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  Catalyst for producing hydrocarbon from synthsis gas and method for producing catalystUSPTO Application #: 20060223693Title: Catalyst for producing hydrocarbon from synthsis gas and method for producing catalyst Abstract: A catalyst for Producing hydrocarbon from a syngas is provided. In particular, the catalyst can be composed of catalyst support which a metallic compound is loaded on and that the impurity content of the catalyst is in the range from 0.01 mass % to 0.15 mass %. In addition. a method for producing the catalyst. and a method for producing the hydrocarbon using the catalyst are Provided. (end of abstract) Agent: Dorsey & Whitney LLP Intellectual Property Department - New York, NY, US Inventors: Kenichiro Fujimoto, Kimihito Suzuki, Shouli Sun USPTO Applicaton #: 20060223693 - Class: 502060000 (USPTO) Related Patent Categories: Catalyst, Solid Sorbent, Or Support Therefor: Product Or Process Of Making, Zeolite Or Clay, Including Gallium Analogs The Patent Description & Claims data below is from USPTO Patent Application 20060223693. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATION(S) [0001] This application is a national stage application of PCT Application No. PCT/JP2004/005013 which was filed on Apr. 7, 2004 and published on Oct. 21, 2004 as International Publication No. WO 2004/089540 (the "International Application"). This application claims priority from the International Application pursuant to 35 U.S.C. .sctn.365. The present application also claims priority under 35 U.S.C. .sctn.119 from Japanese Patent Application No. 2003-103176 filed on Apr. 7, 2003, the entire disclosure of which is incorporated herein by reference. FIELD OF THE INVENTION [0002] The present invention relates to a catalyst for producing hydrocarbon from a syngas, which is suitable for a hydrogenation of carbon monoxide and a hydrocarbon production from carbon monoxide, a method for producing the catalyst, and a method for producing a hydrocarbon using the catalyst. BACKGROUND INFORMATION [0003] Recently, due to emerging environmental issues such as a global warming, a natural gas is becoming highly regarded in that the natural gas exhibits a higher hydrogen/carbon ratio as compared to other hydrocarbon fuels, a coal or the like. Therefore, natural gas can abate emissions of carbon-dioxide being an causative agent of the global warming, and the natural gas has abundant reserves. This, the demand for the natural gas is expected to increase in the future. Under such circumstances, there are a number of small and middle gas fields found in the regions of Southeast Asia, Oceania, etc., which however are still left undeveloped due to their locations of distant places having no infrastructure such as a pipeline and an LNG plant. This may require a significant amount of investment for the infrastructure being incomparable to their minable reserves, so that their developments have been desired to be processed. As one effective development effort, researches and developments for a technology, in which the natural gas is converted into a syngas and then the syngas is converted into a liquid hydrocarbon fuel (such as kerosene and gas oil having excellent transportability and handling characteristics by making use of a Fischer-Tropsch synthesis reaction), are promoted aggressively in various places. [0004] This Fischer-Tropsch synthesis reaction converting the syngas into hydrocarbon with a catalyst is an exothermic reaction, where it is important to effectively remove reaction heat for a stable operation of the plant. As time-proven reaction processes, there are gas-phase synthesis processes (in a fixed bed, entrained bed, or fluid bed) and a liquid-phase synthesis process (in a slurry bed) having respective features. Recently, the liquid-phase synthesis process carried out in the slurry bed is more visible, and is being researched and developed strenuously for the reason that it exhibits a higher heat removing efficiency but avoids the accumulation of generated high-boiling point hydrocarbon on the catalyst as well as a reactor tube plugging caused thereby. [0005] Generally, a higher catalytic activity is preferable, and especially, in the case of the slurry bed. There is a constraint that the concentration of slurry may be needed to be a prescribed value or below so as to keep a favorable slurry state, so that the increase in the catalytic activity is an important factor to increase a process design flexibility. The reported catalytic activities of various types of catalysts for the Fischer-Tropsch synthesis are approximately 1 (kg-hydrocarbon/kg-catalysthour) at most in view of the production rate of liquid hydrocarbon of a carbon number of five or above, which cannot be said always enough from the above-described viewpoints, as described in R. Oukaci et al., "Applied Catalysis A", General, 186 (1999), p. 129-144, the entire disclosure of which is incorporated herein by reference. [0006] As a method for improving the catalytic activity, a reduction in sodium content in silica used as a catalyst support has been described as being is effective--described in J. Chen et al., Cuihua Xuebao, Vol. 21 (2000), p. 169-171, the entire disclosure of which is incorporated herein by reference. However, the comparison was made only between the silica of the sodium content below 0.01 mass % and that of the sodium content of approximately 0.3 mass %, and there is no specific description as to the highest sodium content level started to be effected. [0007] Further, generally, the particle diameter of the catalyst for the Fischer-Tropsch synthesis reaction is preferably provided as small as practically as possible from the aspect of reducing a possibility in which the diffusions of heat and matters come to a rate-determining level. However, in the case of the Fischer-Tropsch synthesis reaction in the slurry bed, out of the generated hydrocarbon, the high-boiling point hydrocarbon is accumulated in the reactor, inevitably requiring a solid-liquid separating operation for separating a product from the catalyst, so that there may be another problem that the catalyst of a too small particle diameter reduces the efficiency of the separating operation. Therefore, for the catalyst for the slurry bed, there should be an optimum particle diameter range, and generally, the range from about 20 .mu.m to about 250 .mu.m, or about 40 .mu.m to about 150 .mu.m as an average particle diameter, is considered to be desirable. However, as discussed below, there may be a case where the catalyst is