Novel Attrition-Resistant Fischer Tropsch Catalyst

Liquid fuels derived from coal can be made from a synthesis gas by the Fischer Tropsch catalytic process, which uses metal catalysts supported on inert alumina or silica particles. These catalysts are subject to physical breakdown, which shortens their useful lives, fouls the chemical process, and necessitates frequent catalyst replacement. The time and capital required for replacing broken-down catalyst, separating the broken catalyst from the product materials, and repairing fouled process equipment are significant costs inherent in current Fischer Tropsch processes. This project will develop technology for using a proprietary, attrition-resistant catalyst support material that would be much more resistant to physical damage and fracturing. Phase I will verify the high resistance of these catalysts to deactivation by physical damage in fluidized beds. Phase II would develop optimal catalyst formulations and verify their physical and chemical stability, activity, and selectivity for producing liquid fuels. Commercial Applications and other Benefits as described by the awardee: The new catalyst concept would significantly reduce the cost of making liquid fuels from a synthesis gas produced by gasifying coal or biomass, or by reforming natural gas. This cost reduction is an important step in decreasing U.S. dependence on imported petroleum.