Abstract: Disclosed is a process for converting synthesis gas to liquid hydrocarbon mixtures useful in the production of fuels and petrochemicals. The synthesis gas is contacted with at least two layers of synthesis gas conversion catalyst wherein each synthesis gas conversion catalyst layer is followed by a layer of hydrocracking catalyst and hydroisomerization catalyst or separate layers of hydrocracking and hydroisomerization catalysts. The process can occur within a single reactor, at an essentially common reactor temperature and an essentially common reactor pressure. The process provides a high yield of naphtha range liquid hydrocarbons and a low yield of wax.

Abstract: A process of form hydrocarbons boiling to the gasoline range and reducing or eliminating net CO2 production during isosynthesis over a ZnO—Cr2O3 plus ZSM-5 catalyst by adding from about 5% to about 15% CO2 to the synthesis gas mixture prior to contact to with catalyst.

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: A method is provided for converting synthesis gas to liquid hydrocarbon mixtures useful as distillate fuel and/or lube base oil containing no greater than about 25 wt % olefins and containing no greater than about 5 wt % C21+ normal paraffins. The synthesis gas is contacted with a synthesis gas conversion catalyst comprising a Fischer-Tropsch synthesis component and an acidic component in an upstream catalyst bed thereby producing a wax-free liquid containing a paraffin component and an olefin component. The olefin component is saturated by contacting the liquid with an olefin saturation catalyst in a downstream catalyst bed.

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: 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: 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: A method is provided for converting synthesis gas to liquid hydrocarbon mixtures useful as distillate fuel and/or lube base oil. The synthesis gas is contacted with a synthesis gas conversion catalyst comprising a Fischer-Tropsch synthesis component in an upstream catalyst bed thereby producing an intermediate hydrocarbon mixture containing olefins and C21+ normal paraffins. The intermediate hydrocarbon mixture is subsequently contacted with a hydroisomerization catalyst and an olefin saturation catalyst, thereby resulting in a product containing no greater than about 25 wt % olefins and containing no greater than about 5 wt % C21+ normal paraffins. The hydroisomerization and olefin saturation catalysts may be in separate beds or mixed in a single bed downstream of the synthesis gas conversion catalyst.

Abstract: A method for forming a cobalt-containing Fischer-Tropsch catalyst involves precipitating a cobalt oxy-hydroxycarbonate species by turbulent mixing, during which a basic solution collides with an acidic solution comprising cobalt. The method further involves depositing the cobalt oxy-hydroxycarbonate species onto an acidic support to provide a catalyst comprising cobalt and the acidic support. The acidic support comprises a zeolite, a molecular sieve, or combinations thereof.

Abstract: A method is disclosed for converting syngas to Fischer-Tropsch (F-T) hydrocarbon products. A synthesis gas including carbon monoxide and hydrogen gas is provided to a F-T reactor. Also, acetylene is supplied to the F-T reactor. The ratio of the volume of acetylene to the volume of synthesis gas is at least 0.01. The synthesis gas and acetylene are reacted under suitable reaction conditions and in the presence of a catalyst to produce F-T hydrocarbon products. The F-T hydrocarbon products are then recovered from the reactor. The synthesis gas and acetylene may be provided in a combined feed stream or introduced separately into the reactor. The acetylene enhanced syngas conversion in a F-T reactor results in the synthesis of F-T products which have a tighter distribution of intermediate length carbon products than do F-T products synthesized according to conventional methods.

Abstract: A method for forming a cobalt-containing Fischer-Tropsch catalyst involves precipitating a cobalt oxy-hydroxycarbonate species by turbulent mixing, during which a basic solution collides with an acidic solution comprising cobalt. The method further involves depositing the cobalt oxy-hydroxycarbonate species onto a support material to provide a catalyst comprising cobalt and the support material. The support material comprises one or more of alumina, silica, magnesia, titania, zirconia, ceria-zirconia, and magnesium aluminate.

Abstract: A method is disclosed for converting syngas to Fischer-Tropsch (F-T) hydrocarbon products. A synthesis gas including carbon monoxide and hydrogen gas is provided to a F-T reactor. Also, acetylene is supplied to the F-T reactor. The ratio of the volume of acetylene to the volume of synthesis gas is at least 0.01. The synthesis gas and acetylene are reacted under suitable reaction conditions and in the presence of a catalyst to produce F-T hydrocarbon products. The F-T hydrocarbon products are then recovered from the reactor. The synthesis gas and acetylene may be provided in a combined feed stream or introduced separately into the reactor. The acetylene enhanced syngas conversion in a F-T reactor results in the synthesis of F-T products which have a tighter distribution of intermediate length carbon products than do F-T products synthesized according to conventional methods.

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: 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 process for converting synthesis gas to liquid hydrocarbon mixtures useful in the production of fuels and petrochemicals. The synthesis gas is contacted with at least two layers of synthesis gas conversion catalyst wherein each synthesis gas conversion catalyst layer is followed by a layer of hydrocracking catalyst and hydroisomerization catalyst or separate layers of hydrocracking and hydroisomerization catalysts. The process can occur within a single reactor, at an essentially common reactor temperature and an essentially common reactor pressure. The process provides a high yield of naphtha range liquid hydrocarbons and a low yield of wax.

Abstract: A method is disclosed for converting syngas to Fischer-Tropsch (F-T) hydrocarbon products. A synthesis gas including carbon monoxide and hydrogen gas is provided to a F-T reactor. Also, acetylene is supplied to the F-T reactor. The ratio of the volume of acetylene to the volume of synthesis gas is at least 0.01. The synthesis gas and acetylene are reacted under suitable reaction conditions and in the presence of a catalyst to produce F-T hydrocarbon products. The F-T hydrocarbon products are then recovered from the reactor. The synthesis gas and acetylene may be provided in a combined feed stream or introduced separately into the reactor. The acetylene enhanced syngas conversion in a F-T reactor results in the synthesis of F-T products which have a tighter distribution of intermediate length carbon products than do F-T products synthesized according to conventional methods.

Abstract: A method is provided for converting synthesis gas to liquid hydrocarbon mixtures useful as distillate fuel and/or lube base oil containing no greater than about 25 wt % olefins and containing no greater than about 5 wt % C21+ normal paraffins. The synthesis gas is contacted with a synthesis gas conversion catalyst comprising a Fischer-Tropsch synthesis component and an acidic component in an upstream catalyst bed thereby producing a wax-free liquid containing a paraffin component and an olefin component. The olefin component is saturated by contacting the liquid with an olefin saturation catalyst in a downstream catalyst bed.

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: Disclosed is a process for converting synthesis gas to liquid hydrocarbon mixtures useful in the production of fuels and petrochemicals. The synthesis gas is contacted with at least two layers of synthesis gas conversion catalyst and at least two layers of acidic hydrocracking catalyst in an alternating layer arrangement within a single reactor tube wherein each synthesis gas conversion catalyst layer is followed by a layer of hydrocracking catalyst. The process is conducted within a single reactor at an essentially common reactor temperature and an essentially common reactor pressure. The process provides a high yield of naphtha range liquid hydrocarbons and a low yield of C21+ normal paraffins.

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.