Sasol Technology Proprietary Limited

Sasol South Africa Limited

Sasol Technology (pty) Limited

Hendrik Van Rensburg

Jan Van De Loosdrecht

Jacobus Lucas Visagie

Jan Mattheus Botha

Denzil James Moodley

Jana Heloise Potgieter

Cornelia Carolina Eloff

Prabashini Moodley

The present invention relates to catalysts, more particularly to a cobalt-containing catalyst composition. The present invention further relates to a process for preparing a cobalt-containing catalyst precursor, a process for preparing a cobalt-containing catalyst, and a hydrocarbon synthesis process wherein such a catalyst is used. According to a first aspect of the invention, there is provided a cobalt-containing catalyst composition comprising cobalt and/or a cobalt compound supported on and/or in a silica (SiO) catalyst support wherein the average pore diameter of the catalyst support is more than 20 nm but less than 50 nm; the catalyst composition also including a titanium compound on and/or in the catalyst support, and a manganese compound on and/or in the catalyst support.

Cobalt-containing catalyst composition

A process for preparing a cobalt-containing hydrocarbon synthesis catalyst includes, in a carbide formation step, treating an initial catalyst precursor comprising a catalyst support supporting cobalt and/or a cobalt compound, with a CO containing gas at a temperature T. T is from 200&#xb0; C. to 280&#xb0; C. The cobalt or cobalt compound is converted to cobalt carbide thereby obtaining a cobalt carbide containing catalyst precursor. The CO containing gas (when it contains H2) does not have a CO to H2 molar ratio equal to or less than 33:1. The carbide formation step is carried out under non-oxidative conditions. In a subsequent activation step, the cobalt carbide containing catalyst precursor is subjected to treatment with a hydrogen containing gas at a temperature T2. T2 is at least 300&#xb0; C. The cobalt carbide is converted to cobalt metal thereby activating the cobalt carbide containing catalyst precursor and obtaining a cobalt-containing hydrocarbon synthesis catalyst.

Process for preparing a fischer-tropsch catalyst

A process for preparing a cobalt-containing hydrocarbon synthesis catalyst includes calcining an initial catalyst precursor comprising a catalyst support supporting a cobalt compound, by heat treating the initial catalyst precursor under non-reducing conditions in order to decompose the cobalt compound and/or to cause the cobalt compound to react with oxygen, thereby to obtain a calcined initial catalyst precursor. A cobalt compound is introduced onto and/or into the calcined initial catalyst precursor so that the calcined initial catalyst precursor supports this cobalt compound thereby obtaining a subsequent catalyst precursor. The subsequent catalyst precursor is directly subjected to reduction conditions to activate the subsequent catalyst precursor, thereby to obtain a cobalt-containing hydrocarbon synthesis catalyst.

Process for preparing a cobalt-containing fischer tropsch catalyst

A process for preparing a cobalt-containing hydrocarbon synthesis catalyst precursor includes calcining a loaded catalyst support comprising a catalyst support supporting a cobalt compound. The calcination includes subjecting the loaded catalyst support to heat treatment by heating the loaded catalyst support to a temperature, T, of at least 220&#xb0; C. at a heating rate below 10&#xb0; C./minute, and effecting gas flow at a space velocity of at least 9 mn/kg cobalt compound/hour over the loaded catalyst support during at least part of the heating. The cobalt-containing hydrocarbon synthesis catalyst precursor is thereby produced.

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Fife, United Kingdom

Hendrik Van Rensburg