Integral synthesis gas conversion catalyst extrudates and methods for preparing and using same

A method for preparing a catalyst comprising:

• a. forming a mixture of a Fischer-Tropsch component comprising an oxide of a metal selected from the group consisting of cobalt, ruthenium and mixtures thereof having a particle size from about 2 nm to about 30 nm, a zeolite component having a zeolite acid site density and a binder;
• b. extruding the mixture to form extrudate particles;
• and
• c. calcining the extrudate particles to form integral synthesis gas conversion catalyst extrudates;
• wherein the integral synthesis gas conversion catalyst extrudates have an acid site density of at least about 80% of the zeolite acid site density.

A process for synthesis gas conversion comprising contacting in a fixed bed reactor a synthesis gas comprising hydrogen and carbon monoxide at a ratio of hydrogen to carbon monoxide of from about 1 to about 3, at a temperature of from about 180° C. to about 280° C. and a pressure of from about 5 atmospheres to about 40 atmospheres, with an integral synthesis gas conversion catalyst extrudate comprising:

• a. a Fischer-Tropsch component comprising an oxide of a metal selected from the group consisting of cobalt, ruthenium and mixtures thereof having a particle size from about 2 nm to about 30 nm;
• b. a zeolite component having a zeolite acid site density;
• and
• c. a binder;
• wherein the integral synthesis gas conversion catalyst extrudate has an acid site density of at least about 80% of the zeolite acid site density;
• to yield a liquid hydrocarbon product containing less than about 10 weight % methane, greater than about 75 weight % C5+;
• less than about 15 weight % C2-4;
• and less than about 5 weight % C21+ normal paraffins.