BACKGROUND OF THE DISCLOSURE
1. Field
[0001] The present disclosure relates generally to reverse water-gas shift catalysts, processes
of making the same, and processes for performing reverse water-gas shift reactions.
The present disclosure also relates to integrating processes for performing reverse
water-gas shift reactions with processes for performing Fischer-Tropsch reactions.
2. Technical Background
[0002] The reverse water-gas shift reaction (rWGS) is an advantageous route to obtain carbon
monoxide from carbon dioxide for further chemical processing. The rWGS converts carbon
dioxide and hydrogen to carbon monoxide and water, as shown in Equation (1).

This can be used, for example, to modify the CO:H
2 ratio of a gas mixture for further processing. The carbon monoxide and hydrogen so
formed is a valuable feedstock for a number of chemical processes, for example, the
well-known Fischer-Tropsch (FT) process, shown in Equation (2).

[0003] However, the rWGS reaction is not favored in all circumstances. For example, a competing
reaction is the Sabatier reaction (Equation (3)), which decreases carbon monoxide
yield in favor of methane production, which is not an active feedstock for FT.

The strongly exothermic Sabatier reaction is thermodynamically favored over the endothermic
rWGS reaction at lower reaction temperatures. As such, minimizing the methanation
during rWGS, especially at low temperatures, can become a significant challenge.
[0004] Similarly, the carbon monoxide product from rWGS can be hydrogenated to methane,
as shown in Equation (4).

Hydrogenation of carbon monoxide to methane is also an exothermic reaction, so it
too is favored at lower temperatures. The stoichiometry of the reaction requires at
least a 3:1 ratio of hydrogen to carbon monoxide. This means that performing the rWGS
reaction with a large excess of hydrogen to drive the equilibrium toward carbon monoxide
(see Equation (1)) is not always ideal because it runs the risk of hydrogenating the
carbon monoxide product to form methane.
[0005] Coupled with Equations (3) and (4), further undesirable side reactions can occur.
These side reactions can form undesirable carbon deposits on the surface of catalysts
used to promote rWGS. Examples of these carbon-producing side reactions are shown
in Equations (5), (6), and (7). All three of these reactions are endothermic and are
favored at higher temperatures, just like the rWGS reaction.
CO + H
2 ↔ C + H
2O
CH
4 ↔ 2H
2 + C
2CO ↔ CO
2 + C

Accordingly, because the carbon-producing side reactions (Equations (5)-(7)) are
also endothermic and are favored at higher temperatures, operation at higher temperatures
to favor the desired carbon monoxide product can severely impact catalyst lifetime
through the deposition of carbon.
[0006] Given the multiple reactions and competing thermodynamics at play, there remains
a need in the art for new rWGS catalysts and processes, especially for integration
with Fischer-Tropsch processes.
[0007] Additionally, CO
2 is a substantial input in these reactions. Carbon dioxide is a widely available gas
(currently present in the atmosphere at about 400 ppm) that is inert to many transformations.
Additionally, the tendency of carbon dioxide to absorb infrared radiation has led
to its designation as a greenhouse gas. Thus, there is a need to develop economical
processes that utilize carbon dioxide, especially waste carbon dioxide that would
otherwise be added to the ever-rising concentration of carbon dioxide in the atmosphere.
SUMMARY
[0008] In one aspect, the present disclosure provides for a supported reverse water-gas
shift catalyst comprising:
a support that is a cerium oxide support, a titanium oxide support, an aluminum oxide
support, zinc oxide support, a zirconium oxide support, or a mixed oxide support comprising
a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide
and zirconium oxide;
a metal selected from at least one of manganese, copper, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium, present in an amount in the range of 0.5
to 20 wt% of the catalyst, based on the total weight of the catalyst; and
optionally, at least one of platinum, palladium, gold, and nickel present in an amount
in the range of 0.05 to 10 wt% of the catalyst, based on the total weight of the catalyst.
[0009] In one aspect, the present disclosure provides for a supported reverse water-gas
shift catalyst comprising:
a support that is a cerium oxide support, a titanium oxide support, an aluminum oxide
support, a zinc oxide support, a zirconium oxide support, or a mixed oxide support
comprising a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide,
zinc oxide and zirconium oxide;
a metal selected from at least one of manganese, copper, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium, present in an amount in the range of 0.5
to 20 wt% of the catalyst, based on the total weight of the catalyst; and
at least one of platinum, palladium, gold, or nickel present in an amount in the range
of 0.05 to 10 wt% of the catalyst, based on the total weight of the catalyst.
