Fischer-tropsch synthesis using microchannel technology and novel catalyst and microchannel reactor

A process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising:

• flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst;
• transferring heat from the process microchannels to a heat exchanger;
• and
• removing the product from the microchannel reactor;
• the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms near gram of catalyst per hour;
• the selectivity to methane in the product being less than about 25%;
• wherein the heat exchanger comprises a heat exchange zone adjacent to at least one process microchannel, the heat exchange zone comprising a plurality of heat exchange channels, the heat exchange channels extending lengthwise at right angles relative to the lengthwise direction of the process microchannel, the heat exchange zone extending lengthwise in the same direction as the process microchannel, the length of the heat exchange zone being shorter than the length of the process microchannel, the process microchannel having an entrance and an exit, the heat exchange zone being positioned at or near the process microchannel entrance.

A process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising:

• flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst;
• transferring heat from the process microchannels to a heat exchanger;
• and
• removing the product from the microchannel reactor;
• the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour;
• and
• the selectivity to methane in the product being less than about 25%;
• wherein the heat exchanger comprises two heat exchange zones adjacent to at least one process microchannel, each heat exchange zone comprising a plurality of heat exchange channels, the heat exchange channels extending lengthwise at right angles relative to the lengthwise direction of the process microchannel, the process microchannel having an entrance and an exit, the heat exchange zones extending lengthwise in the same direction as the process microchannel, the lengths of the heat exchange zones being shorter than the length of the process microchannel, the length of one of the heat exchange zones being shorter than the length of the other heat exchange zone, the heat exchange zones being positioned at or near the process microchannel entrance.

A process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising:

• flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst, the catalyst being in the form of a fixed bed of particulate solids, the catalyst comprising Co supported on alumina, the Co loading being at least about 25% by weight,
• transferring heat from the process microchannels to a heat exchanger;
• and
• removing the product from the microchannel reactor;
• the contact time of the reactant composition with the catalyst being up to about 300 ms;
• the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour;
• and
• the selectivity to methane in the product being less than about 25%.

A process for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms, the process comprising:

• flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst, the catalyst being in the form of a fixed bed of particulate solids, the catalyst comprising Co supported on alumina, the catalyst having a Co loading of at least about 28% by weight and a Co dispersion of at least about 3%;
• transferring heat from the process microchannels to a heat exchanger;
• and
• removing the product from the microchannel reactor;
• the contact time of the reactant composition with the catalyst being up to about 300 ms;
• the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour;
• the CO conversion being about 40% or higher per cycle;
• the selectivity to methane in the product being less than about 25%.