Catalyst and process for selective production of lower hydrocarbons C1-C5 from syngas with low methane and CO2 production

A catalyst composition comprising cobalt;

• manganese;
• hydrophilic silica;
• and at least one element selected from the group consisting of lanthanum, phosphorus, Fe, Zr, and Zn, wherein the relative molar ratios of the elements comprised in the composition are of the formula
• CoMnaSibXcMdOy
• wherein:
• M is one or more elements selected from the group consisting of alkali metal, alkaline earth metal, and transition metal;
• a is about 0.8-1.2;
• b is 0.1 to 1;
• each c is from greater than 0 to about 0.005, wherein the total c is from greater than 0 to about 0.005;
• d is 0 to about 0.005;
• X is two elements, wherein the elements are lanthanum and phosphorus, and wherein c for each of lanthanum and phosphorus is from greater than 0 to about 0.005;
• y is a number determined by the valence of the other elements present;
• and Si is in the form of a hydrophilic silica.

A process for producing ethylene and propylene from syngas, the process comprising the steps of

• a) contacting a syngas with a first catalyst composition to obtain a first product stream comprising ethylene, propylene, and aliphatic hydrocarbons having 4 or more carbon atoms,
• b) splitting the first product stream into
• a second product stream comprising at least 90% of the aliphatic hydrocarbons having 4 or more carbon atoms and
• a third product stream comprising ethylene and propylene,
• c) separating ethylene and propylene in the third product stream so as to form a first ethylene stream and a first propylene stream, and
• d) contacting the second product stream with a second catalyst composition which is an olefin metathesis catalyst suitable for converting 1-butylene and 1-hexene into ethylene and propylene to convert the second product stream into a fourth product stream comprising ethylene and/or propylene
• wherein the first catalyst composition comprises cobalt, manganese, hydrophilic silica, and at least one element selected from the group consisting of lanthanum, phosphorus, Fe, Zr, and Zn, wherein the relative molar ratios of the elements in the composition are represented by the formula
• CoMnaSibXcMdOy
• wherein:
• M is one or more elements selected from the group consisting of alkali metal, alkaline earth metal, and transition metal;
• a is about 0.8-1.2;
• b is 0.1 to 1;
• each c is from greater than 0 to about 0.005, wherein the total c is from greater than 0 to about 0.005;
• d is 0 to about 0.005;
• X is at least one element selected from the group consisting of lanthanum, phosphorus, Fe, Zr, and Zn;
• y is a number determined by the valence of the other elements present;
• wherein the catalyst composition further comprises a binder selected from the group consisting of magnesia, alumina, silica, zirconia, titania, activated carbon, non-activated carbon, and zeolites;
• and Si is in the form of a hydrophilic silica.