Processes for the production of liquid fuels from carbon containing feedstocks, related systems and catalysts

Abstract

The present invention is directed to unique processes, catalysts and systems for the direct production of liquid fuels (e.g., premium diesel fuel) from synthesis gas produced from natural feedstocks such as natural gas, natural gas liquids, carbon dioxide or other similar compounds or materials. In one aspect, the present invention provides a process for the production of a hydrocarbon mixture comprising the steps of: a) reducing a catalyst in-situ in a fixed bed reactor; b) reacting a feed gas that contains hydrogen and carbon monoxide with the catalyst to produce a hydrocarbon product stream, wherein the hydrocarbon product stream comprises light gases, a diesel fuel and a wax, and wherein the diesel fuel fraction is produced without requiring the hydroprocessing of wax, and wherein the catalyst comprises one or more metals deposited on a gamma alumina support at greater than about 5 weight percent, and wherein platinum or rhenium is included on the support in an amount ranging from about 0.01 weight percent and about 2 weight percent as a promoter, and wherein the catalyst has surface pore diameters between about 100 and 150 Angstroms, sub-surface pore diameters between 10 and 30 Angstroms a crush strength greater than about 3 lbs./mm, a mean effective pellet radius less than about 600 microns, and a BET surface area greater than about 100 m/g, and wherein the diesel fuel comprises more than about 70 percent C-Chydrocarbons.