This report describes research conducted to support the DOE program in novel slurry phase catalysts for converting coal-derived synthesis gas to diesel fuels. The primary objective of this research program is to develop attrition resistant catalysts that exhibit high activities for conversion of coal-derived syngas. Three partner institutions, University of New Mexico (UNM), Texas A&M University (TAMU) and Brigham Young University (BYU) have actively worked together to develop these novel catalysts.Specifically, at TAMU we have synthesized several alumina (from Condea) and silica (Davison 948) supported iron Fischer-Tropsch (F-T) catalysts, determined their attrition properties (in collaboration with the UNM) under both reactive and non-reactive conditions, and evaluated their performance during F-T synthesis in a stirred tank slurry reactor (STSR). Also, we have determined attrition properties of a precipitated iron F-T catalyst with nominal composition 100 Fe/3 Cu/4 K/16 SiO 2 (in parts by weight) in a STSR under both reactive and non-reactive conditions. This catalyst was developed at TAMU under DOE sponsorship (Contracts DE-AC22-89PC89968 and DE-AC22-94PC93069) and has excellent performance characteristics: high activity and productivity, excellent stability with time and high selectivity to liquid hydrocarbons and wax.During extended F-T synthesis tests in the STSR we found that the alumina supported catalysts showed formation of fine particles (about 15 wt%) in the size range of 1-10 µm. The silica supported catalyst was more resistant to erosion than the alumina supports. Attrition resistance behavior of the precipitated TAMU catalyst was comparable to or better than that of Davison 948 silica in both types of attrition tests (ultrasound fragmentation and STSR tests). Its attrition resistance could be further improved by preparing the catalyst in form of micro-spherical particles (e.g. by spray drying).
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