caused to be fractured and pulverized to have a smaller particle diameter in the course of the reaction, requiring a caution. [0008] In particular, in the Fischer-Tropsch synthesis reaction in the slurry bed, the operation can be frequently performed at an extremely high material-gas superficial velocity (>0.1 m/second), so that the catalyst particles clash furiously with each other during the reaction to possibly reduce their particle diameters during the reaction when the physical strength and abrasion resistance (resistance to be pulverized) are insufficient. This may at times cause an inconvenience in the separating operation. Further, in the Fischer-Tropsch synthesis reaction, volumes of water can be generated as a by-product. However, in the case of using the catalyst with low water resistance, which deteriorates in strength to be fractured and pulverized with ease due to water, the particle diameter of the catalyst is possibly reduced into a fine powder during the reaction, causing sometimes the inconvenience in the separating operation in the same manner as above. [0009] As described above, the current catalytic activity may not yet be sufficient, and the catalyst with a higher catalytic activity has been requested as a pressing need, also from a viewpoint of extending the design flexibility in the plant. [0010] Furthermore, generally, the catalyst for the slurry bed can be frequently put into practical use there by being prepared through a size control procedure by way of a grinding to have an appropriate particle diameter as described above. However, such a catalyst of a ground type may frequently have a crack or sharp protrusion arisen originally, and can effectuate a lesser mechanical strength and abrasion resistance. Thus, there may be a problem that the catalyst is forced to fracture to generate fine powders, and it becomes difficult to separate the generated high-boiling point hydrocarbon from the catalyst when used in the Fischer-Tropsch synthesis reaction in the slurry bed. Similarly, it is known that a relatively highly-active catalyst can be obtained when a porous silica is used as the catalyst support for the Fischer-Tropsch synthesis reaction. However, the size control based on the grinding may also lead to the strength deterioration due to the previously-described reason. In addition, the silica has lesser water resistance, and is frequently fractured into powders when water exists, thus causing problems especially in the case of the slurry bed. SUMMARY OF THE INVENTION [0011] One of the objects of the present invention is to provide a catalyst for a Fischer-Tropsch synthesis, which brings a solution to the above-described problems and exhibits a high activity without deteriorating its catalytic strength and abrasion resistance; a producing method of the catalyst, and a producing method of hydrocarbon using the catalyst. [0012] Exemplary embodiments of the present invention relates to a catalyst for a Fischer-Tropsch synthesis exhibiting a high strength and activity, a method for producing the catalyst, and a method for producing hydrocarbon using the catalyst. Additional details therefor are provided below. [0013] For example, a catalyst for producing hydrocarbon from a syngas, according to an exemplary embodiment of the present invention, including a catalyst support on which a metallic compound is loaded, in which an impurity content of the catalyst is in a range from 0.01 mass % to 0.15 mass %. An alkali metal or an alkaline-earth metal content in the catalyst support can be in a range from 0.01 mass % to 0.1 mass %. The catalyst support can satisfy a pore diameter in a range from 8 nm to 50 nm, a surface area in a range from 80 m.sup.2/g to 550 m.sup.2/g and a pore volume in a range from 0.5 mL/g to 2.0 mL/g, simultaneously. Further, the catalyst support in use allows the catalyst have a fractured or pulverized ratio of 10% or below when an ultrasonic wave is emitted for four hours at a room temperature to the catalyst dispersed in water. In addition, the catalyst support may be silica of a spherical shape. The metallic compound may contain iron, cobalt, nickel and/or ruthenium. This metallic compound can be made from a precursor of metallic compound of the alkali metal or alkaline-earth metal content of 5 mass % or lower. [0014] According to another exemplary embodiment of the present invention, a method for producing the catalyst described above can be provided, in which the metallic compound is loaded on a catalyst support after a pretreatment to lower an impurity concentration of the catalyst support is performed to the catalyst support. The pretreatment may include rinsing using at least one of acid and an ion-exchanged water. The catalyst can be prepared using a catalyst support obtained using rinsing water of an alkali metal or alkaline-earth metal content of 0.06 mass % or lower in the production step of the catalyst support. The catalyst support (e.g., silica) may have a spherical shape shaped by a spraying method. [0015] According to yet another exemplary embodiment of the present invention, a method for producing hydrocarbon is provided, in which the hydrocarbon is produced from a syngas using the catalyst described herein above. [0016] According to the exemplary embodiments of the present invention, it is possible to produce a catalyst for a Fischer-Tropsch synthesis with extremely high activity without deteriorating strength and abrasion resistance of the catalyst, and to perform a Fischer-Tropsch synthesis reaction exhibiting a high hydrocarbon production rate backed by the catalyst. [0017] These and other objects, features and advantages of the present invention will become apparent upon reading the following detailed description of embodiments of the invention, when taken in conjunction with the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS [0018] Further objects, features and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying figure showing illustrative embodiments, results and/or features of the exemplary embodiment(s) of the present invention, in which: [0019] FIG. 1 is a graph showing a relation between metal contents in a catalyst support of silica and a CO conversion. Continue reading... Full patent description for Catalyst for producing hydrocarbon from synthsis gas and method for producing catalyst Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Catalyst for producing hydrocarbon from synthsis gas and method for producing catalyst patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. 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