Abstract: Iron/carbon (Fe/C) nanocomposite catalysts are prepared for Fischer-Tropsch synthesis reaction. A preparation method includes steps of mixing iron hydrate salts and a mesoporous carbon support to form a mixture, infiltrating the iron hydrate salts into the carbon support through melt infiltration of the mixture near a melting point of the iron hydrate salts, forming iron-carbide particles infiltrated into the carbon support through calcination of the iron hydrate salts infiltrated into the carbon support under a first atmosphere, and vacuum-drying the iron-carbide particles after passivation using ethanol. Using such catalysts, liquid hydrocarbons are produced.

Abstract: A unique process and catalyst is described that operates efficiently at low pressures for the direct production of a high cetane diesel type fuel or diesel type blending stock from stoichiometric mixtures of hydrogen and carbon monoxide. This invention allows for, but is not limited to, the economical and efficient production high quality diesel type fuels from small or distributed fuel production plants that have an annual production capacity of less than 100 million gallons per year by eliminating traditional hydrocracking and other costly upgrading processes. This catalytic process is ideal for distributed diesel fuel production plants such as biomass to fuel production plants and stranded natural gas to diesel fuel production plants, and other applications that require optimized economics based on supporting distributed feedstock resources.

Abstract: A process and system for producing high octane fuel from carbon dioxide and water is disclosed. The feedstock for the production line is industrial carbon dioxide and water, which may be of lower quality. The end product can be high octane gasoline, high cetane diesel or other liquid hydrocarbon mixtures suitable for driving conventional combustion engines or hydrocarbons suitable for further industrial processing or commercial use. Products, such as dimethyl ether or methanol may also be withdrawn from the production line. The process is nearly emission free and reprocesses all hydrocarbons not suitable for liquid fuel to form high octane products. The heat generated by exothermic reactions in the process is fully utilized as is the heat produced in the reprocessing of hydrocarbons not suitable for liquid fuel.

Abstract: A unique process and catalyst is described that operates efficiently at low pressures for the direct production of a high cetane diesel type fuel or diesel type blending stock from stoichiometric mixtures of hydrogen and carbon monoxide. This invention allows for, but is not limited to, the economical and efficient production high quality diesel type fuels from small or distributed fuel production plants that have an annual production capacity of less than 100 million gallons per year by eliminating traditional hydrocracking and other costly upgrading processes. This catalytic process is ideal for distributed diesel fuel production plants such as biomass to fuel production plants and stranded natural gas to diesel fuel production plants, and other applications that require optimized economics based on supporting distributed feedstock resources.

Abstract: A method of utilizing hydrogen in synthesis gas production by forming synthesis gas from one or more carbonaceous materials, the synthesis gas comprising hydrogen and carbon monoxide; separating a hydrogen-rich product and a hydrogen-lean product from the synthesis gas to yield an adjusted synthesis gas product; and activating a hydrocarbon synthesis catalyst with at least a portion of the hydrogen-lean product. A system for carrying out the method is also provided, the system including at least one hydrogen extraction unit and an activation reactor operable to activate hydrocarbon synthesis catalyst, wherein the activation reactor comprises an inlet fluidly connected with the at least one hydrogen extraction unit whereby at least a portion of a hydrogen-lean gas stream, at least a portion of a hydrogen-rich gas stream, or at least a portion of both may be introduced into the activation reactor.

Abstract: Novel methods of treating a Fischer-Tropsch product stream with an acid are disclosed. Such methods are capable of removing contamination from the Fischer-Tropsch product stream such that plugging of the catalyst beds of a subsequent hydroprocessing step is substantially reduced.

Abstract: The method for manufacturing an unsaturated hydrocarbon and an oxygen-containing compound according to the present invention comprises: a first step of dispersing a catalyst in poly-?-olefin and reducing the catalyst with carbon monoxide or synthesis gas, wherein the catalyst is prepared by supporting iron on a support containing manganese and having an average pore size of 2 to 100 nm; and a second step of bringing the catalyst after reduction in the first step into contact with synthesis gas under the conditions of a reaction temperature of 100 to 600° C. and a reaction pressure of 0.1 to 10 MPa to obtain a reaction product containing an unsaturated hydrocarbon and an oxygen-containing compound.

