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.

We claim: 
     
         1 . A process for the production of hydrocarbon fuel products from synthesis gas comprising a single reactor system and a steam reformer, wherein chemical reactions in the single reactor system occur over an alcohol-forming catalyst found in the same matrix as a gasoline-forming catalyst and wherein the alcohol-forming catalyst produces high quality alcohols from the synthesis gas. 
     
     
         2 . The process of  claim 1 , wherein the synthesis gas is contacted in a Fischer-Tropsch reaction with the alcohol-forming catalyst in high pressure hydrogen. 
     
     
         3 . The process of  claim 2 , wherein the catalyst is a zeolite-encaged, molybdenum-based catalyst active for deoxy-aromatization of alcohols and synthesis gas to mixed alcohols, isomerization of alkanes, and aromatization. 
     
     
         4 . The process of  claim 3 , wherein the catalyst is a cluster comprising a molybdenum oxide represented by MoC x O y  encaged in a zeolite and wherein the cluster comprises the active phase. 
     
     
         5 . The process of  claim 4 , wherein the cluster comprises a molybdenum sulfide. 
     
     
         6 . The process of  claim 4 , wherein the cluster further comprises at least one metal modifier selected from the group consisting of the elements of Groups 1A and 2A of the Periodic Table and mixtures of the aforementioned elements. 
     
     
         7 . The process of  claim 3 , wherein the zeolite comprises a support. 
     
     
         8 . The process of  claim 7 , wherein the zeolite comprises one or more members selected from the group consisting of the zeolite-based heterogeneous catalyst HZSM-5, Y, Mordenite, MCM-22, MCM-41, H-Y-faujasite, and H-beta zeolites. 
     
     
         9 . The process of  claim 2 , wherein the catalyst is a zeolite-encaged, rhenium-based catalyst active for deoxy-aromatization of alcohols and synthesis gas to mixed alcohols, isomerization of alkanes, and aromatization. 
     
     
         10 . The process of  claim 9 , wherein the catalyst is a cluster comprising a rhenium oxide represented by ReC x O y  encaged in a zeolite and wherein the cluster comprises the active phase. 
     
     
         11 . The process of  claim 10 , wherein the cluster comprises a rhenium sulfide. 
     
     
         12 . The process of  claim 10 , wherein the cluster further comprises at least one metal modifier selected from the group consisting of the elements of Groups 1A and 2A of the Periodic Table and mixtures of the aforementioned elements. 
     
     
         13 . The process of  claim 9 , wherein the zeolite comprises a support. 
     
     
         14 . The process of  claim 13 , wherein the zeolite comprises one or more members selected from the group consisting of the zeolite-based heterogeneous catalyst HZSM-5, Y, Mordenite, MCM-22, MCM-41, H-Y-faujasite, and H-beta zeolites. 
     
     
         15 . The process of  claim 1 , wherein the hydrocarbon fuel products comprise liquid hydrocarbons and gas hydrocarbons and wherein the products are separated in a separation unit. 
     
     
         16 . The process of  claim 15 , wherein the liquid hydrocarbons comprise branched alkanes and alkyl-substituted aromatics. 
     
     
         17 . The process of  claim 15 , wherein the gas hydrocarbons are fed to and processed through the steam reformer and returned to the single reactor system. 
     
     
         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 . The process of  claim 1 , wherein the chemical reactions produce a hydrocarbon liquid having an aromatics content of about 90% or greater and wherein the alcohol-forming catalyst comprises a metal on an HZSM-5 zeolite. 
     
     
         30 . The process of  claim 1 , wherein the chemical reactions produce a hydrocarbon liquid having a cyclo-paraffin and iso-paraffin content of about 90% or greater and wherein the alcohol-forming catalyst comprises a metal on an H-Y-faujasite zeolite. 
     
     
         31 . The process of  claim 1 , wherein the chemical reactions produce an ethylene-rich and propylene-rich hydrocarbon gas and produce no hydrocarbon liquid and wherein the alcohol-forming catalyst comprises a metal on an H-beta zeolite.