WO2003043734A1 - Ferrihydrite and aluminium-containing fischer-tropsch catalysts - Google Patents
Ferrihydrite and aluminium-containing fischer-tropsch catalysts Download PDFInfo
- Publication number
- WO2003043734A1 WO2003043734A1 PCT/IB2002/004831 IB0204831W WO03043734A1 WO 2003043734 A1 WO2003043734 A1 WO 2003043734A1 IB 0204831 W IB0204831 W IB 0204831W WO 03043734 A1 WO03043734 A1 WO 03043734A1
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- WIPO (PCT)
- Prior art keywords
- catalyst composition
- catalyst
- solution
- precipitate
- ferrihydrite
- Prior art date
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- 239000003054 catalyst Substances 0.000 title claims abstract description 87
- 229910052782 aluminium Inorganic materials 0.000 title claims description 6
- 239000004411 aluminium Substances 0.000 title description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 102
- 239000000203 mixture Substances 0.000 claims abstract description 53
- 229910052742 iron Inorganic materials 0.000 claims abstract description 52
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 claims abstract description 7
- 239000000243 solution Substances 0.000 claims description 33
- 238000000034 method Methods 0.000 claims description 28
- 239000002244 precipitate Substances 0.000 claims description 26
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 17
- 239000010949 copper Substances 0.000 claims description 15
- 239000011701 zinc Substances 0.000 claims description 15
- 239000011572 manganese Substances 0.000 claims description 13
- 229910052802 copper Inorganic materials 0.000 claims description 11
- 238000001556 precipitation Methods 0.000 claims description 11
- 229910052725 zinc Inorganic materials 0.000 claims description 11
- 150000001298 alcohols Chemical class 0.000 claims description 9
- 150000001336 alkenes Chemical class 0.000 claims description 9
- 238000001354 calcination Methods 0.000 claims description 9
- 239000003795 chemical substances by application Substances 0.000 claims description 9
- JLDSOYXADOWAKB-UHFFFAOYSA-N aluminium nitrate Chemical group [Al+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O JLDSOYXADOWAKB-UHFFFAOYSA-N 0.000 claims description 8
- 150000002500 ions Chemical class 0.000 claims description 8
- 150000003839 salts Chemical class 0.000 claims description 8
- 150000001342 alkaline earth metals Chemical class 0.000 claims description 7
- 229910052748 manganese Inorganic materials 0.000 claims description 7
- 239000002798 polar solvent Substances 0.000 claims description 7
- 239000000126 substance Substances 0.000 claims description 7
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 6
- 239000003637 basic solution Substances 0.000 claims description 6
- 239000012018 catalyst precursor Substances 0.000 claims description 6
- 229910052700 potassium Inorganic materials 0.000 claims description 6
- 238000005406 washing Methods 0.000 claims description 6
- 229910052746 lanthanum Inorganic materials 0.000 claims description 5
- 229910052749 magnesium Inorganic materials 0.000 claims description 5
- 239000011777 magnesium Substances 0.000 claims description 5
- 229910052708 sodium Inorganic materials 0.000 claims description 5
- 239000003513 alkali Substances 0.000 claims description 4
- 238000000975 co-precipitation Methods 0.000 claims description 4
- 238000001035 drying Methods 0.000 claims description 4
- MVFCKEFYUDZOCX-UHFFFAOYSA-N iron(2+);dinitrate Chemical group [Fe+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O MVFCKEFYUDZOCX-UHFFFAOYSA-N 0.000 claims description 4
- 229910052763 palladium Inorganic materials 0.000 claims description 4
- 229910052703 rhodium Inorganic materials 0.000 claims description 4
- 229910052707 ruthenium Inorganic materials 0.000 claims description 4
- ONDPHDOFVYQSGI-UHFFFAOYSA-N zinc nitrate Chemical compound [Zn+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O ONDPHDOFVYQSGI-UHFFFAOYSA-N 0.000 claims description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 239000011651 chromium Substances 0.000 claims description 3
- 229910052739 hydrogen Inorganic materials 0.000 claims description 3
- 239000001257 hydrogen Substances 0.000 claims description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 2
- 229910052793 cadmium Inorganic materials 0.000 claims description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 2
- XTVVROIMIGLXTD-UHFFFAOYSA-N copper(II) nitrate Chemical compound [Cu+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O XTVVROIMIGLXTD-UHFFFAOYSA-N 0.000 claims description 2
- MIVBAHRSNUNMPP-UHFFFAOYSA-N manganese(2+);dinitrate Chemical compound [Mn+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O MIVBAHRSNUNMPP-UHFFFAOYSA-N 0.000 claims description 2
