Zeolite Supported Cobalt Hybrid Fischer-Tropsch Catalyst

Abstract

A method for forming a catalyst for synthesis gas conversion comprises impregnating a zeolite extrudate using a solution, for example, a substantially non-aqueous solution, comprising a cobalt salt to provide an impregnated zeolite extrudate and activating the impregnated zeolite extrudate by a reduction-oxidation-reduction cycle.

1 . A method for forming a catalyst for synthesis gas conversion, the method comprising:
 impregnating a zeolite extrudate with cobalt using a solution comprising a cobalt salt to provide an impregnated zeolite extrudate; and   activating the impregnated zeolite extrudate by a reduction-oxidation-reduction cycle.   
   
   
       2 . The method of  claim 1 , wherein the solution comprises a substantially non-aqueous solution. 
   
   
       3 . The method of  claim 1 , wherein the catalyst further comprises an element selected from the group consisting of Ru, Rh, Pd, Cu, Ag, Au, Zn, Cd, Hg, and Re. 
   
   
       4 . The method of  claim 1 , wherein the catalyst further comprises ruthenium. 
   
   
       5 . The method of  claim 4 , wherein the solution further comprises a ruthenium salt. 
   
   
       6 . The method of  claim 1 , wherein the cobalt salt comprises cobalt nitrate. 
   
   
       7 . The method of  claim 1 , wherein the zeolite extrudate comprises an alumina-bound zeolite extrudate. 
   
   
       8 . The method of  claim 1 , wherein impregnating the zeolite extrudate with cobalt comprises multiple impregnations. 
   
   
       9 . The method of  claim 8 , wherein the multiple impregnations further comprise intervening drying and calcination treatments. 
   
   
       10 . The method of  claim 9 , wherein the calcination treatments comprise calcination in air. 
   
   
       11 . The method of  claim 1 , wherein the reduction-oxidation-reduction cycle is conducted at a temperature in a range of about 100° to about 450° C. 
   
   
       12 . The method of  claim 11 , wherein the reduction-oxidation-reduction cycle is conducted at a temperature in a range of about 250° to about 400° C. 
   
   
       13 . The method of  claim 11 , wherein:
 a first reduction step of the reduction-oxidation-reduction cycle is conducted at a temperature in a range of about 200° to about 450° C.;   an oxidation step of the reduction-oxidation-reduction cycle is conducted at a temperature in a range of about 250° to about 350° C.; and   a second reduction step of the reduction-oxidation-reduction cycle is conducted at a temperature in a range of about 200° to about 450° C.   
   
   
       14 . The method of  claim 1 , wherein the activating is conducted while heating at a rate of from about 0.1° to about 2° C. per minute. 
   
   
       15 . The method of  claim 1 , wherein a first reduction step of the reduction-oxidation-reduction cycle is conducted in the presence of substantially pure hydrogen. 
   
   
       16 . A hybrid Fischer-Tropsch catalyst comprising a zeolite extrudate impregnated with cobalt. 
   
   
       17 . The catalyst of  claim 16 , wherein the catalyst further comprises an element selected from the group consisting of Ru, Rh, Pd, Cu, Ag, Au, Zn, Cd, Hg, and Re. 
   
   
       18 . The catalyst of  claim 16 , wherein the zeolite extrudate impregnated with cobalt further comprises ruthenium. 
   
   
       19 . A method of performing a synthesis gas conversion reaction, the method comprising contacting the catalyst of  claim 16  with synthesis gas. 
   
   
       20 . The method of  claim 16 , wherein products of the synthesis gas conversion reaction comprise:
 0-20 weight % CH 4 ;   0-20 weight % C 2 -C 4 ;   50-95 weight % C 5+ ; and   0-8 weight % C 21+ .   
   
   
       21 . The method of  claim 16 , wherein products of the synthesis gas conversion reaction comprise:
 5-15 weight % CH 4 ;   5-15 weight % C 2 -C 4 ;   60-90 weight % C 5+ ; and   0-8 weight % C 21+ .   
   
   
       22 . The method of  claim 16 , wherein products of the synthesis gas conversion reaction comprise:
 8-12 weight % CH 4 ;   8-12 weight % C 2 -C 4 ;   75-80 weight % C 5+ ; and   0-8 weight % C 21+ .