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: The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions to prepare synthesis gas and ultimately C5+ hydrocarbons. In particular, preferred embodiments of the present invention comprise catalyst systems comprising a core and an outer region disposed on said core, wherein a substantial amount of the catalytic metal is located in the outer region of the catalyst support matrix. In addition, the catalyst systems are able to maintain high conversion and selectivity values with very low catalytically active metal loadings. The catalyst systems are appropriate for improved syngas, oxidative dehydrogenation and other partial oxidation reactions, including improved reaction schemes for the conversion of hydrocarbon gas to C5+ hydrocarbons.

Abstract: An effective catalyst includes an amorphous silica-alumina support having a bimodal pore size-distribution. The support may be prepared by a method that includes the physical mixing of two silica-alumina gels prepared so as to have two different average pore sizes. The catalyst has the advantage that both metal dispersion on the support and product diffusion in the pores are optimized. Further, the catalyst has improved performance in the production of hydrocarbons from synthesis gas.

Abstract: A method is provided for forming a highly active Fischer-Tropsch catalyst using boehmite having a particular crystallite size. In this method, a support material comprising boehmite is contacted with a catalytic metal-containing compound to form a catalyst precursor. The boehmite is selected to have an average crystallite size in the range of from about 6 nanometers (nm) to about 30 nm. An alternate embodiment uses a mixture of boehmites with various average crystallite sizes in the range of from about 4 nm to about 30 nm, differing by at least by 1 nm. Subsequently, the catalyst precursor is calcined to convert the boehmite to a stabilized aluminum oxide structure, thereby forming a catalyst support having a good attrition resistance and a relatively high hydrothermal stability.

Abstract: A catalyst and method for producing hydrocarbons using a catalyst support having an improved hydrothermal stability, such as under Fischer-Tropsch synthesis conditions. The stabilized support is made by a method comprising treating a boehmite material in contact with at least one structural stabilizer. Contacting the boehmite with at least one structural stabilizer can include forming a mixture comprising the boehmite material and at the least one structural stabilizer. The mixture can be a sol or a slurry. The treating preferably includes drying or spray drying the mixture, and calcining in an oxidizing atmosphere to obtain the stabilized support. Preferred structural stabilizers can include an element, such as cobalt, magnesium, zirconium, boron, aluminum, barium, silicon, lanthanum, oxides thereof, or combinations thereof; or can include precipitated oxides, such as a co-precipitated silica-alumina.

Abstract: The present invention presents an iron-based Fischer-Tropsch catalyst having a low water-gas shift activity and high selectivity and productivity toward a hydrocarbon wax wherein said catalyst comprises iron; silver; sodium, lithium, potassium, rubidium and/or cesium; optionally, calcium, magnesium, boron, and/or aluminum; and a silica structural promoter. The present invention further presents a method of making a precipitated iron-based Fischer-Tropsch catalyst. The present invention still further presents a process for producing hydrocarbons using the iron-based, precipitated Fischer-Tropsch catalyst of the present invention.

Abstract: According to a preferred embodiment, the present invention features a bulk catalyst that includes precipitated cobalt metal. The precipitated cobalt catalyst further includes a textural promoter, a binder and optionally a Group I metal. The method of making the catalyst is optimized so as to enhance attrition resistance and improve activity. According to some embodiments, the present catalyst is made by a method that includes one or a combination of: calcination under optimized temperature conditions; exposure to an acidic solution; and addition of a binder to a suspension of a precipitate. According to some embodiments, a Fischer-Tropsch process includes contacting the present catalyst with a feed stream containing carbon monoxide and hydrogen so as to produce hydrocarbons.

Abstract: A method for making a catalyst is provided that features loading a catalytic metal to a support using at least two different precursor compounds of that said metal; and loading the promoter to the support in an amount effective so as to achieve similar promotion as for a comparable catalyst comprising a greater amount of the promoter using only one precursor compound, where the catalytic metal is selected from among Group 8 metals, 9 metal, Group 10 metals, and combinations thereof. The promoter is preferably boron, silver, a noble metal, or combination thereof. Also provided are catalysts made by the method and Fischer-Tropsch processes that include contacting synthesis gas with a catalyst made by the method.

Abstract: A hydrothermally-stable catalyst, method for making the same, and process for producing hydrocarbon, wherein the catalyst is used in synthesis gas conversion to hydrocarbons. In one embodiment, the method comprises depositing a compound of a catalytic metal selected from Groups 8, 9, and 10 of the Periodic Table on a support material comprising boehmite to form a composite material; and calcining the composite material to form the catalyst. In other embodiments, the support material comprises synthetic boehmite, natural boehmite, pseudo-boehmite, or combinations thereof.

Abstract: An amorphous support, methods for making the same and methods of using, particularly in hydrocracking. A method of making may comprise mixing a first amorphous material and a second amorphous material of different acidities to form a mixture, and treating by either separately treating the first and second amorphous materials before mixing or treating the mixture, so as to form an amorphous catalyst support. Treating preferably includes calcining. The acidity of the amorphous support may be modified by the different acidities of the precursor amorphous materials, their proportions in the mixture, and/or the order of the mixing and treating steps. A method of use may comprise reacting a hydrocarbon fraction with hydrogen over a hydrocracking catalyst comprising the amorphous catalyst support to form a hydrocracked product. Further embodiments include the first and second amorphous materials comprising silica-alumina, and/or differing in Brönsted acidity, Lewis acidity, or acidity index.