- 229910052759 nickel Inorganic materials 0.000 claims description 2
- 230000001376 precipitating effect Effects 0.000 claims 1
- 230000000694 effects Effects 0.000 abstract description 5
- 229910002651 NO3 Inorganic materials 0.000 description 21
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 21
- 239000002002 slurry Substances 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 8
- 238000003786 synthesis reaction Methods 0.000 description 7
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 6
- 239000007789 gas Substances 0.000 description 5
- 238000002360 preparation method Methods 0.000 description 5
- 238000001694 spray drying Methods 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 238000007792 addition Methods 0.000 description 4
- FGIUAXJPYTZDNR-UHFFFAOYSA-N potassium nitrate Chemical compound [K+].[O-][N+]([O-])=O FGIUAXJPYTZDNR-UHFFFAOYSA-N 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 239000013626 chemical specie Substances 0.000 description 2
- 230000001143 conditioned effect Effects 0.000 description 2
- 230000003750 conditioning effect Effects 0.000 description 2
- 239000012153 distilled water Substances 0.000 description 2
- 239000012065 filter cake Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- -1 iron nitrate Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 229910017604 nitric acid Inorganic materials 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000001993 wax Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 229910016870 Fe(NO3)3-9H2O Inorganic materials 0.000 description 1
- 229910000608 Fe(NO3)3.9H2O Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- PGTXKIZLOWULDJ-UHFFFAOYSA-N [Mg].[Zn] Chemical compound [Mg].[Zn] PGTXKIZLOWULDJ-UHFFFAOYSA-N 0.000 description 1
- 238000004847 absorption spectroscopy Methods 0.000 description 1
- 239000003929 acidic solution Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 239000003599 detergent Substances 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 229910001960 metal nitrate Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
- C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
- C10G2/32—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts
- C10G2/33—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts characterised by the catalyst used
- C10G2/331—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts characterised by the catalyst used containing group VIII-metals
- C10G2/332—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts characterised by the catalyst used containing group VIII-metals of the iron-group
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/74—Iron group metals
- B01J23/745—Iron
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J23/889—Manganese, technetium or rhenium
- B01J23/8892—Manganese
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/03—Precipitation; Co-precipitation
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/15—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively
- C07C29/151—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases
- C07C29/153—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the catalyst used
- C07C29/156—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the catalyst used containing iron group metals, platinum group metals or compounds thereof
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
- C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
- C10G2/32—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts
- C10G2/33—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts characterised by the catalyst used
- C10G2/331—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts characterised by the catalyst used containing group VIII-metals
- C10G2/333—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts characterised by the catalyst used containing group VIII-metals of the platinum-group
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
- B01J21/04—Alumina
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
- B01J37/0027—Powdering
- B01J37/0045—Drying a slurry, e.g. spray drying
Definitions
- THIS invention relates to iron-based catalysts in particular to iron-based catalysts and their use in the conversion of synthesis gas (CO and H 2 ) to alcohols and olefins.
- the catalyst composition includes natural promoters which may be selected from manganese or chromium or a mixture thereof and chemical promoters selected from magnesium zinc, copper and alkaline or alkali earth metals.
- the catalyst is best bound to a refractory oxide support such as silica. According to the specification, the catalyst composition produces significant yield of higher paraffins, olefins and alcohols.