[0010] In another aspect, the present disclosure provides for a method of making the catalyst
as described herein, the method comprising:
providing a support that is a cerium oxide support, a titanium oxide support, an aluminum
oxide support, a zinc oxide support, a zirconium support, or a mixed oxide support
comprising a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide,
zinc oxide and zirconium oxide;
contacting the support with one or more liquids each comprising one or more metal-containing
compounds dispersed in a solvent(s), wherein the metal is selected from manganese,
copper, gallium, indium, lanthanum, titanium, niobium, vanadium, and zirconium, and
optionally one or more platinum-, palladium-, gold-, or nickel-containing compounds;
allowing the solvent to evaporate to provide a catalyst precursor; and calcining the
catalyst precursor.
[0011] In another aspect, the present disclosure provides for a catalyst as described herein
made by the method as described herein.
[0012] In another aspect, the present disclosure provides a method for performing a reverse
water-gas shift reaction, the method comprising contacting at a temperature in the
range of 200-1100 °C a catalyst as described herein with a feed stream comprising
CO
2 and H
2, wherein at least part of the CO
2 of the first feed stream is from biogas, a CO
2 emission source, and/or direct air capture, to provide a product stream comprising
CO and H
2, the product stream having a lower concentration of CO
2 and a higher concentration of CO than the feed stream. For example, in some embodiments,
at least a part of CO
2 of the first feed stream is from biogas. In some embodiments, at least a part of
the CO
2 of the first feed stream is from a CO
2 emission source. And in some embodiments, at least a part of the CO
2 of the first feed stream is from direct air capture.
[0013] In one aspect, the present disclosure provides for a process for performing an integrated
Fischer-Tropsch process, the process comprising:
providing a first feed stream comprising H2 and CO2, wherein at least part of the CO2 of the first feed stream is from biogas, a CO2 emission source and/or direct air capture;
contacting at a first temperature in the range of 200-1100 °C and at a first pressure
a reverse water-gas shift catalyst with the first feed stream to perform a reverse
water-gas shift reaction to provide a first product stream comprising CO and H2, the first product stream having a lower concentration of CO2 and a higher concentration of CO than the first feed stream;
contacting at a second temperature and at a second pressure a Fischer-Tropsch catalyst
with a second feed stream comprising H2 and at least a portion of CO of the first product stream to provide a second product
stream comprising C5+ hydrocarbons,
wherein the reverse water-gas shift catalyst is a supported reverse water-gas shift
catalyst comprising:
a support that is a cerium oxide support, a titanium oxide support, an aluminum oxide
support, zinc oxide support, zirconium oxide support, or a mixed oxide support comprising
a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide
and zirconium oxide;
a metal selected from at least one of manganese, copper, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium, present in an amount in the range of 0.5
to 20 wt% of the catalyst, based on the total weight of the catalyst; and
optionally, at least one of platinum, palladium, gold, and nickel, present in an amount
in the range of 0.05 to 10 wt% of the catalyst, based on the total weight of the catalyst.
For example, in some embodiments, at least a part of CO
2 of the first feed stream is from biogas. In some embodiments, at least a part of
the CO
2 of the first feed stream is from a COz emission source. And in some embodiments,
at least a part of the CO
2 of the first feed stream is from direct air capture.
BRIEF DESCRIPTION OF FIGURES
[0014] The accompanying drawings are included to provide a further understanding of the
methods of the disclosure, and are incorporated in and constitute a part of this specification.
The drawings are not necessarily to scale, and sizes of various elements may be distorted
for clarity. The drawings illustrate one or more embodiment(s) of the disclosure and
together with the description serve to explain the principles and operation of the
disclosure.
FIG. 1 is a schematic of the reverse water-gas shift reaction as described herein.
FIG. 2 is a schematic of a process for performing an integrated Fischer-Tropsch process
as described herein.
FIG. 3 is a schematic of a process for performing an integrated Fischer-Tropsch process
as described herein.
FIG. 4 is a schematic of a process for performing an integrated Fischer-Tropsch process
as described herein.
FIG. 5 is a schematic of a process for performing an integrated Fischer-Tropsch process
as described herein.
FIG. 6 is a schematic of a process for performing an integrated Fischer-Tropsch process
as described herein.
FIG. 7 is a schematic of a process for performing an integrated Fischer-Tropsch process
as described herein.
