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: Rhodium-spinel catalysts with activity for efficiently catalyzing the net partial oxidation of methane at high selectivities for CO and H2 products are disclosed, along with their method of making. A syngas production process employing such catalysts for the net catalytic partial oxidation of a C1-C5 hydrocarbon (e.g., natural gas or methane) to a product gas mixture comprising CO and H2 is also disclosed. Preferred reaction conditions include maintaining the catalyst at a temperature of about 400-1,200° C., superatmospheric pressure, and flow rate sufficient to pass the reactant gas mixture over the catalyst at space velocities of at least about 100,000-25,000,000 hr?1.

Abstract: Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and H2 and, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500° C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Abstract: The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions. In particular, preferred embodiments of the present invention comprise rare earth catalyst supports, catalyst compositions having rare earth supports, and methods of preparing and using the catalysts and supports. Accordingly, the present invention also encompasses an improved method for converting a hydrocarbon containing gas and an oxygen containing gas to a gas mixture comprising hydrogen and carbon monoxide, i.e., syngas, using the rare earth catalyst supports in accordance with the present invention. In addition, the present invention contemplates an improved method for converting hydrocarbon gas to liquid hydrocarbons using the novel syngas catalyst supports and compositions described herein.

Abstract: A pretreatment method for increasing the average pore size of a catalyst support is disclosed which increases the diffusivity and effectiveness factor ?. The pretreatment method includes calcining the support in moisturized air at an elevated temperature sufficient to increase the average pore size. In some embodiments, the support may be treated with an acidic/basic solution prior to the calcination step. Alternatively, the calcination step may occur in a gas mixture including water/air/acidic (or basic) gases.

Abstract: Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and H2 are disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and O2 is passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.

Abstract: Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

Abstract: Lanthanide-promoted rhodium-containing supported catalysts that are active for catalyzing the net partial oxidation of methane to CO and H2 are disclosed, along with their manner of making and high efficiency processes for producing synthesis gas employing the new catalysts. A preferred catalyst comprises highly dispersed, high surface area rhodium on a granular zirconia support with an intermediate coating of a lanthanide metal and/or oxide thereof and is thermally conditioned during catalyst preparation. In a preferred syngas production process a stream of methane-containing gas and O2 is passed over a thermally conditioned, high surface area Rh/Sm/zirconia granular catalyst in a short contact time reactor to produce a mixture of carbon monoxide and hydrogen.

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: The present invention relates to improved catalyst compositions, as well as methods of making and using such compositions. In particular, preferred embodiments of the present invention comprise rare earth catalyst supports, catalyst compositions having rare earth supports, and methods of preparing and using the catalysts and supports. Accordingly, the present invention also encompasses an improved method for converting a hydrocarbon containing gas and an oxygen containing gas to a gas mixture comprising hydrogen and carbon monoxide, i.e., syngas, using the rare earth catalyst supports in accordance with the present invention. In addition, the present invention contemplates an improved method for converting hydrocarbon gas to liquid hydrocarbons using the novel syngas catalyst supports and compositions described herein.

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: The present invention discloses synthesis gas catalysts, and methods for making such catalysts, that are active for promoting partial oxidation of light hydrocarbons to CO and H2. The catalysts comprise a support and an active metal. The catalysts may further comprise a promoter and halide or a rare earth oxyhalide. The present invention further discloses a method for producing synthesis gas by net partial oxidation of light hydrocarbons by contacting O2 and light hydrocarbons in the presence of a synthesis gas catalyst as previously described. The present invention also describes a method for extending the life of a synthesis gas catalyst by contacting the catalyst with a halide. A method for making middle distillates from light hydrocarbons by partial oxidation of light hydrocarbons over a synthesis gas catalyst as previously described and Fischer-Tropsch reaction is also disclosed.

