Abstract: Disclosed are solid titanium-free Fischer-Tropsch catalysts including iron homogeneously modified with a zirconium promoter/stabilizer. The homogeneously mixed solid catalysts can be formed through co-precipitation of iron and zirconium precursors followed by calcination and reduction to form the active catalyst materials. The catalysts can optionally include additional materials such as copper, potassium, and silicon promoters.

Abstract: An attrition resistant precipitated bulk iron catalyst is prepared from iron oxide precursor and a binder by spray drying. The catalysts are preferably used in carbon monoxide hydrogenation processes such as Fischer-Tropsch synthesis. These catalysts are suitable for use in fluidized-bed reactors, transport reactors and, especially, slurry bubble column reactors.

Abstract: A ?-alumina catalyst support having improved attrition resistance produced by a method comprising the steps of treating a particulate ?-alumina material with an acidic aqueous solution comprising water and nitric acid and then, prior to adding any catalytic material thereto, calcining the treated ?-alumina.

Abstract: An attrition resistant precipitated bulk iron catalyst is prepared from iron oxide precursor and a binder by spray drying. The catalysts are preferably used in carbon monoxide hydrogenation processes such as Fischer-Tropsch synthesis. These catalysts are suitable for use in fluidized-bed reactors, transport reactors, and, especially, slurry bubble column reactors.

Abstract: A method for reducing catalyst attrition losses in hydrocarbon synthesis processes conducted in high agitation reaction systems; a method of producing an attrition-resistant catalyst; a catalyst produced by such method; a method of producing an attrition-resistant catalyst support; and a catalyst support produced by such method. The inventive method of reducing catalyst attrition losses comprises the step of reacting a synthesis gas in a high agitation reaction system in the presence of a catalyst. In one aspect, the catalyst preferably comprises a &ggr;-alumina support including an amount of titanium effective for increasing the attrition resistance of the catalyst. In another aspect, the catalyst preferably comprises a &ggr;-alumina support which has been treated, after calcination, with an acidic, aqueous solution. The acidic aqueous solution preferably has a pH of not more than about 5.

Abstract: A catalyst support having improved attrition resistance and a catalyst produced therefrom. The catalyst support is produced by a method comprising the step of treating calcined &ggr;-alumina having no catalytic material added thereto with an acidic aqueous solution having an acidity level effective for increasing the attrition resistance of the calcined &ggr;-alumina.

Abstract: A method for reducing catalyst attrition losses in hydrocarbon synthesis processes conducted in high agitation reaction systems; a method of producing an attrition-resistant catalyst; a catalyst produced by such method; a method of producing an attrition-resistant catalyst support; and a catalyst support produced by such method. The inventive method of reducing catalyst attrition losses comprises the step of reacting a synthesis gas in a high agitation reaction system in the presence of a catalyst. In one aspect, the catalyst preferably comprises a &ggr;-alumina support including an amount of titanium effective for increasing the attrition resistance of the catalyst. In another aspect, the catalyst preferably comprises a &ggr;-alumina support which has been treated, after calcination, with an acidic, aqueous solution. The acidic aqueous solution preferably has a pH of not more than about 5.

Abstract: Cobalt catalysts, and processes employing these inventive catalysts, for hydrocarbon synthesis. The inventive catalyst comprises cobalt on an alumina support and is not promoted with any noble or near noble metals. In one aspect of the invention, the alumina support preferably includes a dopant in an amount effective for increasing the activity of the inventive catalyst. The dopant is preferably a titanium dopant. In another aspect of the invention, the cobalt catalyst is preferably reduced in the presence of hydrogen at a water vapor partial pressure effective to increase the activity of the cobalt catalyst for hydrocarbon synthesis. The water vapor partial pressure is preferably in the range of from 0 to about 0.1 atmospheres.

Abstract: A method for reducing catalyst attrition losses in hydrocarbon synthesis processes conducted in high agitation reaction systems; a method of producing an attrition-resistant catalyst; a catalyst produced by such method; a method of producing an attrition-resistant catalyst support; and a catalyst support produced by such method. The inventive method of reducing catalyst attrition losses comprises the step of reacting a synthesis gas in a high agitation reaction system in the presence of a catalyst. In one aspect, the catalyst preferably comprises a &ggr;-alumina support including an amount of titanium effective for increasing the attrition resistance of the catalyst. In another aspect, the catalyst preferably comprises a &ggr;-alumina support which has been treated, after calcination, with an acidic, aqueous solution. The acidic aqueous solution preferably has a pH of not more than about 5.