DETAILED DESCRIPTION
[0015] As discussed above, the reverse gas-water shift reaction reacts carbon dioxide with
hydrogen to form carbon monoxide and water and can be useful in providing a feedstock
containing carbon monoxide and hydrogen -- often called "synthesis gas" -- for use
in processes such as the Fischer-Tropsch process. However, the Sabatier reaction,
carbon monoxide methanation, and carbon-producing side reactions can interfere with
the rWGS reaction. The Sabatier reaction and CO methanation are exothermic and favored
at lower temperatures, while the rWGS and carbon-producing side reactions are endothermic
and favored at higher temperatures. Additionally, these reactions rely on CO
2, a greenhouse gas. To prevent further waste of CO
2 that would otherwise be added to the atmosphere, here remains a need to develop process
that use CO
2. Advantageously, hydrocarbon synthesis processes that use waste carbon dioxide as
a feed have the potential to be low-carbon, carbon neutral, or even have a negative
carbon footprint. One way to achieve this is to transform carbon dioxide into carbon
monoxide through reverse water-gas shift reactions, as described herein. Accordingly,
there remains a need for rWGS catalysts that can provide good performance in spite
of these complicating factors. Here, the present inventors have provided supported
reverse water-gas shift catalysts that include a metal oxide support, a metal selected
from at least one of manganese, gallium, indium, lanthanum, titanium, niobium, vanadium,
and zirconium, and optionally, at least one of platinum, palladium, gold, and nickel.
Additionally, the present inventors have found rWGS processes that are particularly
advantageous for integration with a Fischer-Tropsch process by using supported reverse
water-gas shift catalysts as described herein and using renewable sources of CO
2.
Reverse Water-Gas Shift Catalysts
[0016] In one aspect, the present disclosure provides a supported reverse water-gas shift
catalyst comprising: a support that is a cerium oxide support, a titanium oxide support,
aluminum oxide support, a zinc oxide support, a zirconium oxide support, or a mixed
oxide support comprising a mixture of two or more of cerium oxide, titanium oxide,
aluminum oxide, zinc oxide and zirconium oxide; a metal selected from at least one
of manganese, copper, gallium, indium, lanthanum, titanium, niobium, vanadium, and
zirconium, present in an amount in the range of 0.5 to 20 wt% of the catalyst, based
on the total weight of the catalyst; and optionally, at least one of platinum, palladium,
gold, and nickel, present in an amount in the range of 0.05 to 10 wt% of the catalyst,
based on the total weight of the catalyst. Suitable catalysts have been described
in International Application No.
PCT/CN2022/102723, filed June 30, 2022, International Application No.
PCT/CN2022/102660, filed June 30, 2022, International Application No.
PCT/CN2022/102685, filed June 30, 2022, International Application No.
PCT/CN2022/102763, filed June 30, 2022, International Application No.
PCT/CN2022/102976, filed June 30, 2022, International Application No.
PCT/CN2022/102812, filed June 30, 2022, International Application No.
PCT/CN2022/102630, filed June 30, 2022, International Application No.
PCT/CN2022/102630, filed June 30, 2022, International Application No.
PCT/CN2022/102799, filed June 30, 2022, International Application No.
PCT/IB2023/056800, filed June 29, 2023, International Application No.
PCT/IB2023/056802, filed June 29, 2023, International Application No.
PCT/IB2023/056803, filed June 29, 2023, International Application No.
PCT/CN2023/104014, filed June 29, 2023, and International Application No.
PCT/CN2023/103835, filed June 29, 2023, each of which is hereby incorporated by reference in its entirety.
[0017] In another aspect, the present disclosure provides a supported reverse water-gas
shift catalyst comprising: a support that is a cerium oxide support, a titanium oxide
support, aluminum oxide support, a zinc oxide support, a zirconium oxide support,
or a mixed oxide support comprising a mixture of two or more of cerium oxide, titanium
oxide, aluminum oxide, zinc oxide, and zirconium oxide; a metal selected from at least
one of manganese, copper, gallium, indium, lanthanum, titanium, niobium, vanadium,
and zirconium, present in an amount in the range of 0.5 to 20 wt% of the catalyst,
based on the total weight of the catalyst; and at least one of platinum, palladium,
gold, and nickel, present in an amount in the range of 0.05 to 10 wt% of the catalyst,
based on the total weight of the catalyst.
[0018] As described above, the reverse water-gas shift catalysts of the present disclosure
are supported catalysts. In various embodiments as otherwise described herein, the
support makes up at least 70 wt%, e.g., at least 75 wt%, or 80 wt%, or 85 wt%, or
90 wt% of the catalyst on an oxide basis.
