Abstract: The present application relates to a Fischer-Tropsch catalyst body having an open-celled foam structure, said catalyst body comprising a substrate material and a catalytic active material or precursor thereof wherein:—The substrate material: ? is a metal alloy or ceramic material; ? having a surface roughness of 50 ?m or more; ? has an open-celled foam structure with at least 15 pores per inch; and—The catalytically active material or precursor thereof which: ? is present on the surface of the substrate material; ? comprises cobalt, iron, ruthenium or a combination thereof; and ? comprises a catalyst support selected from titania, alumina or silica.

Abstract: The present application relates to a process for producing normally gaseous, normally liquid, and optionally normally solid hydrocarbons from synthesis gas in a three-phase reactor, said reactor comprising a top middle and bottom part wherein the bottom and top part are fluidly connected via one or more reactor tubes, wherein one or more reactor tubes comprise randomly stacked catalyst bodies held stationary in the reactor tube and the reactor is at least partially filled with a liquid medium, said process comprising the steps of: (i) introducing the synthesis gas into the reactor via the bottom part; and (ii) contacting the synthesis gas with a stationary catalyst to catalytically convert the synthesis gas at an elevated temperature to obtain the normally gaseous, normally liquid, and optionally normally solid hydrocarbons from synthesis gas; (iii) withdrawing the normally gaseous, normally liquid, and optionally normally solid hydrocarbons; wherein the catalyst bodies have an open celled foam structure.

Abstract: The present application relates to a process for producing normally gaseous, normally liquid, and optionally normally solid hydrocarbons from synthesis gas in a three-phase reactor, said reactor comprising a top middle and bottom part wherein the bottom and top part are fluidly connected via one or more reactor tubes, wherein one or more reactor tubes comprise randomly stacked catalyst bodies held stationary in the reactor tube and the reactor is at least partially filled with a liquid medium, said process comprising the steps of: (i) introducing the synthesis gas into the reactor via the bottom part; and (ii) contacting the synthesis gas with a stationary catalyst to catalytically convert the synthesis gas at an elevated temperature to obtain the normally gaseous, normally liquid, and optionally normally solid hydrocarbons from synthesis gas; (iii) withdrawing the normally gaseous, normally liquid, and optionally normally solid hydrocarbons; wherein the catalyst bodies have an open celled foam structure.

Abstract: The Fischer-Tropsch process can be used for the conversion of hydrocarbonaceous feed stocks into normally liquid and/or solid hydrocarbons. The feed stock (e.g. natural gas, associated gas and/or coal-bed methane, coal) is converted in a first step into a mixture of hydrogen and carbon monoxide (this mixture is often referred to as synthesis gas or syngas). The synthesis gas (or syngas) is then converted in one or more steps over a suitable catalyst at elevated temperature and pressure into paraffinic compounds ranging from methane to high molecular weight molecules comprising up to 200 carbon atoms, or, under particular circumstances, even more. The present invention relates to a catalyst, a method for manufacturing said catalyst. The present invention further relates to a catalyst obtainable by said method. The present invention further relates to a multi tubular reactor comprising said catalyst.

Abstract: The present application relates to a Fischer-Tropsch catalyst body having an open-celled foam structure, said catalyst body comprising a substrate material and a catalytic active material or precursor thereof wherein: —The substrate material: ?is a metal alloy or ceramic material; ?having a surface roughness of 50 ?m or more; ?has an open-celled foam structure with at least 15 pores per inch; and —The catalytically active material or precursor thereof which: ?is present on the surface of the substrate material; ?comprises cobalt, iron, ruthenium or a combination thereof; and ?comprises a catalyst support selected from titania, alumina or silica.

Abstract: The Fischer-Tropsch process can be used for the conversion of hydrocarbonaceous feed stocks into normally liquid and/or solid hydrocarbons. The feed stock (e.g. natural gas, associated gas and/or coal-bed methane, coal) is converted in a first step into a mixture of hydrogen and carbon monoxide (this mixture is often referred to as synthesis gas or syngas). The synthesis gas (or syngas) is then converted in one or more steps over a suitable catalyst at elevated temperature and pressure into paraffinic compounds ranging from methane to high molecular weight molecules comprising up to 200 carbon atoms, or, under particular circumstances, even more. The present invention relates to a catalyst, a method for manufacturing said catalyst. The present invention further relates to a catalyst obtainable by said method. The present invention further relates to a multi tubular reactor comprising said catalyst.

Abstract: The present invention relates to a process for the conversion of cobalt(II)hydroxide into cobalt(III)oxidehydroxide (CoOOH) by reaction of the cobalt(II)hydroxide with oxygen in the presence of certain metal compounds. The invention further relates to the use of cobalt(III)oxidehydroxide thus prepared in the preparation of catalysts or catalysts precursors, especially catalysts or catalyst precursors for the conversion of synthesis gas into normally liquid and normally solid hydrocarbons and to normally liquid or solid hydrocarbons, optionally after additional hydrotreatment, obtained in such a conversion process.

