Novel catalysts and process for liquid hydrocarbon fuel production

Abstract

The present invention provides a novel process and system in which a mixture of carbon monoxide and hydrogen synthesis gas, or syngas, is converted into hydrocarbon mixtures composed of high quality gasoline components, aromatic compounds, and lower molecular weight gaseous olefins in one reactor or step. The invention utilizes a novel molybdenum-zeolite catalyst in high pressure hydrogen for conversion, as well as a novel rhenium-zeolite catalyst in place of the molybdenum-zeolite catalyst, and provides for use of the novel catalysts in the process and system of the invention.

1 - 17 . (canceled) 
     
     
         18 . A catalyst for the production of hydrocarbon fuel products from synthesis gas comprising a molybdenum catalyst encaged in a zeolite support comprising one or more members selected from the group consisting of HZSM-5, Y, Mordenite, MCM-22, MCM-41, H-Y-faujasite, and H-beta zeolites. 
     
     
         19 . The catalyst of  claim 18 , further comprising at least one alkali metal as a promoter for minimizing carbon dioxide products in the production of hydrocarbon fuel products, wherein the alkali metal is selected from the group consisting of the elements of Groups 1A and 2A of the Periodic Table and mixtures thereof. 
     
     
         20 . The catalyst of  claim 18 , wherein the molybdenum catalyst is chosen from the group consisting of molybdenum oxide and molybdenum sulfide. 
     
     
         21 . The catalyst of  claim 19 , wherein the size and shape of the catalyst encaged in the zeolite support selected determines the types of hydrocarbon fuel products that are produced. 
     
     
         22 . A catalyst for the production of hydrocarbon fuel products from synthesis gas comprising a rhenium catalyst encaged in a zeolite support comprising one or more members selected from the group consisting of HZSM-5, Y, Mordenite, MCM-22, MCM-41, H-Y-faujasite, and H-beta zeolites. 
     
     
         23 . The catalyst of  claim 22 , further comprising at least one alkali metal as a promoter for minimizing carbon dioxide products in the production of hydrocarbon fuel products, wherein the alkali metal is selected from the group consisting of the elements of Groups 1A and 2A of the Periodic Table and mixtures thereof. 
     
     
         24 . The catalyst of  claim 22 , wherein the rhenium catalyst is chosen from the group consisting of rhenium oxide and rhenium sulfide. 
     
     
         25 . The catalyst of  claim 23 , wherein the size and shape of the catalyst encaged in the zeolite support selected determines the types of hydrocarbon fuel products that are produced. 
     
     
         26 . A catalyst system for producing a hydrocarbon liquid having an aromatics content of about 90% or greater, wherein the system comprises a metal on an HZSM-5 zeolite. 
     
     
         27 . A catalyst system for producing a hydrocarbon liquid having a cyclo-paraffin and iso-paraffin content of about 90% or greater, wherein the system comprises a metal on an H-Y-faujasite zeolite. 
     
     
         28 . A catalyst system for producing an ethylene-rich and propylene-rich hydrocarbon gas and producing no hydrocarbon liquid, wherein the system comprises a metal on an H-beta zeolite. 
     
     
         29 - 31 . (canceled)