[0019] In various embodiments as otherwise described herein, the support is a cerium oxide
support. As used herein, a "cerium oxide" support is a support that presents at least
a surface layer (e.g., 50 microns in thickness) that is at least 50 wt% cerium oxide,
on an oxide basis. In various embodiments of the disclosure as described herein, at
least a surface layer of the cerium oxide support includes at least 60 wt% cerium
oxide, e.g., at least 70 wt% cerium oxide, or at least 80 wt% cerium oxide. In some
such embodiments, at least a surface layer of the cerium oxide support includes at
least 90 wt% cerium oxide. For example, in some embodiments, at least a surface layer
of the cerium oxide support includes at least 95 wt% cerium oxide or at least 98 wt%
cerium oxide. In various examples, the cerium oxide support contains cerium oxide
substantially throughout, e.g., at least 50 wt% of the cerium oxide support is cerium
oxide, on an oxide basis. For example, in various embodiments, the cerium oxide support
includes at least 60 wt% cerium oxide, e.g., at least 70 wt% cerium oxide, or at least
80 wt% cerium oxide. In various embodiments, the cerium oxide support includes at
least 90 wt% cerium oxide, e.g., at least 95 wt% cerium oxide, or at least 98 wt%
cerium oxide. In some embodiments, the cerium oxide support may further include additional
metals or metal oxides.
[0020] In various embodiments as otherwise described herein, the support is a titanium oxide
support. As used herein, a "titanium oxide" support is a support that presents at
least a surface layer (e.g., 50 microns in thickness) that is at least 50 wt% titanium
oxide, on an oxide basis. In various embodiments of the disclosure as described herein,
at least a surface layer of the titanium oxide support includes at least 60 wt% titanium
oxide, e.g., at least 70 wt% titanium oxide, or at least 80 wt% titanium oxide. In
some such embodiments, at least a surface layer of the titanium oxide support includes
at least 90 wt% titanium oxide. For example, in some embodiments, at least a surface
layer of the titanium oxide support includes at least 95 wt% titanium oxide or at
least 98 wt% titanium oxide. In various examples, the titanium oxide support contains
titanium oxide substantially throughout, e.g., at least 50 wt% of the titanium oxide
support is titanium oxide, on an oxide basis. For example, in various embodiments,
the titanium oxide support includes at least 60 wt% titanium oxide, e.g., at least
70 wt% titanium oxide, or at least 80 wt% titanium oxide. In various embodiments,
the titanium oxide support includes at least 90 wt% titanium oxide, e.g., at least
95 wt% titanium oxide, or at least 98 wt% titanium oxide. In some embodiments, the
titanium oxide support may further include additional metals or metal oxides.
[0021] In various embodiments as otherwise described herein, the support is an aluminum
oxide support. As used herein, an "aluminum oxide" support is a support that presents
at least a surface layer (e.g., 50 microns in thickness) that is at least 50 wt% aluminum
oxide, on an oxide basis. In various embodiments of the disclosure as described herein,
at least a surface layer of the aluminum oxide support includes at least 60 wt% aluminum
oxide, e.g., at least 70 wt% aluminum oxide, or at least 80 wt% aluminum oxide. In
some such embodiments, at least a surface layer of the aluminum oxide support includes
at least 90 wt% aluminum oxide. For example, in some embodiments, at least a surface
layer of the aluminum oxide support includes at least 95 wt% aluminum oxide or at
least 98 wt% aluminum oxide. In various examples, the aluminum oxide support contains
aluminum oxide substantially throughout, e.g., at least 50 wt% of the aluminum oxide
support is aluminum oxide, on an oxide basis. For example, in various embodiments,
the aluminum oxide support includes at least 60 wt% aluminum oxide, e.g., at least
70 wt% aluminum oxide, or at least 80 wt% aluminum oxide. In various embodiments,
the aluminum oxide support includes at least 90 wt% aluminum oxide, e.g., at least
95 wt% aluminum oxide, or at least 98 wt% aluminum oxide. In some embodiments, the
aluminum oxide support may further include additional metals or metal oxides.
[0022] In various embodiments as otherwise described herein, the support is a zinc oxide
support. As used herein, a " zinc oxide" support is a support that presents at least
a surface layer (e.g., 50 microns in thickness) that is at least 50 wt% zinc oxide,
on an oxide basis. In various embodiments of the disclosure as described herein, at
least a surface layer of the zinc oxide support includes at least 60 wt% zinc oxide,
e.g., at least 70 wt% zinc oxide, or at least 80 wt% zinc oxide. In some such embodiments,
at least a surface layer of the zinc oxide support includes at least 90 wt% zinc oxide.
For example, in some embodiments, at least a surface layer of the zinc oxide support
includes at least 95 wt% zinc oxide or at least 98 wt% zinc oxide. In various examples,
the zinc oxide support contains zinc oxide substantially throughout, e.g., at least
50 wt% of the zinc oxide support is zinc oxide, on an oxide basis. For example, in
various embodiments, the zinc oxide support includes at least 60 wt% zinc oxide, e.g.,
at least 70 wt% zinc oxide, or at least 80 wt% zinc oxide. In various embodiments,
the zinc oxide support includes at least 90 wt% zinc oxide, e.g., at least 95 wt%
zinc oxide, or at least 98 wt% zinc oxide. In some embodiments, the zinc oxide support
may further include additional metals or metal oxides.