Abstract: The present invention provides a method to start a steady state process for producing normally gaseous, normally liquid and optionally normally solid hydrocarbons from synthesis gas, which method comprises the steps of: (i) providing an activated catalyst in tubes of a fixed bed reactor, preferably a multitubular fixed bed reactor, the catalyst being suitable to convert synthesis gas to normally gaseous, normally liquid and optionally normally solid hydrocarbons; (ii) contacting the activated catalyst with a liquid to obtain a wetted activated catalyst; (iii) contacting the wetted activated catalyst with synthesis gas and catalytically converting the synthesis gas at an elevated temperature and pressure to obtain the normally gaseous, normally liquid and optionally normally solid hydrocarbons.

Abstract: A method for transforming at least a part of the catalyst precursor hematite into x-carbide (Fe5C2) and ??-carbide (FeC2.2) without a large amount of fines generation. This method slows the transformation of the hematite to iron carbides by reducing the partial pressure of the synthesis gas by inert gas dilution. The activation time is about three to about five hours.

Abstract: Process for conversion of syngas to liquid hydrocarbons using a catalyst composition containing a support and a Fischer-Tropsch metal for the conversion of syngas to liquid hydrocarbons, in which a silylating compound modifier is added to the catalyst composition during catalyst preparation or during a post-treatment stage.

Abstract: A catalyst composition and a process of using a catalyst composition for preparing high molecular weight hydrocarbons, such as polymethylene, from a fluid containing hydrogen and carbon monoxide are disclosed. The catalyst composition contains ruthenium and a treated silica support component. The treated silica support component is prepared by a process including contacting a silica support component, such as silicon dioxide, and a treating agent, such as a silicon-containing compound.

Abstract: According to the present invention there is provided the use of a source of chromium in combination with a precipitated iron catalyst in a high temperature Fischer-Tropsch process to convert CO and H2 to hydrocarbons and possibly oxygenates thereof. In the process CO and H2 are contacted with the source of chromium in combination with the precipitated iron catalyst in a high temperature Fischer-Tropsch reaction. The invention also relates to the use of a source of chromium in the preparation of a precipitated iron catalyst for use in high temperature Fischer-Tropsch process and to a precipitated iron catalyst suitable for use in a high temperature Fischer-Tropsch process which contains a source of chromium.

Abstract: A method for transforming at least a part of the catalyst precursor hematite into ?-carbide (Fe5C2) and ??-carbide (FeC2.2) without a large amount of fines generation. This method slows the transformation of the hematite to iron carbides by reducing the partial pressure of the synthesis gas by inert gas dilution. The activation time is about three to about five hours.

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 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: Methods and apparatus for improving the efficiency and effectiveness of in situ reduction of a Fischer-Tropsch catalyst slurry. The preferred embodiments of the present invention are characterized by a system that utilizes a co-feed of carbon monoxide along with the reducing gas into a reduction vessel maintained at an elevated temperature. As the metal oxide reduces to the active Fischer-Tropsch metal, the carbon monoxide acts as a poison to hydrogenolysis and reduces the loss of liquid from the slurry and the production of methane. The carbon monoxide is generally in parts-per-million quantities and will achieve the desired results in quantities less than 5,000 ppm, preferably less than 2,000 ppm.

Abstract: A process is disclosed for regenerating a catalyst used in a process for synthesizing hydrocarbons. The synthesis process involves contacting a feed stream comprising hydrogen and carbon monoxide with a catalyst in a reaction zone maintained at conversion-promoting conditions effective to produce an effluent stream comprising hydrocarbons. The regeneration process involves contacting a deactivated Fischer-Tropsch catalyst with a regeneration gas under regeneration-promoting conditions that include a pressure lower than the mean Fischer-Tropsch reaction pressure, for a period of time sufficient to reactivate the Fischer-Tropsch catalyst.

Abstract: The invention provides heat treated self-supported precipitated iron-based Fischer-Tropsch catalyst particles. The particles of the present invention are breakage resistant and exhibit superior synthesis performance. The invention also provides a method for producing said particles and a process for using said particles.

Abstract: A continuous process is disclosed for the production of hydrocarbon liquids and wax by Fischer-Tropsch conversion of synthesis gas in contact with promoted skeletal iron catalyst particles in a slurry reactor. Wax product is readily separated from the skeletal iron catalyst in a catalyst settling drum and concentrated catalyst particles in wax slurry are recycled from the settling drum to the slurry reactor, while essentially solid-free wax is recovered as a product.

