Catalyst

Abstract

A calcium promoted, aluminum compound supported nickel reforming catalyst for use in a hydrocarbon feed stream containing steam, CO 2 , CH 4 and CO at levels such that the H 2 O/CH 4 is less than 0.8 and the CO 2 /CH 4 is greater than 0.5 and the feed stream further containing quantities of sulfur compounds up to about 20 ppm. The catalyst contains from about 0.5 percent to about 25 percent by weight of a calcium compound additive, from about 2 percent to about 30 percent by weight nickel, and from about 25 percent to about 98 percent by weight of an aluminum compound carrier, wherein substantially all of the calcium is combined with the alumina. The catalyst can be used in reforming reactions to produce syngas and has advantages in producing low hydrogen to carbon monoxide ratio syngas for applications such as iron ore reduction.

1 . A reforming catalyst for use in a feed stream containing hydrocarbons, such as CH 4 , steam, CO 2 , and CO at levels such that the H 2 O/CH 4  is less than 0.8 and the CO 2 /CH 4  is greater than 0.5, the feed stream further containing relatively high quantities of sulfur compounds, the catalyst comprising from about 0.5 percent to about 25 percent by weight of a calcium compound additive, from about 2 percent to about 30 percent by weight nickel, and from about 25 percent to about 98 percent by weight of an aluminum compound carrier, wherein substantially all of the calcium is combined with the alumina.  
     
     
         2 . The catalyst of  claim 1  wherein the calcium compound combined with the aluminum compound comprises calcium aluminate.  
     
     
         3 . The catalyst of  claim 1  wherein the amount of free calcium oxide present in the catalyst is not detectable by x-ray diffraction.  
     
     
         4 . The catalyst of  claim 1  wherein the calcium compound comprises from about 2 percent to about 20 percent by weight of the catalyst.  
     
     
         5 . The catalyst of  claim 1  wherein the nickel comprises from about 2 percent to about 20 percent by weight of the catalyst.  
     
     
         6 . The catalyst of  claim 1  wherein the nickel comprises from about 3 percent to about 20 percent by weight of the catalyst.  
     
     
         7 . The catalyst of  claim 1  with a BET surface area greater than about 4 m 2 /g.  
     
     
         8 . The catalyst of  claim 1  with a BET surface area from about 4 m 2 /g to about 35 m 2 /g.  
     
     
         9 . The catalyst of  claim 1  with a nickel surface area greater than about 2 m 2 /g.  
     
     
         10 . The catalyst of  claim 1  with a nickel surface area greater than about 4 m 2 /g.  
     
     
         11 . The catalyst of  claim 1  with a pore volume greater than about 0.2 cc/gm.  
     
     
         12 . A process for formation of a calcium promoted, nickel catalyst for use in feed streams containing hydrocarbons, such as CH 4 , steam, CO 2 , and CO at levels such that the H 2 O/CH 4  is less than 0.8 and the CO 2 /CH 4  is greater than 0.5, the feed stream further containing relatively high quantities of sulfur compounds, the process comprising blending an aluminum compound carrier with a calcium compound promoter, forming the blended material into a desirable shape, treating and calcining the shaped material to form a catalyst precursor, impregnating the catalyst precursor with a nickel compound and calcining the impregnated material to form the catalyst.  
     
     
         13 . A process for the conversion of a hydrocarbon feed stream containing steam, CO 2 , CH 4 , and CO at levels such that the H 2 O/CH 4  is less than 0.8 and the CO 2 /CH 4  is greater than 0.5, the feed stream further containing relatively high quantities of sulfur compounds, the catalyst comprising from about 0.5 percent to about 25 percent by weight of a calcium compound additive, from about 2 percent to about 30 percent by weight nickel, and from about 25 percent to about 98 percent by weight of an aluminum compound carrier, wherein substantially all of the calcium is combined with the alumina.  
     
     
         14 . The process of  claim 13  wherein the concentration of sulfur in the hydrocarbon feed stream is greater than about 0.1 ppm.  
     
     
         15 . The process of  claim 13  wherein the concentration of sulfur in the hydrocarbon feed stream is greater than about 1 ppm.  
     
     
         16 . The process of  claim 13  wherein the quantity of steam in the hydrocarbon feed stream is less than about 20 mole percent.  
     
     
         17 . The process of  claim 13  wherein the quantity of the CO and CO 2  in the hydrocarbon feed stream is at least about 20 mole percent.