[0023] In various embodiments as otherwise described herein, the support is a zirconium
oxide support. As used herein, a "zirconium oxide" support is a support that presents
at least a surface layer (e.g., 50 microns in thickness) that is at least 50 wt% zirconium
oxide, on an oxide basis. In various embodiments of the disclosure as described herein,
at least a surface layer of the zirconium oxide support includes at least 60 wt% zirconium
oxide, e.g., at least 70 wt% zirconium oxide, or at least 80 wt% zirconium oxide.
In some such embodiments, at least a surface layer of the zirconium oxide support
includes at least 90 wt% zirconium oxide. For example, in some embodiments, at least
a surface layer of the zirconium oxide support includes at least 95 wt% zirconium
oxide or at least 98 wt% zirconium oxide. In various examples, the zirconium oxide
support contains zirconium oxide substantially throughout, e.g., at least 50 wt% of
the zirconium oxide support is zirconium oxide, on an oxide basis. For example, in
various embodiments, the zirconium oxide support includes at least 60 wt% zirconium
oxide, e.g., at least 70 wt% zirconium oxide, or at least 80 wt% zirconium oxide.
In various embodiments, the zirconium oxide support includes at least 90 wt% zirconium
oxide, e.g., at least 95 wt% zirconium oxide, or at least 98 wt% zirconium oxide.
In some embodiments, the zirconium oxide support may further include additional metals
or metal oxides.
[0024] In various embodiments as otherwise described herein, the support is a mixed oxide
support. These can be provided, for example, by admixture of multiple of the oxides
above and formation into a support that includes both. For example, in some embodiments,
the mixed oxide support is a mixture of two or more metal oxides, such as cerium oxide,
titanium oxide, aluminum oxide, zinc oxide, and zirconium oxide. In some embodiments,
at least a surface layer of the support includes at least 50 wt% total of two or more
of cerium oxide, titanium oxide, aluminum oxide, zinc oxide, and zirconium oxide,
on an oxide basis. In some embodiments, at least a surface layer of the mixed oxide
support includes at least 60 wt% total, e.g., at least 70 wt%, or at least 80 wt%
of two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide, and zirconium
oxide. In some embodiments, at least a surface layer of the mixed oxide support includes
at least 90 wt%, e.g., at least 95 wt%, or at least 98 wt% of two or more cerium oxide,
titanium oxide, aluminum oxide, zinc oxide, and zirconium oxide. In various examples,
the mixed oxide support contains the oxides substantially throughout, e.g., at least
50 wt% of the mixed oxide support is two or more of cerium oxide, titanium oxide,
aluminum oxide, zinc oxide, and zirconium oxide. In various embodiments, the mixed
oxide support includes at least 60 wt% total, e.g., at least 70 wt%, or at least 80
wt% of two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide, and
zirconium oxide. In various embodiments, the mixed oxide support includes at least
90 wt% total, e.g., at least 95 wt%, or at least 98 wt% of two or more of cerium oxide,
titanium oxide, aluminum oxide, zinc oxide, and zirconium oxide. In some embodiments,
the mixed oxide support may further include additional metals or metal oxides.
[0025] The present inventors have found that cerium oxide, titanium oxide, aluminum oxide,
zinc oxide and zirconium oxide can provide good performance in the absence of substantial
amounts of other metals in the support. For example, in various embodiments of the
disclosure as otherwise described herein, the support does not include additional
metals in a total amount of additional metals in excess of 2 wt%, e.g., in excess
of 1 wt% or in excess of 0.5 wt%, on an oxide basis.
[0026] However, the inventors have noted that in many cases performance can be desirably
effected by the inclusion of other metals in the support. Accordingly, in other embodiments
as otherwise described herein, the support includes at least one additional metal.
In various embodiments, the total amount of the at least one additional metal is in
the range of 0.5-20 wt%, e.g., 1-20 wt%, or 2-20 wt%, or 0.5-15 wt%, or 1-15 wt%,
or 2-15 wt%, or 0.5-10 wt%, or 1-10 wt%, or 2-10 wt%, or 0.5-5 wt%, or 1-5 wt%, on
an oxide basis.