- an iron-based Fischer-Tropsch catalyst composition wherein the main iron phase is ferrihydrite and wherein the catalyst composition includes alumina as a structural promoter.
- iron-based is meant that Fe makes up at least 30% (by mass) of the composition.
- the main iron phase is ferrihydrite means that at least 75% of the iron phase is ferrihydrite, as determined by X-ray diffraction using Co K alpha radiation.
- the preferred catalyst compositions exhibit hyperfine interaction parameters similar to those of ferrihydrite, as determined by Mossbauer absorption spectroscopy (MAS).
- a "structural promoter” is a chemical species/element that helps to stabilise the ferrihydrite phase of the catalyst.
- a “chemical promoter” is a chemical species/element that alters the product selectivity and activity of a catalyst.
- the iron-based catalyst composition also includes Mn.
- the iron-based catalyst composition also includes a chemical promoter or promoters selected from Zn, Mg, Cu, Ru, Pd, Rh and/or an alkali or alkaline earth metal such as K, Na or La.
- a chemical promoter or promoters selected from Zn, Mg, Cu, Ru, Pd, Rh and/or an alkali or alkaline earth metal such as K, Na or La.
- the alumina comprises 5% to 20%, by mass, of the catalyst composition.
- the catalyst composition comprises, by mass, 35% to 60% Fe, 1 % to 25% Mn, 1% to 15% Zn, 1% to 25% Cu, and 0.1% to 3% K 2 O.
- the catalyst does not have to be bound with a binder and has a surface area of 150-300m 2 /g and a pore volume of 0.1-0.5 cm 3 /g.
- a process for preparing an iron-based catalyst pre-cursor wherein the main iron phase is ferrihydrite, and wherein the catalyst composition includes alumina, wherein the alumina is included by co-precipitation with the iron phase.
- the process for preparing an iron-based catalyst pre-cursor wherein the main iron phase is ferrihydrite, and wherein the catalyst composition includes alumina includes the following steps:
- the Al ions may be included in step 2 with the precipitation agent.
- the first solution may be formed by dissolving a ferric salt, such as iron nitrate, and an alumina salt such as aluminium nitrate, in the polar solvent.
- the ions of structural promoters such as Mn, Cu, Zn, Cd, Ni, Co and chemical promoters such as Zn, Mg, Cu, Cr, Ru, Pd, Rh or and alkaline or alkali earth metals such as K, Na and La are included in the first solution.
- the first solution includes iron nitrate, manganese nitrate, aluminium nitrate, copper nitrate and zinc nitrate.
- the process for preparing the iron- based catalyst pre-cursor wherein the main iron phase is ferrihydrite, and wherein the catalyst composition includes alumina includes the following steps:
- the Al ions may be included in step 2 with the precipitation agent.
- the calcined precipitate is further impregnated with a desired level of the alkaline or alkaline earth metal, such as K, Na and La.
- a process for producing higher paraffins, alcohols and olefins selectively by reacting hydrogen with carbon monoxide in the presence of a catalyst substantially as described herein above.
- a process for producing linear paraffins, alcohols and olefins selectively in a preferred embodiment of the invention there is provided a process for producing linear paraffins, alcohols and olefins selectively.
- this invention relates to a catalyst composition for, and method of, selectively converting synthesis gas under Fischer-Tropsch conditions (at pressures of 20 to 100 bar (2 to 10 MPa) and low temperatures of 200 to 310°C) to paraffins, olefins and, more especially, to linear alcohols in significant yields, up to and including detergent alcohols.
- Catalyst compositions according to preferred embodiments of the invention are iron-based and the main iron phase is ferrihydrite and include alumina as a structural promoter.
- alumina as a structural promoter in an iron-based catalyst composition wherein the main iron phase is ferrihydrite increases the activity and selectivity of the catalyst (compared to the catalyst described in WO 01/89689) by 1.5 to 3 times.
