Fischer tropsch catalyst system
AssigneeNexceris Innovation Holdings, LLC
InventorsMatthew M. SEABAUGH, Sergio A. IBANEZ, Cody J. LOCKHART, Anna Lee TONKOVICH, Yong WANG
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Abstract
A novel Fischer Tropsch (FT) catalyst that has improved thermal characteristics and a highly active surface catalyst coating on a pellet to produce high quality hydrocarbon liquids and waxes even at high reactor temperatures. The catalyst shows a surprising increase in hydrocarbons and wax formation at high temperature and a much higher specific catalyst activity than demonstrated to date. More generally, a catalyst support, method of making a catalyst, and methods of FT synthesis are described.
Claims28
A catalyst support, comprising three distinct layers:
- and comprising:
- a core comprising Al, Si, C, and O;
- a first layer adjacent to the core, comprising Al and Si, C and O;
- a second layer adjacent the first layer comprising Al, Si, C and O;
- wherein the first layer has greater porosity than the second layer and wherein the concentration of O in the core is at least 2.5 wt % less O than the first layer;
- or
- a core comprising Si, C, Al, and O, and comprising at least 2 vol % of a metallic Al alloy;
- a first layer adjacent the core comprising Si, C, Al, and O, and comprising no more than 1 vol % of a metallic phase (preferably no discernable metallic phase);
- a second layer adjacent the first layer comprising Si, C, Al, and O and comprising no more than 1 vol % of a metallic phase (preferably no discernable metallic phase);
- wherein the first layer has greater porosity than the second layer and wherein the concentration of O in the core is at least 2.5 wt % less O than the first layer.
The catalyst support of any of the above claims wherein the core, first layer and second layer each comprise SiC and Al2O3.
The catalyst support of any of the above claims characterizable by a thermal expansion of 1.0% or less (or 0.50% or less or 0.25% or less) when measured according to the conditions corresponding to the data in Table 1.6.2.
A method of conducting the Fischer-Tropsch reaction, comprising:
- passing a gaseous mixture of CO and H2 over a thermally-conductive catalyst at a temperature of at least 200° C.;
- wherein the thermally conductive catalyst comprises Co metal disposed on the outside of a catalyst pellet comprising a core comprising Al, Si, C and O having a first porosity and an outer protective alloy-derived coating layer surrounding and adjacent to the core;
- wherein the alloy-derived coating has a higher porosity than the core;
- wherein the alloy-derived coating is disposed between the core and the Co metal.
The method of any of the above method claims comprises an outer catalyst layer comprising the Co metal in the form of metal particles disposed on a porous alumina layer wherein the outer catalyst layer has a thickness of between 10 and 100 μm or between 20 and 50 μm.
The method of any of the above method claims wherein the core and alloy coating layer define a core pellet and wherein the core pellet has a thermal conductivity between 2 and 50 W/m—K or between 5 and 20 W/m—K.
The method of any of the above method claims wherein the temperature has a high temperature in the range of 210 to 280° C., or 240 to 280, or 260 to 280.
The method of any of the above method claims wherein the feed ratio of H2:CO is in the range of 1:2 to 3:1 or 1.6 to 2.0.
The method of any of the above method claims wherein the gaseous mixture is pretreated to remove sulfur and/or ammonia to ≤1 ppm.
The method of any of the above method claims wherein the partial pressure of steam in a reacting mixture is maintained at 6 barg or less.
The method of any of the above method claims wherein pressure in the reactor is in the range of 10 to 40 barg, or at least 20 barg
The method of any of the above method claims wherein the reaction is run 500 h without regeneration;
- or regenerated every 1000 or 2000 h.
The method of any of the above method claims wherein the reaction is run at 240° C. or higher and wax is produced.
The method of any of the above method claims wherein methane selectivity is 15% or less or 10% or less.
A pellet comprising central region comprising the 10 wt % of the pellet that is furthest from a surface and comprises aluminum oxide, aluminum alloy and SiC, and an outer alumina region comprising 10 wt % of the pellet corresponding to the volume of the pellet that is furthest from the central region;
- and wherein the outer alumina region comprises aluminum oxide, SiC;
- and wherein the outer alumina region comprises at least 5% higher oxygen concentration as compared to the central region.
Dependencies are inferred from the claim text.