[0027] Supports suitable for use herein can be provided with a range of pore volumes. The
person of ordinary skill in the art will select a pore volume appropriate for a desired
catalytic process. For example, in various embodiments as otherwise described herein,
the pore volume is at least 0.05 mL/g, e.g., at least 0.1 mL/g. In various embodiments
as otherwise described herein, the pore volume is at most 1.5 mL/g, e.g., at most
1 mL/g. In various embodiments of the present disclosure as described herein, the
pore volume is in the range of 0.05-1.5 mL/g, e.g., 0.1 mUg to 1 mL/g. Pore volumes
are measured by mercury porosimetry, for example, as measured according to ASTM D4284-12.
[0028] As described above, the supported reverse water-gas shift catalysts of the disclosure
include a metal selected from at least one of manganese, copper, gallium, indium,
lanthanum, titanium, niobium, vanadium, and zirconium. In some embodiments, the metal
is selected from one of manganese, copper, gallium, indium, lanthanum, titanium, niobium,
vanadium, and zirconium. The present inventors have determined that inclusion of the
metal(s) in the catalyst can provide improved CO selectivity for the rWGS reaction,
as described in the Examples below. For the purposes of this disclosure, the amount
of metal present is calculated as a weight percentage of metal atoms in the catalyst
based on the total weight of the catalyst, despite the form in which that metal may
be present. The metal may be present in the catalyst in a variety of forms; most commonly,
metal is principally present as metal oxide, metal, or a combination thereof.
[0029] In various embodiments of the present disclosure as otherwise described herein, manganese
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, manganese is present
in the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, manganese is present in the catalyst in an
amount in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12
wt% or 1 to 10 wt%, based on the total weight of the catalyst. In various embodiments
of the present disclosure as described herein, manganese is present in an amount in
the range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, manganese is present in an amount in the range
of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%,
based on the total weight of the catalyst.
[0030] In various embodiments of the present disclosure as otherwise described herein, copper
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, copper is present in
the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, copper is present in the catalyst in an amount
in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12 wt%, or
1 to 10 wt%, based on the total weight of the catalyst. In various embodiments of
the present disclosure as described herein, copper is present in an amount in the
range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2 to 10
wt%, based on the total weight of the catalyst. In various embodiments of the present
disclosure as described herein, copper is present in an amount in the range of 4 to
20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%, based on
the total weight of the catalyst.
[0031] In various embodiments of the present disclosure as otherwise described herein, gallium
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, gallium is present in
the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, gallium is present in the catalyst in an amount
in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12 wt%, or
1 to 10 wt%, based on the total weight of the catalyst. In various embodiments of
the present disclosure as described herein, gallium is present in an amount in the
range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2 to 10
wt%, based on the total weight of the catalyst. In various embodiments of the present
disclosure as described herein, gallium is present in an amount in the range of 4
to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%, based
on the total weight of the catalyst.
[0032] In various embodiments of the present disclosure as otherwise described herein, indium
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, indium is present in
the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, indium is present in the catalyst in an amount
in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12 wt%, or
1 to 10 wt%, based on the total weight of the catalyst. In various embodiments of
the present disclosure as described herein, indium is present in an amount in the
range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2 to 10
wt%, based on the total weight of the catalyst. In various embodiments of the present
disclosure as described herein, indium is present in an amount in the range of 4 to
20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%, based on
the total weight of the catalyst.
[0033] In various embodiments of the present disclosure as otherwise described herein, lanthanum
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, lanthanum is present
in the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, lanthanum is present in the catalyst in an
amount in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12
wt%, or 1 to 10 wt%, based on the total weight of the catalyst. In various embodiments
of the present disclosure as described herein, lanthanum is present in an amount in
the range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, lanthanum is present in an amount in the range
of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%,
based on the total weight of the catalyst.
[0034] In various embodiments of the present disclosure as otherwise described herein, titanium
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, titanium is present in
the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, titanium is present in the catalyst in an
amount in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12
wt%, or 1 to 10 wt%, based on the total weight of the catalyst. In various embodiments
of the present disclosure as described herein, titanium is present in an amount in
the range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, titanium is present in an amount in the range
of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%,
based on the total weight of the catalyst.
[0035] In various embodiments of the present disclosure as otherwise described herein, niobium
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, niobium is present in
the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, niobium is present in the catalyst in an amount
in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12 wt%, or
1 to 10 wt%, based on the total weight of the catalyst. In various embodiments of
the present disclosure as described herein, niobium is present in an amount in the
range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2 to 10
wt%, based on the total weight of the catalyst. In various embodiments of the present
disclosure as described herein, niobium is present in an amount in the range of 4
to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%, based
on the total weight of the catalyst.
[0036] In various embodiments of the present disclosure as otherwise described herein, vanadium
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, vanadium is present in
the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, vanadium is present in the catalyst in an
amount in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12
wt%, or 1 to 10 wt%, based on the total weight of the catalyst. In various embodiments
of the present disclosure as described herein, vanadium is present in an amount in
the range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, vanadium is present in an amount in the range
of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%,
based on the total weight of the catalyst.
