waxes. The product from the first stage is fed into the second stage where the chain growth probabilities are relatively high. The wax and other paraffins produced in the first reaction are largely inert under these conditions. The light olefins compete with heavier olefins for chain initiation, and fewer chains will be initiated at C20+. With most chains initiated at C2-8, moderate chain growth probability will produce a relatively larger fraction in the C5-12 range. In this manner, wax yield is minimized.

Abstract: Methods for discovering optimum catalyst systems for the conversion of syngas to higher molecular weight products via Fischer-Tropsch synthesis are disclosed. A combinatorial approach is used to identify combinations of catalyst systems useful for performing the reactions. The combinations of catalyst systems include Fischer-Tropsch catalysts and olefin isomerization catalysts. The method can advantageously be used to generate a database of combinations of catalyst systems and/or reaction conditions that provide various product streams, such that as market conditions vary and/or product requirements change, conditions suitable for forming desired products can be identified with little or no downtime. The catalysts are combined in a logical manner, for example in the form of arrays.

Abstract: An integrated process for producing liquid fuels from syngas via a two-stage Fischer-Tropsch reaction is disclosed. The first stage of the Fischer-Tropsch chemistry is performed using conditions in which chain growth probabilities are relatively low to moderate, and the product of the reaction includes a relatively high proportion of low molecular (C2-8) weight olefins and a relatively low proportion of high molecular weight (C30+) waxes. The product from the first stage is fed into the second stage where the chain growth probabilities are relatively high. The wax and other paraffins produced in the first reaction are largely inert under these conditions. The light olefins compete with heavier olefins for chain initiation, and fewer chains will be initiated at C20+. With most chains initiated at C2-8, moderate chain growth probability will produce a relatively larger fraction in the C5-12 range. In this manner, wax yield is minimized.

Abstract: Salable hydrocarbon products prepared by reacting a light hydrocarbon gaseous stream with a gaseous oxidant to produce carbon oxides and hydrogen, which is contacted in a hydrocarbon synthesis zone to produce a product stream comprising salable hydrocarbon products. That product stream is separated into a gaseous fraction and at least one fraction of salable hydrocarbon products. The light hydrocarbon gaseous stream is formed by separating a light hydrocarbon gaseous feed comprising alkanes into a lighter fraction and a heavier fraction and contacting that heavier fraction in a disproportionation zone to convert a significant portion of the alkanes in the heavier fraction by disproportionation into both higher and lower alkanes, then at least part of the lighter fraction and the lower alkanes form the light hydrocarbon gaseous stream.

Abstract: An improved process is provided for adding a hydrogenation component to a non-zeolitic molecular sieve catalytic particulates with minimal loss in micropore volume for improved performance catalytic performance. The process includes adding an active source of the hydrogenation component dissolved in a non-aqueous solvent.

Abstract: Catalyst for synthesis gas conversion in which a gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon is prepared by subjecting cobalt or nickel on a refractory metal oxide support to an activation procedure at a temperature of from about 100.degree. to about 450.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

Abstract: A catalyst for the conversion of synthesis gas comprising cobalt on a high surface area, high purity, low acidity alumina support of gamma-alumina, eta-alumina or mixtures thereof, whereby the catalyst is prepared by (A) impregnation of the alumina support with a non-aqueous, organic solvent impregnation solution of cobalt nitrate containing sufficient amounts of a Group IIIB or IVB metal salt to provide said catalyst with from about 0.05 to about 100 parts by weight of a Group IIIB or IVB metal oxide per 100 parts by weight cobalt, (B) reduction of the impregnated alumina support by heating, in the presence of hydrogen, at a heating rate of from about 0.5.degree. to about 5.degree. C. per minute to a maximum temperature in the range of 180.degree. to about 220.degree. C. for a hold time of 6 to about 24 hours and thereafter heating the impregnated alumina support in the presence of hydrogen while heating up to a maximum hold temperature of from about 250.degree. to about 400.degree. C.

