Modified catalyst supports

a technology of catalyst support and modified catalyst, which is applied in the direction of physical/chemical process catalyst, organic compound/hydride/coordination complex catalyst, metal/metal-oxide/metal-hydroxide catalyst, etc., can solve the problems of significant collision and frictional force, and attrition of catalyst and/or catalyst support. , to achieve the effect of increasing the operating cost of the catalys

Inactive Publication Date: 2009-08-20
ROBOTA HEINZ J +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The treated catalyst supports exhibit improved attrition resistance and regenerability, reducing the formation of fines and maintaining catalyst activity, thereby lowering operating costs and extending catalyst lifespan.

Problems solved by technology

Supported catalysts used in Fischer-Tropsch reactors, including for example, slurry bubble column reactors and continuously stirred tank reactors (“CSTR”), are subjected to agitation causing significant collisions and frictional forces.
Such collisions and forces can result in damage mechanisms which, over time, may cause attrition of the catalyst and / or catalyst support.
Attrition of catalyst and / or catalyst support raises operating costs due to increased catalyst requirements.
Moreover, attrition results in the production of fines which must be removed by filtration.
The filtration process may cause loss of active catalyst in addition to removal of the fines, thereby further raising operating costs.
Catalyst supports used in fixed bed reactors may also be subjected to movement and collisions during batch or continuous regeneration processes.
Consequently, some attrition may occur with fixed bed reactors.
Moreover, catalyst supports, such as shaped extrudates, frequently show appreciable attrition during catalyst production, e.g. cobalt deposition onto the support.
However, the use of non-aqueous solvents raises costs due to the cost of the solvents themselves as well as the cost of specialized equipment.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

Preparation of Catalyst Sample I

[0040]MSA reagent solution was prepared with 94.9 g TEOS rapidly added to 4 L of acidified-demineralized water under vigorous stirring. Sufficient HNO3 was added to the water to bring the pH to between 2.2 and 2.5 and held between 3° C. and 8° C. 15 minutes after TEOS addition, an aliquot was removed and the rate of color change tested. Greater than 90% of the full color developed within 5 minutes. In a separate stirred, heated vessel, a slurry of the alumina support containing 640 g alumina suspended in 2 L of demineralized water was heated. The slurry was held at 50°±5° C. throughout the addition of the MSA reagent, which was added at a rate of 35 ml / min. Following completion of the MSA addition, the slurry was stirred and kept at 50°±5° C. until >95% of the silicon Was reacted with the alumina. Once reaction was complete, stirring was stopped, the solids allowed to settle, and the clear mother liquor decanted from the vessel. The remaining dense sl...

example 2

Preparation of Catalyst Sample 2

[0042]MSA reagent solution was prepared with 73.6 g TEOS rapidly added to 667 ml of acidified demineralized water under vigorous stirring. Sufficient HNO3 was added to the water to bring the pH to between 2.2 and 2.5 and held between 3° C. and 8° C. 15 minutes after TEOS addition, an aliquot was removed and the rate of color change tested. Greater than 90% of the full color developed within 5 minutes. In a separate stirred, heated vessel, a slurry of the alumina support containing 10 g alumina suspended in 333 ml of demineralized water was heated. The slurry was held at 50°±50° C. throughout the addition of the MSA reagent, which was added at a rate of 5 ml / min. Following completion of the MSA addition, the slurry was stirred and kept at 50°±5° C. until >95% of the silicon was reacted with the alumina. Once reaction was complete, stirring was stopped, the solids allowed to settle, and the clear mother liquor decanted from the vessel. The remaining den...

example 3

Preparation of Catalyst Sample 3

[0044]MSA reagent solution was prepared with 94.9 g TEOS rapidly added to 4 L of acidified demineralized water under vigorous stirring. Sufficient HNO3 was added to the water to bring the pH to between 2.2 and 2.5 and held between 3° C. and 8° C. 15 minutes after TEOS addition, an aliquot was removed and the rate of color change tested. Greater than 90% of the full color developed within 5 minutes. A slurry of the alumina support containing 640 g alumina suspended in 2 L of demineralized water was added to the MSA. The mixture was then heated to 50°±5° C. The mixture was stirred and kept at 50°±5° C. until >95% of the silicon was reacted with the alumina. Once reaction was complete, stirring was stopped, the solids allowed to settle, and the clear mother liquor decanted from the vessel. The remaining dense slurry was vacuum filtered to remove the remainder of the solution. The filtered solid was spread onto a drying tray to a thickness less than 1.5 c...

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Abstract

A modified catalyst support exhibiting attrition resistance and / or deaggregation resistance is provided. A catalyst composition including the modified catalyst support is also provided. A process to produce a modified catalyst support including treatment of a support slurry with a solution of monosilicic acid is provided. A process to use a catalyst including the modified catalyst support in a Fischer-Tropsch synthesis is provided.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional application of U.S. Ser. No. 11 / 008,883 filed Dec. 10, 2004, which claims benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 60 / 529,310 entitled “Attrition Resistant Catalyst Supports” filed on Dec. 12, 2003. The entire contents of each of the above-referenced applications are hereby expressly incorporated herein by reference.FEDERALLY SPONSORED RESEARCH[0002]Not applicable.REFERENCE TO MICROFICHE APPENDIX[0003]Not applicable.FIELD OF THE INVENTION[0004]The invention relates to modified catalyst supports showing attrition resistance, and / or, deaggregation-resistance, and / or regenerability. The invention further relates to a process to produce modified catalyst supports. The invention further relates to the use of Fischer-Tropsch catalysts including attrition-resistant catalyst, and / or, deaggregation-resistant, and / or regenerable supports in Fischer-Tropsch synthesis.BACKGROUND ...

Claims

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Application Information

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Patent Type & AuthorityApplications(United States)
IPC IPC(8): B01J23/04B01J21/06B01J21/12B01J23/10B01J23/889B01J23/89B01J31/02B01J37/02C10G2/00C10L1/00
CPCB01J21/12B01J23/8896B01J23/8913B01J23/894B01J23/8946B01J31/0274B01J37/0205B01J37/0209B01J2231/648C10G2/331C10G2/332C10G2/333
InventorROBOTA, HEINZ J.GOODMAN, SHELLY
OwnerROBOTA HEINZ J