Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Metal – metal oxide or metal hydroxide
Patent
1984-04-19
1986-09-09
Shine, W. J.
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Metal, metal oxide or metal hydroxide
502303, 502304, 502305, 502323, 502439, 518721, 585671, B01J 2104, B01J 2310, B01J 2330, B01J 2376
Patent
active
046109757
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to the production of hydrocarbons. In particular, the present invention relates to primary and secondary catalysts for use in the Fischer-Tropsch process for synthesising hydrocarbons adapted for gasoline production and to supports for such primary catalysts.
BACKGROUND OF THE INVENTION
The Fischer-Tropsch process is one of the major processes for producing synthetic hydrocarbons. The process is based on the use of carbon monoxide and hydrogen which can both be readily derived from gasification of coal or char or by steam reforming of natural gas. The process relies on catalytic synthesis and basically comprises passing a gaseous feed stream of carbon monoxide and hydrogen over a catalyst bed. The catalyst and process operating conditions are selected so that one or other of the following reactions predominates:
The Fischer-Tropsch process is subject to a number of limitations. One limitation is that the hydrocarbons produced by the process include a significant proportion of straight chain hydrocarbons of low octane number. Various processes have been proposed to improve the octane number of the hydrocarbons, and thus the suitability for use in gasoline production, by converting the straight chain hydrocarbons into branched hydrocarbons. However, the known processes tend to be expensive and are not adapted to form part of a continuous process with the Fischer-Tropsch process.
Another limitation is that it is difficult to control the process reaction to selectively form hydrocarbons having carbon numbers suitable for use in gasoline production. One reason for this particular limitation of the Fischer-Tropsch process is the selection of catalysts for use in the process. Iron is a major component of most existing commercial catalysts, and although it is active as a catalyst, the hydrocarbons produced cover a wide distribution of carbon numbers, many of which are not suitable for gasoline production. For example, depending on the process conditions, the hydrocarbons produced include significant proportions of either low carbon number gaseous products or high carbon number straight chain products which form as waxes. Both products are generally not suitable for use in gasoline production.
One object of the present invention is to provide an improved primary and an improved secondary catalyst, improved methods for the manufacture of the catalysts, improved supports for the primary catalyst and improved processes for using the catalysts which alleviate the disadvantages described in, the preceding paragraphs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of the weight percent of products versus product carbon number;
FIG. 2 is a graph of the yield, in mole percent, versus product carbon number;
FIG. 3 is a plot of the weight percent of products versus product carbon number; and
FIG. 4 is a plot of weight percent of product versus product carbon number.
DESCRIPTION OF THE INVENTION
According to the present invention there is provided a method of forming a support for use with a primary catalyst for conversion of a feed stream comprising carbon monoxide and hydrogen into hydrocarbons, said method comprising heat treating .gamma.-alumina at a predetermined temperature for a predetermined time to form a material having a crystallographic structure predominantly indicative of .alpha.-alumina, a surface area intermediate between .gamma.-alumina and .alpha.-alumina, said material exhibiting basic properties at the surface thereof.
Preferably, the temperature is greater than 1100.degree. C. and the time is less than 2 hour. It is particularly preferred that the temperature is 1250.degree. C. and the time is 10 minutes.
According to the present invention there is also provided a support for use with a primary catalyst for conversion of a feed stream comprising carbon monoxide and hydrogen into hydrocarbons formed by the method described above.
According to the present invention there is provided a primary catalyst for conversion of a feed stream comprising carbon monoxide and h
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Baker Bruce G.
Clark Neville J.
McArthur Hamish
Summerville Edward
Shine W. J.
The Flinders University of South Australia
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