Rentech, Inc.

Res Usa, LLC

Eltron Research & Development, Inc.

Sara L Rolfe

Harold A Wright

Belma Demirel

Jesse Wade Taylor

Dawid J Duvenhage

Charles B Benham

Bahman Rejai

Pandurang V Nikrad

Sergio Mohedas

Olga Ionkina

Deena Ferdous

Richard A Bley

Dan Fraenkel

James H White

Ray J Huang

Olga P Ionkina

Erick J Schutte

Danny M Dubuisson

Ray Huang

A method of strengthening a precipitated unsupported iron catalyst by: preparing a precipitated unsupported iron catalyst containing copper and potassium; adding a solution comprising a structural promoter to the previously prepared catalyst; drying the mixture; and calcining the dried catalyst. A method for preparing an iron catalyst, the method comprising: precipitating a catalyst precursor comprising iron phases selected from hydroxides, oxides, and carbonates; adding a promoter to the catalyst precursor to yield a promoted precursor; drying the promoted precursor to yield dried catalyst; and calcining the dried catalyst, wherein the catalyst further comprises copper and potassium. A method of preparing a strengthened precipitated iron catalyst comprising: co-precipitating iron, copper, magnesium, and aluminum; washing the precipitate; alkalizing the precipitate; and drying the precipitate to yield a dried catalyst precursor. The dried catalyst precursor may be calcined and treated with a gas comprising carbon monoxide.

Strengthened iron catalyst for slurry reactors

A method of preparing a spray dried catalyst by combining spray dried catalyst particles with wax so the spray dried catalyst particles are coated with wax, yielding wax coated catalyst particles, and shaping the wax coated catalyst to provide shaped wax coated catalyst. A method of activating Fischer-Tropsch catalyst particles containing oxides by contacting the catalyst particles with a reducing gas in an activation vessel to produce an activated catalyst, wherein contacting is performed in the absence of a liquid medium under activation conditions. A system for activating a Fischer-Tropsch catalyst containing an activation reactor configured to introduce an activation gas to a fixed or fluidized bed of the Fischer-Tropsch catalyst in the absence of a liquid medium and at least one separation device configured to separate a gas stream comprising entrained catalyst fines having an average particle size below a desired cutoff size from the activation reactor.

Protected Fischer-Tropsch catalyst and method of providing same to a Fischer-Tropsch process

A method of producing stable ferrous nitrate solution by dissolving iron in nitric acid to form a ferrous nitrate solution and maintaining the solution at a first temperature for a first time period, whereby the Fe(II) content of the ferrous nitrate solution changes by less than about 2% over a second time period. A method of producing stable Fe(II)/Fe(III) nitrate solution comprising ferrous nitrate and ferric nitrate and having a desired ratio of ferrous iron to ferric iron, including obtaining a stable ferrous nitrate solution; dissolving iron in nitric acid to form a ferric nitrate solution; maintaining the ferric nitrate solution at a second temperature for a third time period; and combining amounts of stable ferrous nitrate solution and ferric nitrate solution to produce the stable Fe(II)/Fe(III) nitrate solution. A method of preparing an iron catalyst is also described.

Stable ferrous-ferric nitrate solutions for fischer-tropsch catalyst preparation

Protected fischer-tropsch catalyst and method of providing same to a fischer-tropsch process

Processes are disclosure which comprise alternately contacting an oxygen-carrying catalyst with a reducing substance, or a lower partial pressure of an oxidizing gas, and then with the oxidizing gas or a higher partial pressure of the oxidizing gas, whereby the catalyst is alternately reduced and then regenerated to an oxygenated state. In certain embodiments, the oxygen-carrying catalyst comprises at least one metal oxide-containing material containing a composition having the following formulas: (a) CeBB'B&#x2033;O, wherein B=Ba, Sr, Ca, or Zr; B&#x2032;=Mn, Co, and/or Fe; B&#x2033;=Cu; 0.01&#x3c;x&#x3c;0.99; 0&#x3c;y&#x3c;0.6; 0&#x3c;z&#x3c;0.5; (b) CeNiBO, wherein B=Zr, Ba, Ca, La, or K; 0.02&#x3c;x&#x3c;0.1; 0&#x3c;y&#x3c;0.1; and 0.02&#x3c;*&#x3c;0.15; and 1&#x3c;&#x3b4;&#x3c;2.2 and (c) coal ash either as a catalyst material itself or as a support for said unary or binary metal oxides.

Cyclic catalytic upgrading of chemical species using metal oxide materials

A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe:Feratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe:Feratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.

Precipitated iron catalyst for hydrogenation of carbon monoxide

A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe:Feratio in the range of about 0.01%: 99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe:Feratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.

A method of activating an iron Fischer-Tropsch catalyst by introducing an inert gas into a reactor comprising a slurry of the catalyst at a first temperature, increasing the reactor temperature from the first temperature to a second temperature at a first ramp rate, wherein the second temperature is in the range of from about 150&#xb0; C. to 250&#xb0; C., introducing synthesis gas having a ratio of H:CO to the reactor at a space velocity, and increasing the reactor temperature from the second temperature to a third temperature at a second ramp rate, wherein the third temperature is in the range of from about 270&#xb0; C. to 300&#xb0; C. The iron Fischer-Tropsch catalyst may be a precipitated unsupported iron catalyst, production of which is also provided.

Method for activating strengthened iron catalyst for slurry reactors

Processes are disclosure which comprise alternately contacting an oxygen-carrying catalyst with a reducing substance, or a lower partial pressure of an oxidizing gas, and then with the oxidizing gas or a higher partial pressure of the oxidizing gas, whereby the catalyst is alternately reduced and then regenerated to an oxygenated state. In certain embodiments, the oxygen-carrying catalyst comprises at least one metal oxide-containing material containing a composition having one of the following formulas: (a) CeBB'B&#x2033;O, wherein B=Ba, Sr, Ca, or Zr; B&#x2032;=Mn, Co, or Fe; B&#x2033;=Cu; 0.01&#x3c;x&#x3c;0.99; 0&#x3c;y&#x3c;0.6; 0&#x3c;z&#x3c;0.5; and 1&#x3c;&#x3b4;&#x3c;2.2; (b) SrLaBB&#x2032;B&#x2033;O, wherein B=Co or Fe; B&#x2032;=Al or Ga; B&#x2033;=Cu; 0.01&#x3c;v&#x3c;1.4; 0.1&#x3c;w&#x3c;1.6; 0.1&#x3c;x&#x3c;1.9; 0.1&#x3c;y&#x3c;0.9; 0&#x3c;z&#x3c;2.2; and 3&#x3c;&#x3b4;&#x3c;5.5).

Growing community of inventors

Loveland, CO, United States of America

Sara L Rolfe