[0037] In various embodiments of the present disclosure as otherwise described herein, zirconium
is present in the catalyst in an amount in the range of 0.5 to 20 wt%, based on total
weight of the catalyst. For example, in various embodiments, zirconium is present
in the catalyst in an amount in the range of 0.5 to 15 wt%, or 0.5 to 12 wt%, or 0.5
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, zirconium is present in the catalyst in an
amount in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1 to 12
wt%, or 1 to 10 wt%, based on the total weight of the catalyst. In various embodiments
of the present disclosure as described herein, zirconium is present in an amount in
the range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2 to 12 wt%, or 2
to 10 wt%, based on the total weight of the catalyst. In various embodiments of the
present disclosure as described herein, zirconium is present in an amount in the range
of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4 to 12 wt%, or 4 to 10 wt%,
based on the total weight of the catalyst.
[0038] As described above, the supported reverse water-gas shift catalysts of the disclosure
optionally include at least one of platinum, palladium, gold, and nickel. For example,
in various embodiments as otherwise described herein, platinum is present in the catalyst.
For the purposes of this disclosure, the amount of platinum present is calculated
as a weight percentage of platinum atoms in the catalyst based on the total weight
of the catalyst, despite the form in which that platinum may be present. The platinum
may be present in the catalyst in a variety of forms; most commonly, platinum is principally
present as metal, metal oxide, or a combination thereof. In some embodiments of the
present disclosure as described herein, platinum is present in the catalyst in an
amount in the range of 0.05 to 10 wt%, e.g., in the range of 0.1 to 10 wt%, or 0.5
to 10 wt%, 1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight
of the catalyst. For example, in some embodiments, platinum is present in the catalyst
in an amount in the range of 0.05 to 7 wt%, e.g., in the range of 0.1 to 7 wt%, or
0.5 to 7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total weight of the catalyst.
In some embodiments, platinum is present in the catalyst in an amount in the range
of 0.05 to 5 wt%, e.g., in the range of 0.1 to 5 wt%, or 0.5 to 5 wt%, or 1 to 5 wt%,
or 2 to 5 wt%, based on the total weight of the catalyst. For example, in some embodiments
of the present disclosure as described herein, platinum is present in the catalyst
in an amount in the range of 0.05 to 2 wt%, e.g., in the range of 0.1 to 2 wt%, or
0.3 to 2 wt%, or 0.5 to 2 wt%, based on the total weight of the catalyst. In some
embodiments, platinum is present in the catalyst in an amount in the range of 0.05
to 1.5 wt%, e.g., in the range of 0.1 to 1.5 wt%, or 0.3 to 1.5 wt%, or 0.5 to 1.5
wt%, based on the total weight of the catalyst. In some embodiments, platinum is present
in an amount in the range of 0.05 to 1 wt%, e.g., in the range of 0.1 to 1 wt%, or
0.3 to 1 wt%, or 0.5 to 1 wt%, based on the total weight of the catalyst. In some
embodiments, platinum is present in the catalyst in an amount in the range of 0.05
to 0.8 wt%, e.g., in the range of 0.1 to 0.8 wt%, or 0.3 to 0.8 wt%, or 0.5 to 0.8
wt%, based on the total weight of the catalyst.
[0039] In various embodiments as otherwise described herein, palladium is present in the
catalyst. For the purposes of this disclosure, the amount of palladium present is
calculated as a weight percentage of palladium atoms in the catalyst based on the
total weight of the catalyst, despite the form in which that palladium may be present.
The palladium may be present in the catalyst in a variety of forms; most commonly,
palladium is principally present as metal, metal oxide, or a combination thereof.
In some embodiments of the present disclosure as described herein, palladium is present
in the catalyst in an amount in the range of 0.05 to 10 wt%, e.g., in the range of
0.1 to 10 wt%, or 0.5 to 10 wt%, 1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based
on the total weight of the catalyst. For example, in some embodiments, palladium is
present in the catalyst in an amount in the range of 0.05 to 7 wt%, e.g., in the range
of 0.1 to 7 wt%, or 0.5 to 7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total
weight of the catalyst. In some embodiments, palladium is present in the catalyst
in an amount in the range of 0.05 to 5 wt%, e.g., in the range of 0.1 to 5 wt%, or
0.5 to 5 wt%, or 1 to 5 wt%, or 2 to 5 wt%, based on the total weight of the catalyst.