Abstract: The present invention relates to thermally stable, high surface area alumina supports and method of preparing such supports with at least one modifying agent. The method includes adding the modifying agent to the alumina prior to calcining. More particularly, the invention relates to the use of such catalysts for the catalytic partial oxidation of light hydrocarbons (e.g., methane or natural gas) to produce primarily synthesis gas. The present invention further relates to gas-to-liquids conversion processes, more specifically for producing C5+ hydrocarbons.

Abstract: The present invention generally relates to catalysts comprising at least one oxidized active metal; at least one lanthanide; and a refractory support. The active metal is selected from the group consisting of rhodium, ruthenium, rhenium, platinum, palladium, iridium, and osmium. In particular, the present invention relates to catalysts effective for initiating and sustaining the partial oxidation of light hydrocarbons, preferably methane, to a product mixture comprising carbon monoxide and hydrogen, e.g. synthesis gas. The present invention still further discloses a method of making a supported synthesis gas catalyst comprising an oxidized metal and at least one lanthanide.

Abstract: A pretreatment method for increasing the average pore size of a catalyst support is disclosed which increases the diffusivity and effectiveness factor &eegr;. The pretreatment method includes calcining the support in moisturized air at an elevated temperature sufficient to increase the average pore size. In some embodiments, the support may be treated with an acidic/basic solution prior to the calcination step. Alternatively, the calcination step may occur in a gas mixture including water/air/acidic (or basic) gases.

Abstract: Embodiments include a method and apparatus for converting a hydrocarbon and oxygen feed stream to a product stream such as syngas, including multiple serially aligned reaction zones and multiple hydrocarbon feeds. The first reaction zone catalyzes the net partial oxidation of the feed hydrocarbon. The subsequent zones catalyze reactions such as the stream or dry reforming of hydrocarbons or the water gas shift reaction, depending on the stream composition in the vicinity of the zone, and the desired product stream composition.

Abstract: Controlled pore structure catalysts are disclosed that are active for catalyzing the partial oxidation of methane to CO and H2 and, advantageously, are capable of initiating the reaction without the need for an additional ignition source. A preferred catalyst comprises rhodium and samarium supported on an alumina or modified alumina support having certain surface area, pore volume, pore size and metal dispersion characteristics that permit light-off of the reaction at temperatures below 500° C. and with little or no use of an ignition agent. A method of partially oxidizing a light hydrocarbon to form synthesis gas, and a method of enhancing low-temperature light-off of the process are also described.

Abstract: Catalysts comprising promoted cobalt-chromium oxide disposed on a lanthanide coated refractory support that are active for catalyzing the net partial oxidation of methane or natural gas to products containing CO and H2 are disclosed, along with short contact time processes employing the new catalysts for producing synthesis gas. Preferred promoters are rhodium and cerium, and a preferred lanthanide coating material is ytterbium.

Abstract: A family of supported hexagonal phase mixed metal oxide catalysts are disclosed that have the general formula M2.5LnRh6O13 (expressed as atomic ratios), wherein M refers to Group II elements such as Mg, Ca, Ba, Sr and Be or a Group VIII transition metal that can exist in a +2 oxidation state, such as Ti, V, Mn, Fe, Co, Ni, Cu, Zn, Nb, Pd, Cd and Ta. Ln refers to the rare earth lanthanide group of elements, such as La, Yb, Sm and Ce. This family of catalysts demonstrate unexpected activity for efficiently catalyzing the net partial oxidation of methane in a short contact time reactor, with high selectivities for H2 product.

Abstract: Rhodium-spinel catalysts with activity for efficiently catalyzing the net partial oxidation of methane at high selectivities for CO and H2 products are disclosed, along with their method of making. A syngas production process employing such catalysts for the net catalytic partial oxidation of a C1-C5 hydrocarbon (e.g., natural gas or methane) to a product gas mixture comprising CO and H2 is also disclosed. Preferred reaction conditions include maintaining the catalyst at a temperature of about 400-1,200° C., superatmospheric pressure, and flow rate sufficient to pass the reactant gas mixture over the catalyst at space velocities of at least about 100,000-25,000,000 hr−1.