Abstract: Disclosed are hybrid synthesis gas conversion catalysts containing at least one Fischer-Tropsch component and at least one acidic component deposited on a monolith catalyst support for use in synthesis gas conversion processes and methods for preparing the catalysts. Also disclosed are synthesis gas conversion processes in which the hybrid synthesis gas conversion catalysts are contacted with synthesis gas to produce a hydrocarbon product containing at least 50 wt % C5+ hydrocarbons. Also disclosed are synthesis gas conversion processes in which at least one layer of Fischer-Tropsch component deposited onto a monolith support is alternated with at least one layer of acidic component in a fixed bed reactor.

Abstract: A process is described for converting synthesis gas containing carbon monoxide and hydrogen to hydrocarbons via methanol as an intermediate, by contacting the synthesis gas with a catalyst system containing a mixture of gallium silicate zeolite catalyst and a methanol catalyst. The process results in reduced amounts of undesirable low carbon number hydrocarbons, e.g., C4 and lower, undesirable high carbon number hydrocarbons, e.g., C10 and higher, and aromatic hydrocarbons. The process provides higher yields of useful, high octane hydrocarbons boiling in the gasoline range.