Abstract: This invention relates to a new method for producing an iron-based Fischer-Tropsch catalyst composition wherein the main iron phase is ferrihydrite in a precipitation reaction. It has been found that the reduction of Fe(III) species to Fe(II), and thus an increase in the Fe(II)/Fe(III) ratio, prior to precipitation affects the crystallite size of the crystallite particles of the catalyst, and enhances the olefin selectivity of the catalyst. The reduction of the Fe(III) species to Fe(II) can be attained in situ by the addition of a reduction agent (such as oxalic acid or formic acid) during the catalyst preparation method.

Abstract: The invention provides heat treated self-supported precipitated iron-based Fischer-Tropsch catalyst particles. The particles of the present invention are breakage resistant and exhibit superior synthesis performance. The invention also provides a method for producing said particles and a process for using said particles.

Abstract: A Fischer-Tropsch catalyst comprising a catalytically active first metal selected from the group consisting of at least one metal selected from the group consisting of iron, nickel, cobalt, chromium, and mixtures thereof, at least one second metal selected from the group consisting of silver, iron, zinc, copper, platinum, zirconium and combinations thereof; and a matrix structure comprising a polymer selected from the group consisting of polyacrylates and polymethacrylates. The first and second metals are incorporated into the polymer.

Abstract: Fine iron-based catalyst particles from. Fischer-Tropsch (F-T) synthesis processes are effectively separated from catalyst/liquid/wax slurry by contacting and/or mixing the slurry with a coalescence enhancing treating solution to facilitate gravity separation and settling of such catalyst, and thereby yield a substantially clean hydrocarbon liquid/wax product. The treating solution includes a surface tension reducing agent, an agglutinating agent, and a coalescing agent each in selected proportions in aqueous solution. Useful mixing and settling conditions are 10-250° C. temperature, 0-500 psig pressure and treating solution to slurry volume ratio of 0.5-5:1, with the settling time for at least about 90% and preferably substantially all of the catalyst fines after the mixing step being less than about 15 minutes. The treating solution can be desirably recovered and reused in the F-T synthesis process, and the recovered catalyst either recycled or disposed as desired.

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: The invention relates to a process for synthesizing mainly linear and saturated hydrocarbons containing at least 80% by weight of C.sub.5 + hydrocarbons in relation to all of the hydrocarbons formed, from a synthesis gas CO--(CO.sub.2)--H.sub.2, the synthesis gas being converted into hydrocarbons under a total pressure ranging between 0.1 and 15 MPa, the temperature ranging between 150.degree. and 350.degree. C., the hourly space velocity ranging between 100 and 30,000 volumes of synthesis gas per volume of catalyst and per hour, and the H.sub.2 /CO molar ratio in the synthesis gas ranging between 1:2 and 5:1, said process being characterized in that it is carried out in a reaction zone with an ebullating catalytic bed in the presence of a catalyst comprising at least one metal from group VIII, and in the presence of a liquid phase.

Abstract: Several Fischer-Tropsch reaction schemes using a promoted iron catalyst in a slurry reactor produce oxygenated naphtha and diesel fractions on distillation that reduce particulate emissions in diesel engines. High carbon conversion efficiencies and optimum chain growth are characteristics of the processes.

Abstract: Ferrisilicate molecular sieves of the ZSM-5 type, having SiO.sub.2 /Fe.sub.2 O.sub.3 mole ratios ranging from 20 to 400, are prepared by adding a silica source and a quaternary ammonium salt in that order to an acedified solution of an iron (III) compound, crystallizing the resulting gel to form a ferrisilicate molecular sieve, and thermally treating the molecular sieve with nitrogen, air and/or steam at 300.degree. to 700.degree. C. Preferred thermal treatment comprises treating with nitrogen first, then with air or steam. Thermally treated molecular sieves contain iron both in and outside the crystal framework; most of the non-framework iron is dispersed as very finely divided iron oxides or internal surfaces. Molecular sieves are useful as catalysts in Fischer-Tropsch and other iron oxide-catalyzed reactions.

Abstract: A method of inducing surface ensembles on a transition metal catalyst used in the conversion of a reactant gas or gas mixture, such as carbon monoxide and hydrogen into hydrocarbons (the Fischer-Tropsch reaction) is disclosed which comprises adding a Lewis base to the syngas (CO+H.sub.2) mixture before reaction takes place. The formation of surface ensembles in this manner restricts the number and types of reaction pathways which will be utilized, thus greatly narrowing the product distribution and maximizing the efficiency of the Fischer-Tropsch reaction. Similarly, amines may also be produced by the conversion of reactant gas or gases, such as nitrogen, hydrogen, or hydrocarbon constituents.

