Sasol Technology Proprietary Limited

Sasol Technology (pty) Limited

Abdool Muthalib Saib

Jan Van De Loosdrecht

Jan Mattheus Botha

Michael Steven Datt

Johannes Gerhardus Koortzen

Alta Bohmer

Jacobus Lucus Visagie

Jacobus Lucas Visagie

Herman Preston

A process for producing hydrocarbons and, optionally, oxygenates of hydrocarbons is provided. A synthesis gas comprises hydrogen, carbon monoxide and N-containing contaminants selected from the group consisting of HCN, NH, NO, RNH, R&#x2014;CN and heterocyclic compounds containing at least one nitrogen atom as a ring member of a heterocyclic ring of the heterocyclic compound. The N-containing contaminants constitute, in total, at least 100 vppb but less than 1 000 000 vppb of the synthesis gas. The synthesis gas is contacted at an elevated temperature and an elevated pressure, with a particulate supported Fischer-Tropsch synthesis catalyst. The catalyst comprises a catalyst support, Co in catalytically active form supported on the catalyst support, and a dopant selected from the group consisting of platinum (Pt), palladium (Pd), ruthenium (Ru) and/or rhenium (Re). The dopant level is expressed by a formula. Hydrocarbons and, optionally, oxygenates of hydrocarbons are obtained.

Production of hydrocarbons

A process for regenerating a spent cobalt Fischer-Tropsch synthesis catalyst includes subjecting a spent particulate cobalt Fischer-Tropsch synthesis catalyst sequentially to a dewaxing treatment, an oxidation treatment at a pressure of 4 to 30 bar(a) and a reduction treatment, thereby regenerating the catalyst.

Catalysts

A process for producing a supported cobalt-based Fischer-Tropsch synthesis catalyst includes, in a first activation stage, treating a particulate catalyst precursor with a reducing gas, at a heating rate, HR1, until the precursor has reached a temperature, T, where 80&#xb0; C.&#x2266;T&#x2266;180&#xb0; C., to obtain a partially treated precursor. In a second activation stage, the partially treated precursor is treated with a reducing gas, at an average heating rate, HR2, with x step increments, where 0&#x3c;HR2&#x3c;HR1, for a time, t, where tis from 0.1 to 20 hours, to obtain a partially reduced precursor. Thereafter, in a third activation stage, the partially reduced precursor is treated with a reducing gas, at a heating rate, HR3, where HR3&#x3e;HR2 until the partially reduced precursor reaches a temperature, T. The partially reduced precursor is maintained at Tfor a time, t, where tis from 0 to 20 hours, to obtain an activated catalyst.

A process for producing a supported cobalt-based Fischer-Tropsch synthesis catalyst includes, in a first activation stage, treating a particulate catalyst precursor with a reducing gas, at a heating rate, HR1, until the precursor has reached a temperature, T, where 80&#xb0; C.&#x2266;T&#x2266;180&#xb0; C., to obtain a partially treated precursor. In a second activation stage, the partially treated precursor is treated with a reducing gas, at a heating rate, HR2, where 0&#x2266;HR2&#x3c;HR1, for a time, t, where tis from 0.1 to 20 hours, to obtain a partially reduced precursor. Thereafter, in a third activation stage, the partially reduced precursor is treated with a reducing gas, at a heating rate, HR3, where HR3&#x3e;HR2 until the partially reduced precursor reaches a temperature, T. The partially reduced precursor is maintained at Tfor a time, t, where tis from 0 to 20 hours, to obtain an activated catalyst.

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Vanderbijlpark, South Africa

Abdool Muthalib Saib