- the catalyst composition also preferably includes manganese as a structural promoter, and chemical promoters selected from magnesium and zinc.
- a preferred catalyst composition according to the invention includes alumina, manganese, zinc, copper and potassium.
- a typical composition of this invention comprises, by mass, 35% to 65% Fe, 1% to 25% Mn, 1% to 15% Zn, 1% to 25% Cu, 0.1% to 3% K 2 O, and 5% to 20% AI 2 O 3 .
- the catalyst composition of the invention may be produced by making a first acidic solution containing Fe nitrate (Fe (NO 3 ) 3 - 9H 2 O), Mn nitrate (Mn (NO 3 ) 3 - 4H 2 O), Zn nitrate Zn (NO 3 ) 3 - 6H 2 O), Cu nitrate Cu (NO 3 ) 3 - 3H 2 O), K nitrate (KNO 3 ) and Al nitrate (Al (NO 3 ) 3 - 9H 2 O), and heating the solution to 75°C. A second basic solution, containing 25%, by mass, KOH and at a temperature of 45°C is then added to the solution.
- the rate at which the second solution is added to the first solution is adjusted so that the pH is maintained at a range of approximately 8 and the temperature at approximately 70°C.
- the addition of the second solution to the first solution causes the formation of a precipitate, which is the catalyst composition of the invention.
- the precipitate is then filtered, and washed and the filter cake then reslurried and spray-dried at an inlet temperature of 260°C and an outlet temperature of 120°C. Thereafter, on-spec catalyst is calcined at 450°C for 16 hours and sieved to a particle size of 38-150 ⁇ m.
- the alumina can be included by co-precipitation by adding Al nitrate to the second basic solution, or it could be added to the washed precipitate by mixing a solution containing Al nitrate or Al hydroxide with the slurried precipitate and spray-drying and calcining the resulting mixture.
- the K can also be added in other ways, for example by impregnation after calcination of the composition. Descriptions of these alternative methods are provided in the Examples.
- the catalyst composition according to the invention so-formed is iron- based, the main iron phase is ferrihydrite, and the catalyst has a surface area of 150-300m 2 /g and a pore volume of 0.1-0.5, typically 0.3 m 3 /g.
- the preparation stage is simplified as the binder addition stage may be eliminated.
- a Fischer-Tropsch synthesis process is carried out with an iron-based catalyst composition according to the invention as described above in a slurry bed reactor containing a crude synthetic paraffin or wax liquid with a carbon chain length varying from C 10 to C 12 0, such as the wax obtained from a slurry bed reactor process, using either Fe or Co based catalysts.
- An iron-based catalyst composition as described above is then suspended in the slurry medium, the catalyst loading ranging between 10 and 40 % by weight of the slurry.
- the slurry is stirred and conditioned by causing pure H 2 , CO or a hydrogen rich H 2 /CO mixture to flow continuously through the medium for approximately 20 hours.
- catalyst conditioning that is reduction and carbiding
- H 2 , CO or H 2 /CO Thereafter, synthesis gas is caused to flow continuously through the conditioned slurry.
- the composition of the synthesis gas feed generally comprises H 2 and CO in an H 2 :CO molar ratio in the range of about 5:1 to about 1 :5, preferably in the range of about 1 :1 to 2:1.
- the feed synthesis gas may also comprise about 1 to 25 volume percent CO 2 , N 2 , and /or CH 4 .
- the reactor is operated at a temperature between 200 and 310°C; preferably between 220 and 250°C, most preferably at about 240 °C; and pressure between 10 and 100 bar (1 and 10 MPa).
- Fischer-Tropsch activity is increased 1.5-3 times.
- Productivity towards olefins and alcohols is increased 1.5-3 times and selectivities increased 1.5-2 times.
- a further advantage of the catalyst of the invention is enhancement of the C 6+ alcohol and olefin fractions in the order of 1.5-2 times.
