Catalyst structure and method of fischer-tropsch synthesis

Abstract

The present invention includes Fischer-Tropsch catalysts, reactions using Fischer-Tropsch catalysts, methods of making Fischer-Tropsch catalysts, processes of hydrogenating carbon monoxide, and fuels made using these processes. The invention provides the ability to hydrogenate carbon monoxide with low contact times, good conversion rates and low methane selectivities. In a preferred method, the catalyst is made using a metal foam support.

1 - 12 . (canceled) 
     
     
         13 . A catalyst, comprising:
 a porous stainless steel support;   a titania layer disposed over the porous stainless steel support;   an alumina interfacial layer disposed over the titania layer; and   a Fischer-Tropsch catalytic metal selected from iron, cobalt, nickel, ruthenium, rhenium, osmium and combinations thereof disposed on the alumina interfacial layer.   
     
     
         14 . The catalyst of  claim 13  wherein the interfacial layer has a surface area, as measured by BET, of at least 1.0 m 2 /g. 
     
     
         15 . The catalyst of  claim 13  wherein the porous stainless steel support has a porosity of 30% to 99%. 
     
     
         16 . The catalyst of  claim 13  wherein the catalyst does not show spalling after 3 thermal cycles from room temperature to 600° C. in air. 
     
     
         17 . A catalyst, comprising:
 a porous nickel support;   a titania layer disposed over the porous stainless steel support;   an alumina interfacial layer disposed over the titania layer; and   a Fischer-Tropsch catalytic metal selected from iron, cobalt, nickel, ruthenium, rhenium, osmium and combinations thereof disposed on the alumina interfacial layer.