Abstract: A process for the preparation of a catalyst or catalyst precursor, comprising the steps of: (a) admixing: (i) a catalytically active metal or metal compound (ii) a carrier material (iii) a gluing agent; and (iv) optionally one or more promoters, and/or one or more co-catalysts; (b) forming the mixture of step (a); and (c) drying the product of step (b) for more than 5 hours at a temperature up to 100 C to form the catalyst or catalyst precursor. The catalyst material mixture does not need to be calcined after forming to achieve the required minimum strength for use in a suitable reaction, such as Fischer Tropsch.

Abstract: The present invention provides a catalyst carrier, catalyst and catalyst precursor comprising a refractory metal oxide and support structure comprising a wire gauze having between 1002 to 6002 openings per inch2, and having a wire thickness in the range of 20 micrometer to 110 micrometer. The volume of the support structure is less than 50% of the volume of the catalyst carrier and at least 70% of said openings are filled with the refractory metal oxide.

Abstract: The invention relates to a process for preparing a catalyst. The process allows the delamination of layered crystals which are used as a starting material for a catalyst. The starting material is subsequently converted into an active portion of a catalyst with an increased dispersion resulting in a higher activity. Preferred delaminating agents are di-carboxylic acids and one particular example is citric acid. Preferably at least 0.75 wt %, more preferably at least 1.5 wt % of a delaminating agent is added to the catalyst starting material.

Abstract: The present invention provides a catalyst carrier, catalyst and catalyst precursor comprising a refractory metal oxide and support structure comprising a wire gauze having between 1002 to 6002 openings per inch2, and having a wire thickness in the range of 20 micrometer to 110 micrometer. The volume of the support structure is less than 50% of the volume of the catalyst carrier and at least 70% of said openings are filled with the refractory metal oxide.

Abstract: A method of manufacturing a catalyst, a catalyst precursor, or a catalyst support comprising: (a) mixing a refractory metal oxide or precursor thereof with a liquid to form a paste; (b) adding said paste to an extruder, the extruder having a die plate comprising one or more dies, each die having a plurality of apertures, the outlet of each aperture having a cross sectional area of 6 mm2 or less; (c) extruding the paste through the apertures to form catalyst support extrudates; wherein the inlet of the apertures has a greater cross sectional area than the outlet of said apertures; and wherein for at least one die the combined cross sectional area of all apertures at the inlet relative to the total cross sectional area of the die at the inlet is higher than 50%.

Abstract: A process for the preparation of a titania catalyst or a titania catalyst carrier is described. It comprises the steps of: obtaining a wet filtercake of titania, the titania having been made by hydrolysis of a suitable titanium compound, optionally admixing the wet filtercake with one or more catalyst materials, extruding said filtercake or said admixture, and drying and/or calcining the so-formed extrudate. The wet filtercake of titania can be provided from any known route or source or reaction. These include the the wet chloride or sulphate processes. The present invention removes the need for current separate drying and calcination of the titania sulphate product prior to its admixture with a catalyst material. It provides a catalyst with increased strength, which catalyst has also been found to provide greater catalytic activity, especially in C5+ selectivity.

Abstract: A process for the preparation of a catalyst or catalyst precursor, comprising the steps of: (a) admixing: (i) a catalytically active metal or metal compound (ii) a carrier material (iii) a gluing agent; and (iv) optionally one or more promoters, and/or one or more co-catalysts; (b) forming the mixture of step (a); and (c) drying the product of step (b) for more than 5 hours at a temperature up to 100 C to form the catalyst or catalyst precursor. The catalyst material mixture does not need to be calcined after forming to achieve the required minimum strength for use in a suitable reaction, such as Fischer Tropsch.

Abstract: A method of manufacturing a catalyst, a catalyst precursor, or a catalyst support comprising: (a) mixing a refractory metal oxide or precursor thereof with a liquid to form a paste; (b) adding said paste to an extruder, the extruder having a die plate comprising one or more dies, each die having a plurality of apertures, the outlet of each aperture having a cross sectional area of 6 mm2 or less; (c) extruding the paste through the apertures to form catalyst support extrudates; wherein the inlet of the apertures has a greater cross sectional area than the outlet of said apertures; and wherein for at least one die the combined cross sectional area of all apertures at the inlet relative to the total cross sectional area of the die at the inlet is higher than 50%.

Abstract: This invention relates to a process for preparing a catalyst. The process allows the delamination of layered crystals which are used as a starting material for a catalyst. The starting material is subsequently converted into an active portion of a catalyst with an increased dispersion resulting in a higher activity. Preferred delaminating agents are di-carboxylic acids and one particular example is citric acid. Preferably at least 0.75 wt %, more preferably at least 1.5 wt % of a delaminating agent is added to the catalyst starting material.