Synthesis gas conversion and novel catalysts for same

#The invention relates to catalyst compositions useful in synthesis gas (i.e., carbon monoxide and hydrogen) upgrading processes and methods for their production and use. In another aspect, this invention relates to processes for converting synthesis gas into olefins, with an increase in olefin selectivity and carbon monoxide conversion resulting from the conversion of such synthesis gas in the presence of such catalyst compositions.

#It is known in the art to convert synthesis gas into olefins in the presence of catalysts. One concern with the use of catalysts in the conversion of synthesis gas to olefins is that not enough of the synthesis gas is converted. It is desirable to improve processes for the conversion of synthesis gas to olefins by increasing the percentage of carbon monoxide that is converted to olefins. It is also desirable to have a catalyst that is useful in producing significant quantities of butene conversion products.

#It is an object of this invention to provide improved catalyst compositions which when used in the conversion of synthesis gas result in increased carbon monoxide conversion and increased butene selectivity.

#In accordance with the first embodiment of the present invention, the inventive catalyst composition consists of or consists essentially of (a) a metal material comprising a metal selected from the group consisting of zirconium, copper, zinc and combinations thereof; and (b) alumina.

#The metal material used in the inventive catalyst composition can be any metal material that is effective in the conversion of synthesis gas to olefins when contacted under reaction conditions with synthesis gas. Preferably, the metal of the metal material is zirconium. “Synthesis gas,” as employed herein, comprises, consists of, or consists essentially of a mixture of carbon monoxide and hydrogen.

#Also preferably, the metal material is a metal oxide. Any metal oxide which can convert synthesis gas into olefins under reaction conditions can be used. More preferably, the metal oxide can be selected from the group consisting of zirconium oxide, copper oxide, and zinc oxide. Most preferably, the metal oxide is zirconium oxide.