Abstract: Disclosed is a carbonaceous material which reacts rapidly with hydrogen to produce a methane-rich gas containing at least 20% by volume methane. The carbonaceous material is formed by contacting a carbon monoxide containing gas with an initiator including a ferrous group metal such as iron, cobalt, or nickel. The carbonaceous material grows from the surface of the initiator as fibers which include a ferrous metal component derived from the initiator. This ferrous metal component, which may be a metal, an alloy, a carbide, or other metallic substance, is dispersed throughout the carbon network as small nodules which are at least partially bonded to the carbon.

Abstract: A catalyst useful for producing substantially C.sup.2 + alkane hydrocarbons from mixtures of CO and H.sub.2 which comprises a mixture of iron carbide and ilmenite supported on titania wherein the ratio of the iron present in the supported iron carbide and ilmenite, calculated as Fe.sub.2 O.sub.3, to the surface area of the titania support ranges from about 2.times.10.sup.-3 to 25.times.10.sup.-3 grams per square meter.

Abstract: Single phase, unsupported, Group IA or IIA metal salt promoted manganese-containing iron spinel catalysts, having Fe:Mn atomic ratios of 2:1 or above, have been found to be highly active for the selective conversion of CO/H.sub.2 to alpha olefins.

Abstract: Slurried, high surface area, Cu and Group IA or IIA dual metal promoted Mn-Fe spinels which are fully reduced and carburized provide exceptionally high catalytic activity and selectivity in the conversion of CO/H.sub.2 to alpha-olefins, particularly when reduced and carbided in-situ. These copper and Group IA or IIA metal promoted iron-manganese catalysts maintain good activity and selectivity under low pressure reaction conditions.

Abstract: Catalysts comprising iron carbide on a surface modified titania support wherein said support comprises a surface modifying oxide of tantalum, niobium, vanadium and mixtures thereof supported on said titania wherein at least a portion of said surface modifying oxide is in a non-crystalline form. These catalysts are useful for Fischer-Tropsch hydrocarbon synthesis reactions. Preferably, at least about 25 wt. % of said surface modifying oxide will be in a non-crystalline form.

Abstract: Fly ash is activated by heating a screened magnetic fraction of the ash in a steam atmosphere and then reducing, oxidizing and again reducing the hydrothermally treated fraction. The activated fly ash can be used as a carbon monoxide disproportionating catalyst useful in the production of hydrogen and methane.

Abstract: Substantially C.sub.2 + alkane hydrocarbons are produced from mixtures of CO and H.sub.2 by contacting same, at elevated temperature, with a catalyst comprising a mixture of iron carbide and ilmenite supported on titania wherein the ratio of the iron present in said supported iron carbide and ilmenite, calculated as Fe.sub.2 O.sub.3, to the surface area of the titania support ranges from about 2.times.10.sup.-3 to 25.times.10.sup.-3 grams per square meter.

Abstract: Catalysts comprising a medium to large port zeolite modified by the oxide or acid of an element selected from the group consisting of Group IIIA to VIIA elements and, a Fischer-Tropsch catalyst wherein the ratio of zeolite to Fischer-Tropsch component is from about 0.1 to 50:1 can be employed to produce fuel grade saturated gaseous hydrocarbons from synthesis gas. A process is employed which includes the step of contacting synthesis gas over the foregoing catalyst at a reaction temperature of from about 100.degree. C. to 500.degree. C. and at a pressure of from about one atmosphere (0.1 MPa) to about 200 atmospheres (20 MPa) and at a gas hourly space velocity of from about 10 to 100,000. A method is also provided for the preparation of the combination catalyst. The catalyst and process for its use results in a small liquid aromatic product also being formed which is suitable for forming gasoline. Olefins and oxygenates are essentially eliminated.

Abstract: A process is described using novel thallium-promoted iron catalysts in CO hydrogenation with steam. Mixtures of CO and steam are converted to liquid C.sub.6 -C.sub.13 hydrocarbons containing substantial amounts of C.sub.6 -C.sub.13 aromatics.