Abstract: Synthesis gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon by contacting the synthesis gas under conversion conditions with a catalyst prepared by subjecting a cobalt carbonyl-impregnated alumina or silica support to an activation procedure at a temperature not exceeding 500.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

Abstract: Synthesis gas is converted to straight chain paraffins boiling in the diesel fuel boiling range utilizing a catalyst consisting essentially of cobalt and a Group IIIB or IVB metal oxide on an alumina support of gamma-alumina, eta-alumina or mixtures thereof wherein the catalyst has a hydrogen chemisorption value of between about 100 and about 300 micromol per gram.

Abstract: Synthesis gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon by contacting the synthesis gas under conversion conditions with a catalyst prepared by subjecting a cobalt carbonyl-impregnated alumina or silica support to an activation procedure at a temperature not exceeding 500.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

Abstract: Synthesis gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon by contacting the synthesis gas under conversion conditions with a catalyst prepared by subjecting cobalt or nickel on a refractory metal oxide support to an activation procedure at a temperature below 500.degree. C. comprising, in sequence, (A) reduction in hydrogen, (B) oxidation in an oxygen-containing gas, and (C) reduction in hydrogen.

Abstract: Synthesis gas is converted to diesel fuel and a high octane gasoline in two stages. In the first stage the synthesis gas is converted to straight chain paraffins mainly boiling in the diesel fuel boiling range utilizing a catalyst consisting essentially of cobalt, preferably promoted with a Group IIIB or IVB metal oxide, on a support of gamma-alumina, eta-alumina or mixtures thereof. A straight chain paraffin portion of the effluent in the C.sub.5 -C.sub.9 range is converted in a second stage to a highly aromatic and branched chain paraffinic gasoline using a platinum group metal catalyst.

Abstract: Synthesis gas comprising carbon monoxide and hydrogen is converted to a liquid hydrocarbon by contacting the synthesis gas under conversion conditions with a supported cobalt-ruthenium catalyst in which the cobalt to ruthenium molar ratio is greater than about 200:1. The catalyst is preferably prepared by using a non-aqueous impregnation solution and using an activation procedure involving reduction, oxidation and reduction.

Abstract: Synthesis gas conversion catalyst prepared from synthetic layered aluminosilicate having a montmorillonite-type structure and containing cobalt substituted in the crystal lattice are activated for the conversion of synthesis gas by a sequential reduction, oxidation and reduction treatment. A Group VIII noble metal such as ruthenium can be impregnated on the catalyst prior to the final reduction stage. The catalyst is used in the production of liquid hydrocarbons from synthesis gas.

Abstract: A catalyst useful in the conversion of synthesis gas to diesel fuel in a fluidized bed is prepared by contacting finely divided alumina with an aqueous impregnation solution of a cobalt salt, drying the impregnated support and thereafter contacting the support with a nonaqueous, organic impregnation solution of salts of ruthenium and a Group IIIB or IVB metal.

Abstract: A process for converting synthesis gas to liquid hydrocarbons using a catalyst prepared from synthetic layered aluminosilicate having a montmorillonite-type structure and containing cobalt substituted in the crystal lattice and activated for the conversion by a sequential reduction, oxidation and reduction treatment.

Abstract: A catalyst useful in the conversion of synthesis gas to diesel fuel in a fluidized bed is prepared by contacting finely divided alumina with an aqueous impregnation solution of a cobalt salt, drying the impregnated support and thereafter contacting the support with a nonaqueous, organic impregnation solution of salts of ruthenium and a Group IIIB or IVB metal.

Abstract: Synthesis gas is converted to a gasoline boiling range product high in branched chain paraffins and olefins utilizing a catalyst consisting essentially of (A) silicalite and (B) cobalt, preferably promoted with a Group IIIB or IVB metal oxide on an alumina support of gamma-alumina, eta-alumina or mixtures thereof.