Abstract: Cobalt catalysts, and processes employing these inventive catalysts, for hydrocarbon synthesis. The inventive catalyst comprises cobalt on an alumina support and is not promoted with any noble or near noble metals. In one aspect of the invention, the alumina support preferably includes a dopant in an amount effective for increasing the activity of the inventive catalyst. The dopant is preferably a titanium dopant. In another aspect of the invention, the cobalt catalyst is preferably reduced in the presence of hydrogen at a water vapor partial pressure effective to increase the activity of the cobalt catalyst for hydrocarbon synthesis. The water vapor partial pressure is preferably in the range of from 0 to about 0.1 atmospheres.

Abstract: Cobalt catalysts, and processes employing these inventive catalysts, for hydrocarbon synthesis. The inventive catalyst comprises cobalt on an alumina support and is not promoted with any noble or near noble metals. In one aspect of the invention, the alumina support preferably includes a dopant in an amount effective for increasing the activity of the inventive catalyst. The dopant is preferably a titanium dopant. In another aspect of the invention, the cobalt catalyst is preferably reduced in the presence of hydrogen at a water vapor partial pressure effective to increase the activity of the cobalt catalyst for hydrocarbon synthesis. The water vapor partial pressure is preferably in the range of from 0 to about 0.1 atmospheres.

Abstract: A process for hydrocarbon synthesis comprising the step of reacting a synthesis gas in the presence of a cobalt catalyst promoted with palladium.

Abstract: Processes and catalysts for conducting Fischer-Tropsch synthesis in a slurry bubble column reactor (SBCR). One aspect of the invention involves the use of cobalt catalysts without noble metal promotion in an SBCR. Another aspect involves using palladium promoted cobalt catalysts in an SBCR. Methods for preparing noble metal promoted catalysts via totally aqueous impregnation and procedures for producing attrition resistant catalysts are also provided.

Abstract: A process for converting synthesis gas, a mixture of hydrogen and carbon monoxide, into a mixture of predominately paraffinic hydrocarbons using a catalyst which includes catalytically active amounts of cobalt and a loading-insensitive second metal selected from the group consisting of platinum, iridium, rhodium and mixtures thereof, composited on an alumnia support. The finished catalyst exhibits a positive x-ray diffraction pattern. A metal oxide promoter may also be added.

Abstract: A catalyst for converting synthesis gas, a mixture of hydrogen and carbon monoxide, into a mixture of predominately paraffinic hydrocarbons. The catalyst includes catalytically active amounts of cobalt and a loading-insensitive second metal selected from the group consisting of platinum, iridium, rhodium and mixtures thereof, composited on an aluminia support. The finished catalyst exhibits a positive x-ray diffraction pattern. A metal oxide promoter may also be added.

Abstract: A catalyst for converting synthesis gas composed of hydrogen and carbon monoxide to hydrocarbons. The catalyst includes cobalt in catalytically active amounts up to about 60 wt % of the catalyst, rhenium in amounts of about 0.5 to 50 wt % of the cobalt content of the catalyst and an alkali in amounts ranging from about 0.5 to 5 atom percent of the cobalt content of the catalyst, supported on alumina. A metal oxide promoter may be added.

Abstract: A process for converting synthesis gas composed of hydrogen and carbon monoxide to hydrocarbons. The process includes the step of contacting at reaction conditions a synthesis gas feed to a catalyst which includes cobalt in catalytically active amounts up to about 60 wt % of the catalyst and rhenium in catalytically active amounts of about 0.5 to 50 wt % of the cobalt content of the catalyst supported on alumina. A metal oxide promoter may be added.

Abstract: A catalyst for converting synthesis gas composed of hydrogen and carbon monoxide to hydrocarbons. The catalyst includes cobalt in catalytically active amounts up to about 60 wt % of the catalyst and rhenium in catalytically active amounts of about 0.5 to 50 wt % of the cobalt content of the catalyst supported on alumina. A metal oxide promoter may be added.