Method of manufacturing iron-base catalysts and methods of manufacturing hydrocarbons using iron-base catalysts made by the method

Patent metadata

Field	Value
Publication number	US-10508243-B2
Application number	US-201615568538-A
Country	US
Kind code	B2
Filing date	Apr 22, 2016
Priority date	Apr 23, 2015
Publication date	Dec 17, 2019
Grant date	Dec 17, 2019

Abstract

The present invention relates to a method for producing liquid or solid hydrocarbons from a synthesis gas via Fischer-Tropsch synthesis which does not carry out a separate reduction pre-treatment for catalyst activation. The method for producing liquid or solid hydrocarbons from a synthesis gas using Fischer-Tropsch synthesis according to the present invention comprises: a first step of applying an iron-based catalyst for the Fischer-Tropsch synthesis in which the number of iron atoms in the ferrihydrite phase fraction equals 10 to 100% and the number of iron atoms in the hematite phase fraction equals 0 to 90%, with respect to 100% of the number of the number of iron atoms, to a Fischer-Tropsch synthesis reactor; and a second step of activating the catalyst for the Fischer-Tropsch synthesis by a synthesis gas which is a reactant under the conditions of the Fischer-Tropsch synthesis and carrying out the Fischer-Tropsch synthesis by means of the activated catalyst for the Fischer-Tropsch synthesis. As such, the present invention is capable of efficiently producing liquid or solid hydrocarbons from a synthesis gas via Fischer-Tropsch synthesis, even without a separate reduction pre-treatment.

First claim

What is claimed is:

1. A method of producing an activated iron-based catalyst, comprising performing an activation of an iron-based catalyst by synthesis gas at a high pressure of 1 to 3 MPa, without performing a separate activation of an iron-based catalyst by synthesis gas at a low pressure of less than 1 MPa,
wherein the iron-based catalyst includes ferrihydrite and hematite,
wherein the number of iron atoms in the ferrihydrite is from not less than 10% to not more than 100%, and the number of iron atoms in the hematite is from more than 0% to not more than 90% with respect to 100% of the number of iron atoms in the iron-based catalyst,
wherein the iron-based catalyst is made by using silica (SiO 2 ) as the structural promoter and the mass ratio of iron (Fe) to silica (SiO 2 ) in the iron-based catalyst is Fe:SiO 2 =100:11 to 100:27.

2. The method according to claim 1 , wherein the number of iron atoms in the ferrihydrite is 100% with respect to 100% of the number of iron atoms in the iron-based catalyst.

3. The method according to claim 1 , wherein the activation is performed in a slurry bubble column reactor.

4. The method according to claim 1 , wherein the ferrihydrite is represented by the following Chemical Formula 1:
FeOOH. n H 2 O (0 <n< 1).  [Chemical Formula 1]

5. The method according to claim 1 , wherein the activation is performed at a temperature of 240 to 300° C. and a space velocity of 2 to 20 NL/g (cat) /h.

6. The method according to claim 1 , wherein the synthesis gas introduced for the activation has a H 2 /CO ratio of 0.7 to 2.5 by volume.

7. A method of producing hydrocarbons, comprising performing an activation of an iron-based catalyst by synthesis gas at a high pressure of 1 to 3 MPa, without performing a separate activation of an iron-based catalyst by synthesis gas at a low pressure of less than 1 MPa, and simultaneously performing a Fischer-Tropsch synthesis reaction to produce hydrocarbons which include liquid-phase hydrocarbons,
wherein the iron-based catalyst includes ferrihydrite and hematite,
wherein the number of iron atoms in the ferrihydrite is from not less than 10% to not more than 100%, and the number of iron atoms in the hematite is from more than 0% to not more than 90% with respect to 100% of the number of iron atoms in the iron-based catalyst,
wherein the iron-based catalyst is made by using silica (SiO 2 ) as the structural promoter and the mass ratio of iron (Fe) to silica (SiO 2 ) in the iron-based catalyst is Fe:SiO 2 =100:11 to 100:27.

8. The method according to claim 7 , wherein the number of iron atoms in the ferrihydrite is 100% with respect to 100% of the number of iron atoms in the iron-based catalyst.

9. The method according to claim 7 , wherein the activation and the Fischer-Tropsch synthesis reaction are performed in a slurry bubble column reactor.

10. The method according to claim 7 , wherein the ferrihydrite is represented by the following Chemical Formula 1:
FeOOH. n H 2 O (0 <n< 1).  [Chemical Formula 1]

11. The method according to claim 7 , wherein the activation and the Fischer-Tropsch synthesis reaction are performed at a temperature of 240 to 300° C. and a space velocity of 2 to 20 NL/g (cat) /h.

12. The method according to claim 7 , wherein the synthesis gas introduced for the activation and the Fischer-Tropsch synthesis reaction has a H 2 /CO ratio of 0.7 to 2.5 by volume.

Assignees

• Korea Inst Energy Res

Inventors

• Chun Dong Hyun
• Jung Heon
• Hong Sung Jun
• Park Ji Chan
• Lee Ho Tae
• Yang Jung Il

Classifications

• C10G2/342

  with moving solid catalysts · CPC title

• B01J37/0045

  Drying a slurry, e.g. spray drying · CPC title

• B01J37/033

  Using Hydrolysis · CPC title

• B01J23/002

  Mixed oxides other than spinels, e.g. perovskite · CPC title

• B01J2523/00

  Constitutive chemical elements of heterogeneous catalysts · CPC title