Abstract: The invention generally relates to methods for modifying a porous amorphous material comprising micropores to reduce its micropore volume and to form a support for a hydroprocessing catalyst, to methods of making said catalyst, as well as to methods for hydrocracking employing said hydroprocessing catalyst characterized by a lower selectivity towards undesirable gaseous hydrocarbon products. In one embodiment, the method for modifying the amorphous material comprises depositing an inorganic oxide or inorganic oxide precursor to the amorphous material; and treating the deposited amorphous material so as to reduce its micropore volume by at least about 5 percent, while its mean pore diameter is substantially unchanged or changed by not more than about 10 percent. Further embodiments include the amorphous material comprising silica-alumina, and the deposited inorganic oxide or inorganic oxide precursor comprising silicon.

Abstract: A stabilized catalyst support having improved hydrothermal stability, catalyst made therefrom, and method for producing hydrocarbons from synthesis gas using said catalyst. The stabilized support is made by a method comprising treating a crystalline hydrous alumina precursor in contact with at least one structural stabilizer or compound thereof. The crystalline hydrous alumina precursor preferably includes an average crystallite size selected from an optimum range delimited by desired hydrothermal resistance and desired porosity. The crystalline hydrous alumina precursor preferably includes an alumina hydroxide, such as crystalline boehmite, crystalline bayerite, or a plurality thereof differing in average crystallite sizes by at least about 1 nm. The crystalline hydrous alumina precursor may be shaped before or after contact with the structural stabilizer or compound thereof. The treating includes calcining at 450° C. or more.

Abstract: This invention relates to catalysts comprising a catalytic metal deposited on a composite support with well-dispersed chemical “anchor” species acting as nucleation centers for catalytic metal crystallites growth. The catalysts have the advantage that the average catalytic metal crystallite size can be controlled by the molar ratio of catalytic metal to chemical “anchor,” and is not limited by the porous structure of the support. A preferred embodiment comprises a cobalt-based catalyst on a silica-alumina support made by a co-gel method, wherein its average pore size can be controlled by the pH. The alumina species in the support most likely serve as chemical “anchors” to control the dispersion of cobalt species, such that the average cobalt crystallite size can be greater than the average pore size.

Abstract: A method for making a catalyst is provided that features loading a catalytic metal to a support using at least two different precursor compounds of that said metal; and loading the promoter to the support in an amount effective so as to achieve similar promotion as for a comparable catalyst comprising a greater amount of the promoter using only one precursor compound, where the catalytic metal is selected from among Group 8 metals, 9 metal, Group 10 metals, and combinations thereof. The promoter is preferably boron, silver, a noble metal, or combination thereof. Also provided are catalysts made by the method and Fischer-Tropsch processes that include contacting synthesis gas with a catalyst made by the method.

Abstract: An effective catalyst includes an amorphous silica-alumina support having a bimodal pore size-distribution. The support may be prepared by a method that includes the physical mixing of two silica-alumina gels prepared so as to have two different average pore sizes. The catalyst has the advantage that both metal dispersion on the support and product diffusion in the pores are optimized. Further, the catalyst has improved performance in the production of hydrocarbons from synthesis gas.

Abstract: A catalytic partial oxidation process for producing synthesis gas is disclosed which comprises passing a light hydrocarbon and oxygen mixture over a composite catalyst to produce a mixture of carbon monoxide and hydrogen. Preferred composite catalysts are prepared by mixing together discrete particles of catalytic metal and of promoter. The resulting catalyst resists deactivation due to reaction between the active metal and the promoter. A catalyst and method for making a catalyst and a method for making middle distillates from light hydrocarbons are also disclosed.

Abstract: According to a preferred embodiment, the present invention features a bulk catalyst that includes precipitated cobalt metal. The precipitated cobalt catalyst further includes a textural promoter, a binder and optionally a Group I metal. The method of making the catalyst is optimized so as to enhance attrition resistance and improve activity. According to some embodiments, the present catalyst is made by a method that includes one or a combination of: calcination under optimized temperature conditions; exposure to an acidic solution; and addition of a binder to a suspension of a precipitate. According to some embodiments, a Fischer-Tropsch process includes contacting the present catalyst with a feed stream containing carbon monoxide and hydrogen so as to produce hydrocarbons.

Abstract: A method for making a catalyst is provided that features loading a catalytic metal to a support using at least two different precursor compounds of that said metal; and loading the promoter to the support in an amount effective so as to achieve similar promotion as for a comparable catalyst comprising a greater amount of the promoter using only one precursor compound, where the catalytic metal is selected from among Group 8 metals, 9 metal, Group 10 metals, and combinations thereof. The promoter is preferably boron, silver, a noble metal, or combination thereof. Also provided are catalysts made by the method and Fischer-Tropsch processes that include contacting synthesis gas with a catalyst made by the method.

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: The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions to prepare synthesis gas and ultimately C5+ hydrocarbons. In particular, preferred embodiments of the present invention comprise catalyst systems comprising a core and an outer region disposed on said core, wherein a substantial amount of the catalytic metal is located in the outer region of the catalyst support matrix. In addition, the catalyst systems are able to maintain high conversion and selectivity values with very low catalytically active metal loadings. The catalyst systems are appropriate for improved syngas, oxidative dehydrogenation and other partial oxidation reactions, including improved reaction schemes for the conversion of hydrocarbon gas to C5+ hydrocarbons.