Sud-chemie Inc.

Clariant Corporation

Robert J O'Brien

X D Hu

Guido Petrini

Esterino Conca

Jeff Braden

David C Wolfe

Samantha E Sargent

Patrick J Loi

Joe Stack

Patrick McLaughlin

Richard Tuell

Paul D Schneider

Yeping Cai

Carlo Rubini

Dennis J Smith

Xd Hu

Esternio Conca

Jeff Kirchner

Todd Osbourne

Samantha Sargent

David Wolfe

Jospeh Stack

Paul Schneider

A process for producing a high surface area iron material, comprising predominantly low crystalline iron oxides, starting with a low surface area iron metal is disclosed. The iron material of the present invention has a surface area of at least about 200 m/g, and is prepared via a method which comprises reacting a low surface area iron metal with oxygen and an organic acid. The high surface area iron material formed via this method is essentially free of contaminants.

Preparation of iron oxides

A catalyst for use in the Fischer-Tropsch process, and a method to prepare the catalyst is disclosed. The catalyst of the present invention has a higher surface area, more uniform metal distribution, and smaller metal crystallite size than Fischer-Tropsch catalysts of the prior art.

High surface area, small crystallite size catalyst for Fischer-Tropsch synthesis

A method for producing a high surface area iron material starting with a low surface area iron metal is disclosed. The iron material of the present invention has a surface area of at least about 200 m/g, and is prepared via a method which comprises reacting a low surface area iron metal with oxygen and an organic acid. The high surface area iron material formed via this method is essentially free of contaminants.

High surface area iron material prepared from a low surface area iron metal precursor

A method for producing a cobalt on alumina catalyst is disclosed. The catalyst is prepared by thoroughly mixing cobalt nitrate into a peptized alumina slurry, and then spray-drying the slurry to form attrition resistant microspheres. The cobalt prepared by this invention is fully reducible. Optionally, metals such as ruthenium can be added to the cobalt/alumina catalyst by impregnation or methods known in the prior art.

Fluid/slurry bed cobalt-alumina catalyst made by compounding and spray drying

The Fischer-Tropsch catalyst of the present invention is a transition metal-based catalyst having a high surface area, a smooth, homogeneous surface morphology, an essentially uniform distribution of cobalt throughout the support, and a small metal crystallite size. In a first embodiment, the catalyst has a surface area of from about 100 m/g to about 250 m/g; an essentially smooth, homogeneous surface morphology; an essentially uniform distribution of metal throughout an essentially inert support; and a metal oxide crystallite size of from about 40 &#x212b; to about 200 &#x212b;. In a second embodiment, the Fischer-Tropsch catalyst is a cobalt-based catalyst with a first precious metal promoter and a second metal promoter on an aluminum oxide support, the catalyst having from about 5 wt % to about 60 wt % cobalt; from about 0.0001 wt % to about 1 wt % of the first promoter, and from about 0.01 wt % to about 5 wt % of the second promoter. The high surface area transition metal-based catalysts of the present invention are prepared in a non-acidic solution at a pH greater than about 7.0 , and starting with a non-acidic transition metal complex. The resulting product is a catalyst with a uniform distribution of metal throughout the catalyst particles, with a smooth and homogeneous surface morphology, and with slow crystallite growth upon heating.

A method for producing a catalyst for use in the dehydrogenation of ethylbenzene to styrene is disclosed. The catalyst of the present invention comprises a high purity metal and at least one promoter in the form of solid oxides, oxide hydrates, hydroxides, hydroxycarbonates or metals. The catalyst is prepared via a method which comprises the preparation of at least one high purity iron precursor with or without an additional support material and which uses a nominal amount of water in the catalyst production. The catalyst pellets prepared with the high purity metal precursor are essentially free of sulfur and chloride contaminants.

Catalyst for the dehydrogenation of ethyl benzene to STYRENE prepared with a high purity iron precursor

A Fischer-Tropsch catalyst comprising iron and at least one promoter is prepared via a method which comprises the preparation of a high purity iron precursor and which uses a nominal amount of water in the catalyst production. The catalyst particles prepared with the high purity iron precursor have an essentially spherical particle shape, a relatively narrow particle size distribution range, and a high surface area.

Fischer-tropsch catalyst prepared with a high purity iron precursor

The present development relates to a process for enrobing active catalytic materials with a protective coating to form pastilles, and to an apparatus for making the pastilles. The process comprises mixing an active catalyst powder with a hydrocarbon material in a low-shear jacketed blender at a temperature slightly above the congealing point of the hydrocarbon, and then making pastilles from the catalyst/hydrocarbon mixture while cooling the mixture to temperature below the congealing point of the hydrocarbon.

Method and apparatus for production of enrobed catalyst pastilles or flakes

A high temperature water gas shift catalyst comprising iron and at least one promoter is prepared via a method which comprises the preparation of a high purity iron precursor and which uses a nominal amount of water in the catalyst production. The catalyst prepared according to the inventive method is more efficient in hydrogen production under the high temperature water gas shift reaction conditions in a fixed bed test than prior art catalysts of similar composition.

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Louisville, KY, United States of America

Robert J O'Brien