Catalyst structure and method of Fischer-Tropsch synthesis
AssigneeBattelle Memorial Institute
InventorsYong Wang, David P. Vanderwiel, Anna Lee Y. Tonkovich, Yufei Gao, Eddie G. Baker
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Abstract
The present invention includes Fischer-Tropsch catalysts, reactions using Fischer-Tropsch catalysts, methods of making Fischer-Tropsch catalysts, processes of hydrogenating carbon monoxide, and fuels made using these processes. The invention provides the ability to hydrogenate carbon monoxide with low contact times, good conversion rates and low methane selectivities. In a preferred method, the catalyst is made using a metal foam support.
Claims15
A catalyst structure for Fischer-Tropsch synthesis, comprising
- said catalyst structure comprising a first porous structure with a first pore surface area and a first pore size of at least about 0.1 μm;
- a buffer layer disposed on said porous structure;
- a porous interfacial layer with a second pore surface area and a second pore size less than said first pore size, said porous interfacial layer disposed upon said buffer layer;
- a Fischer-Tropsch catalyst selected from the group consisting of cobalt, ruthenium, iron, rhenium, nickel, osmium and combinations thereof placed upon said second pore surface area.
A method of Fischer-Tropsch reaction, comprising the steps of:
- (a) providing a catalyst structure comprising a porous support with a first pore surface area and a first pore size of at least about 0.1 μm;
- a buffer layer disposed on said porous support
- a porous interfacial layer with a second pore surface area and a second pore size less than said first pore size, said porous interfacial layer disposed upon said buffer layer;
- a Fischer-Tropsch catalyst selected from the group consisting of cobalt, ruthenium, iron, rhenium, osmium and combinations thereof placed upon said second pore surface area;
- and
- (b) passing a feed stream having a mixture of hydrogen gas with carbon monoxide gas through said catalyst structure and heating said catalyst structure to at least 200° C. at an operating pressure, said feed stream having a residence time within said catalyst structure less than 5 seconds, thereby obtaining a product stream of at least 25% conversion of carbon monoxide, and at most 25% selectivity toward methane.
A method of making a Fischer-Tropsch catalyst structure, comprising the steps of:
- providing a catalyst structure comprising a porous support with a first pore surface area and a first pore size of at least about 0.1 μm;
- depositing a buffer layer on said porous support;
- depositing a porous interfacial layer with a second pore surface area and a second pore size less than said first pore size, upon said buffer layer;
- placing a Fischer-Tropsch catalyst selected from the group consisting of cobalt, ruthenium, iron, rhenium, osmium and combinations thereof upon said second pore surface area.
Dependencies are inferred from the claim text.