Abstract: Catalysts comprising iron carbide on a surface modified titania support wherein said support comprises a surface modifying oxide of tantalum, niobium, vanadium and mixtures thereof supported on said titania wherein at least a portion of said surface modifying oxide is in a non-crystalline form. These catalysts are useful for Fischer-Tropsch hydrocarbon synthesis reactions. Preferably, at least about 25 wt. % of said surface modifying oxide will be in a non-crystalline form.

Abstract: A catalyst composition comprising a catalytic metal and a support, the support being prepared by depositing a metal alkoxide salt on a core support, then calcining the support.

Abstract: Finely divided, hydrogen-activated catalyst compositions comprising iron, silicon and carbon or iron and silicon that selectively convert gaseous mixtures of CO and H.sub.2, at a temperature of about 150.degree.-450.degree. C. and at pressures of about 10-2000 kPa, into a reaction mixture containing at least about 75% C.sub.2 -C.sub.6 alkenes and no more than about 25% of CH.sub.4 and undesirable CO.sub.2 by-products are disclosed. A wide range of iron/silicon-based catalyst compositions are conveniently prepared by laser pyrolysis and hydrogen-pretreatment and readily reactivated with hydrogen at elevated temperatures.

Abstract: Substantially C.sub.2 + alkane hydrocarbons are produced from mixtures of CO and H.sub.2 by contacting same, at elevated temperature, with a catalyst comprising a mixture of iron carbide and ilmenite supported on titania wherein the ratio of the iron present in said supported iron carbide and ilmenite, calculated as Fe.sub.2 O.sub.3, to the surface area of the titania support ranges from about 2.times.10.sup.-3 to 25.times.10.sup.-3 grams per square meter.

Abstract: Iron-cobalt spinels which contain low levels of cobalt, in an iron/cobalt atomic ratio of 7:1 to 35:1, are converted to Fischer-Tropsch catalysts upon reduction and carbiding that exhibit high activity and selectivity to C.sub.2 -C.sub.6 olefins and low CH.sub.4 production.

Abstract: CO hydrogenation process is described utilizing novel thallium-promoted iron catalysts. Mixtures of CO/H.sub.2 are selectively converted to liquid C.sub.6 -C.sub.11 hydrocarbons containing C.sub.6 -C.sub.11 aromatics, alpha olefins and very small amounts of C.sub.23 + hydrocarbon waxes.

Abstract: CO hydrogenation process for producing alcohols is described utilizing novel thallium-promoted iron catalysts. Mixtures of CO/H.sub.2 are selectively converted to liquid C.sub.6 -C.sub.12 hydrocarbons containing C.sub.6 -C.sub.12 alcohols with attendant low methane and low CO.sub.2 make.

Abstract: Finely divided, hydrogen-activated catalyst compositions comprising iron, silicon and carbon or iron and silicon that selectively convert gaseous mixtures of CO and H.sub.2, at a temperature of about 150.degree.-450.degree. C. and at pressures of about 10-2000 kPa, into reaction mixture containing at least about 75% C.sub.2 -C.sub.6 alkenes and no more than about 25% of CH.sub.4 and undesirable CO.sub.2 by-products are disclosed. A wide range of iron/silicon-based catalyst compositions are conveniently prepared by laser pyrolysis and hydrogen-pretreatment and readily reactivated with hydrogen at elevated temperatures.

Abstract: A method is disclosed for converting synthesis gas to hydrocarbons enriched in linear alpha-olefins which involves the use of a ZSM-5 type zeolite which is substantially catalytically inert and onto which is deposited a carbon oxide reducing component including Fischer-Tropsch type catalysts, such as iron, cobalt and ruthenium.

Abstract: An unsupported particulate catalyst especially useful for methanation reactions is prepared by a method comprising fluid-bed roasting agglomerates of nickel sulfide to form a particulate precursor material which can be reduced to composite particles consisting essentially of a nickel-oxide core with a then coherent adherent layer of nickel thereon, the reduced particles being characterized at the surface by the presence of microcapillary pores interconnecting with each other and the outer surface of the particles.

Abstract: A method is disclosed for the conversion of synthesis gas to a liquid hydrocarbon product having a boiling range of less than 400.degree. F. at a 90% overhead utilizing a novel catalyst prepared from finely divided iron powder or iron oxide. The novel method involves contacting synthesis gas with a single particle catalyst containing iron, a crystalline acidic aluminosilicate zeolite having a silica-to-alumina ratio of at least 12, a pore size greater than about 5 Angstrom units, and a constraint index of about 1 to 12, and a matrix. The catalyst does not contain promoters.