- Preparation of the catalyst composition of the invention according to the preferred method also has economic and environmental advantages as co-precipitation of aluminium together with all other elements reduces the loss of metals during the preparation process.
- a solution containing 1787g of Fe(NO 3 ) 3 .9H 2 O; 400g of Mn(NO 3 ) 3 .4H 2 O; 345g of AI(NO 3 ) 3 .9H 2 O; 69g of Cu(NO 3 ) 3 .3H 2 O and 143g of Zn(NO 3 ) 3 .6H 2 O in 4200 ml of water was heated to 75°C and mixed with a second solution containing 25% (mass) KOH kept at 45°C. The rate at which these solutions were fed was adjusted such that the precipitation pH was ⁇ 8 and the temperature was ⁇ 70°C. The precipitate was filtered, washed thoroughly with water until the conductivity was 2.0mSv.
- the filter cake was then reslurried and spray dried at an inlet temperature of 260°C and outlet of 120°C. Thereafter the on-spec catalyst was calcined at 450°C for 16 hours and finally sieved between 38 and 150 microns before being characterised and tested.
- the composition of the first catalyst of the invention is represented in Table 1. Table 1.
- a second catalyst of the invention was prepared by the same procedure outlined in Example 1 but with the aim of removing all the K 2 O during washing.
- the K 2 O level after calcination was 0.16g/100g Fe.
- the catalyst was impregnated to the desired K 2 O level of 1.00g/100g Fe using the slurry impregnation method:
- Catalyst 3 was prepared by the same procedure outlined in Example 1. The K 2 O level after calcination was 5.3g/100g Fe. The excess K 2 O was removed by washing the catalyst with dilute HNO 3 as follows:
- Catalysts 4-6 are prepared via a continuous preparation method.
- a metal solution Fe, Zn, Mn and Cu nitrates
- the rate at which these solution were fed was adjusted such that the precipitation pH was ⁇ 8 and the temperature was ⁇ 70 °C.
- the precipitate was filtered and washed until the conductivity was 2.0 mSv. The precipitate was then separated into different batches and Al additions investigated as described in the Examples 4-6.
- Al hydroxide was mixed with the washed iron slurry to obtain desired alumina levels. This procedure is followed by spray drying and calcination. The final composition of the fifth catalyst is present in Table 5.
- Catalysts 7 and 8 were prepared with co-precipitating AI(NO 3 ) 3 .9H 2 O together with the other metal nitrates whereas in catalysts 9 and 10, AI(NO 3 ) 3 .9H 2 O was mixed into the catalyst slurry before spray drying.
Abstract
Description
Claims
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AU2002347460A AU2002347460A1 (en) | 2001-11-22 | 2002-11-20 | Ferrihydrite and aluminium-containing fischer-tropsch catalysts |
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US33200401P | 2001-11-23 | 2001-11-23 | |
US60/332,004 | 2001-11-23 |
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WO2009043445A1 (en) * | 2007-09-27 | 2009-04-09 | Bayer Materialscience Ag | Method for the production of a catalyst used for manufacturing carbon nanotubes |
CN100594060C (en) * | 2004-06-24 | 2010-03-17 | 青岛金王应用化学股份有限公司 | Catalyst for preparing pyroparaffine from synthesis gas and preparation method thereof |
EP2237882A2 (en) * | 2007-12-17 | 2010-10-13 | Sud-Chemie, Inc. | Iron-based water gas shift catalyst |
US20110201702A1 (en) * | 2009-08-14 | 2011-08-18 | Sumit Bali | Ultra small synthetic doped ferrihydrite with nanoflake morphology for synthesis of alternative fuels |
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EP2439185A1 (en) * | 2010-08-20 | 2012-04-11 | Shell Internationale Research Maatschappij B.V. | Process for preparing olefins from synthesis gas using a cobalt and manganese containing catalyst |
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AU2002347460A1 (en) | 2003-06-10 |
CN1589176A (en) | 2005-03-02 |
CN100584454C (en) | 2010-01-27 |
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