Abstract: There is provided a process for renewing the activity of supported metal catalysts for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons comprising decreasing the hydrocarbon content of the catalyst, preferably by contact with hydrogen-containing gas at elevated temperatures, impregnating under a non-oxidizing atmosphere with a solution of at least one of an ammonium salt and an alkyl ammonium salt, optionally in combination with up to five moles of ammonia per liter of solution to the point where it has absorbed a volume of solution equal to at least about 10% of its calculated pore volume; oxidizing the catalyst with a gaseous oxidant in the presence of the impregnating solution and activating the catalyst by reduction with hydrogen at elevated temperatures. Optionally, the catalyst is calcined after the oxidation step, and passivated after the activation step.

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 The treatment may be carried out in a single reactor, or by carrying out up to all steps after catalyst may be withdrawn from a reactor and returned to at least one reactor, both preferably during operations.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: There is provided a process for renewing the activity of used, supported metal catalysts for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons comprising decreasing the hydrocarbon content of the catalyst, impregnating said catalyst under an non-oxidative atmosphere with a solution at least one weak organic acid, preferably a mono- or di-carboxylic acid, to the point where it has absorbed a volume of said solution equal to at least about 10% of its calculated pore volume, oxidizing the catalyst with a gaseous oxidant in the presence of the impregnating solution and activating the catalyst by reduction with hydrogen at elevated temperatures. Optionally, the catalyst is calcined after the oxidation step, and passivated after the activation step. A preferred means of decreasing the hydrocarbon content of the catalyst is contacting it with a hydrogen-containing gas at elevated temperatures.

Abstract: A process for activating a supported metal catalyst or catalyst precursor useful for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons, comprising reducing with a hydrogen-containing gas at elevated temperature so that at least a portion is in the metallic state, impregnating under a non-oxidizing atmosphere with a solution of at least one member selected from the group consisting of ammonium salts, alkyl ammonium salts and weak organic acids, optionally further including ammonia, to the point where it has absorbed a volume of solution equal to at least about 10% of its calculated pore volume, oxidizing with a gaseous oxidant in the presence of the impregnating solution and reducing with hydrogen-containing gas at elevated temperatures to form an active catalyst. The steps beginning with the impregnation may be repeated. Optionally, the catalyst may be calcined after the oxidation step and/or passivated after activation.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas in a synthesis reactor also hydroisomerizes the synthesized hydrocarbon liquid, which comprises the slurry liquid, in one or more lift reactors immersed in the slurry body in the synthesis reactor. A monolithic catalyst is preferably used for the hydroisomerization, and slurry circulation up through the lift reactors from the surrounding slurry body, is achieved at least in part by the lift action of the hydroisomerization treat gas. Preferably, catalyst particles are also removed before the slurry contacts the catalyst. Hydroisomerization occurs while the synthesis reactor is producing hydrocarbons, without interfering with the synthesis reaction. A gas bubble reducing downcomer may be used to produce and feed the gas bubble reduced slurry into the lift reactor, thereby providing a hydraulic head assist in the slurry circulation up through and out of the lift reactor.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas in a synthesis reactor also hydroisomerizes the synthesized hydrocarbons in one or more external lift reactor hydroisomerizing loops outside of the reactor, but which are a part of the reactor. A monolithic catalyst is used for the hydroisomerization and slurry circulation between the synthesis reactor and one or more loops is achieved, at least in part, by the lift action of a hydrogen treat gas injected into each loop.

Abstract: There is provided a process for renewing the activity of used, supported metal catalysts for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons comprising decreasing the hydrocarbon content of the catalyst, impregnating said catalyst under an non-oxidative atmosphere with a solution at least one weak organic acid, preferably a mono- or di-carboxylic acid, to the point where it has absorbed a volume of said solution equal to at least about 10% of its calculated pore volume, oxidizing the catalyst with a gaseous oxidant in the presence of the impregnating solution and activating the catalyst by reduction with hydrogen at elevated temperatures. Optionally, the catalyst is calcined after the oxidation step, and passivated after the activation step. A preferred means of decreasing the hydrocarbon content of the catalyst is contacting it with a hydrogen-containing gas at elevated temperatures.

Abstract: There is provided a process for renewing the activity of supported metal catalysts for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons comprising decreasing the hydrocarbon content of the catalyst, preferably by contact with hydrogen-containing gas at elevated temperatures, impregnating under a non-oxidizing atmosphere with a solution of at least one of an ammonium salt and an alkyl ammonium salt, optionally in combination with up to five moles of ammonia per liter of solution to the point where it has absorbed a volume of solution equal to at least about 10% of its calculated pore volume; oxidizing the catalyst with a gaseous oxidant in the presence of the impregnating solution and activating the catalyst by reduction with hydrogen at elevated temperatures. Optionally, the catalyst is calcined after the oxidation step, and passivated after the activation step.

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 activating a supported metal catalyst or catalyst precursor useful for the hydrogenation of carbon monoxide to form a mixture of hydrocarbons, comprising reducing with a hydrogen-containing gas at elevated temperature so that at least a portion is in the metallic state, impregnating under a non-oxidizing atmosphere with a solution of at least one member selected from the group consisting of ammonium salts, alkyl ammonium salts and weak organic acids, optionally further including ammonia, to the point where it has absorbed a volume of solution equal to at least about 10% of its calculated pore volume, oxidizing with a gaseous oxidant in the presence of the impregnating solution and reducing with hydrogen-containing gas at elevated temperatures to form an active catalyst. The steps beginning with the impregnation may be repeated. Optionally, the catalyst may be calcined after the oxidation step and/or passivated after activation.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas, in a hydrocarbon synthesis reactor, also hydroisomerizes the synthesized hydrocarbons in one or more external downcomer reactor hydroisomerizing loops outside of the reactor, but which are a part of the synthesis reactor. A monolithic catalyst is used for the hydroisomerization, and slurry circulation between the synthesis reactor and the one or more hydroisomerization loops is achieved, at least in part, by density-difference driven hydraulics created by removing gas bubbles from the slurry passed into the loop. Preferably, catalyst particles are also removed before the slurry contacts the monolithic hydroisomerization catalyst.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas in a synthesis reactor also hydroisomerizes the synthesized hydrocarbon liquid, which comprises the slurry liquid, in one or more lift reactors immersed in the slurry body in the synthesis reactor. A monolithic catalyst is preferably used for the hydroisomerization, and slurry circulation up through the lift reactors from the surrounding slurry body, is achieved at least in part by the lift action of the hydroisomerization treat gas. Preferably, catalyst particles are also removed before the slurry contacts the catalyst. Hydroisomerization occurs while the synthesis reactor is producing hydrocarbons, without interfering with the synthesis reaction. A gas bubble reducing downcomer may be used to produce and feed the gas bubble reduced slurry into the lift reactor, thereby providing a hydraulic head assist in the slurry circulation up through and out of the lift reactor.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas in a synthesis reactor also hydroisomerizes the synthesized hydrocarbons in one or more external lift reactor hydroisomerizing loops outside of the reactor, but which are a part of the reactor. A monolithic catalyst is used for the hydroisomerization and slurry circulation between the synthesis reactor and one or more loops is achieved, at least in part, by the lift action of a hydrogen treat gas injected into each loop.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas, in a hydrocarbon synthesis reactor, also hydroisomerizes the synthesized hydrocarbons in one or more external downcomer reactor hydroisomerizing loops outside of the reactor, but which are a part of the synthesis reactor. A monolithic catalyst is used for the hydroisomerization, and slurry circulation between the synthesis reactor and the one or more hydroisomerization loops is achieved, at least in part, by density-difference driven hydraulics created by removing gas bubbles from the slurry passed into the loop. Preferably, catalyst particles are also removed before the slurry contacts the monolithic hydroisomerization catalyst.

Abstract: A slurry Fischer-Tropsch hydrocarbon synthesis process for synthesizing liquid hydrocarbons from synthesis gas in a hydrocarbon synthesis reactor also hydroisomerizes the synthesized hydrocarbon liquid, which comprises the slurry liquid, in one or more downcomer reactors immersed in the slurry body in the synthesis reactor. A monolithic catalyst is preferably used for the hydroisomerization, and slurry circulation down through the downcomer reactors from the surrounding slurry body, is achieved at least in part by density-difference driven hydraulics created by removing gas bubbles from the slurry passed into the downcomers. Preferably, catalyst particles are also removed before the slurry contacts the catalyst. Hydroisomerization occurs while the synthesis reactor is producing hydrocarbons, without interfering with the hydrocarbon synthesis reaction.