For example, in some embodiments of the present disclosure as described herein, palladium
is present in the catalyst in an amount in the range of 0.05 to 2 wt%, e.g., in the
range of 0.1 to 2 wt%, or 0.3 to 2 wt%, or 0.5 to 2 wt%, based on the total weight
of the catalyst. In some embodiments, palladium is present in the catalyst in an amount
in the range of 0.05 to 1.5 wt%, e.g., in the range of 0.1 to 1.5 wt%, or 0.3 to 1.5
wt%, or 0.5 to 1.5 wt%, based on the total weight of the catalyst. In some embodiments,
palladium is present in an amount in the range of 0.05 to 1 wt%, e.g., in the range
of 0.1 to 1 wt%, or 0.3 to 1 wt%, or 0.5 to 1 wt%, based on the total weight of the
catalyst. In some embodiments, palladium is present in the catalyst in an amount in
the range of 0.05 to 0.8 wt%, e.g., in the range of 0.1 to 0.8 wt%, or 0.3 to 0.8
wt%, or 0.5 to 0.8 wt%, based on the total weight of the catalyst.
[0040] In various embodiments as otherwise described herein, gold is present in the catalyst.
For the purposes of this disclosure, the amount of gold present is calculated as a
weight percentage of gold atoms in the catalyst based on the total weight of the catalyst,
despite the form in which that palladium may be present. The gold may be present in
the catalyst in a variety of forms; most commonly, gold is principally present as
metal, metal oxide, or a combination thereof. In some embodiments of the present disclosure
as described herein, gold is present in the catalyst in an amount in the range of
0.05 to 10 wt%, e.g., in the range of 0.1 to 10 wt%, or 0.5 to 10 wt%, 1 to 10 wt%,
or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight of the catalyst. For example,
in some embodiments, gold is present in the catalyst in an amount in the range of
0.05 to 7 wt%, e.g., in the range of 0.1 to 7 wt%, or 0.5 to 7 wt%, or 1 to 7 wt%,
or 2 to 7 wt%, based on the total weight of the catalyst. In some embodiments, gold
is present in the catalyst in an amount in the range of 0.05 to 5 wt%, e.g., in the
range of 0.1 to 5 wt%, or 0.5 to 5 wt%, or 1 to 5 wt%, or 2 to 5 wt%, based on the
total weight of the catalyst. For example, in some embodiments of the present disclosure
as described herein, gold is present in the catalyst in an amount in the range of
0.05 to 2 wt%, e.g., in the range of 0.1 to 2 wt%, or 0.3 to 2 wt%, or 0.5 to 2 wt%,
based on the total weight of the catalyst. In some embodiments, gold is present in
the catalyst in an amount in the range of 0.05 to 1.5 wt%, e.g., in the range of 0.1
to 1.5 wt%, or 0.3 to 1.5 wt%, or 0.5 to 1.5 wt%, based on the total weight of the
catalyst. In some embodiments, gold is present in an amount in the range of 0.05 to
1 wt%, e.g., in the range of 0.1 to 1 wt%, or 0.3 to 1 wt%, or 0.5 to 1 wt%, based
on the total weight of the catalyst. In some embodiments, gold is present in the catalyst
in an amount in the range of 0.05 to 0.8 wt%, e.g., in the range of 0.1 to 0.8 wt%,
or 0.3 to 0.8 wt%, or 0.5 to 0.8 wt%, based on the total weight of the catalyst.
[0041] In various embodiments as otherwise described herein, nickel is present in the catalyst.
For the purposes of this disclosure, the amount of nickel present is calculated as
a weight percentage of nickel atoms in the catalyst based on the total weight of the
catalyst, despite the form in which that nickel may be present. The nickel may be
present in the catalyst in a variety of forms; most commonly, nickel is principally
present as metal, metal oxide, or a combination thereof. In some embodiments of the
present disclosure as described herein, nickel is present in the catalyst in an amount
in the range of 0.05 to 10 wt%, e.g., in the range of 0.1 to 10 wt%, or 0.5 to 10
wt%, 1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight of the
catalyst. For example, in some embodiments, nickel is present in the catalyst in an
amount in the range of 0.05 to 7 wt%, e.g., in the range of 0.1 to 7 wt%, or 0.5 to
7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total weight of the catalyst. In
some embodiments, nickel is present in the catalyst in an amount in the range of 0.05
to 5 wt%, e.g., in the range of 0.1 to 5 wt%, or 0.5 to 5 wt%, or 1 to 5 wt%, or 2
to 5 wt%, based on the total weight of the catalyst. For example, in some embodiments
of the present disclosure as described herein, nickel is present in the catalyst in
an amount in the range of 0.05 to 2 wt%, e.g., in the range of 0.1 to 2 wt%, or 0.3
to 2 wt%, or 0.5 to 2 wt%, based on the total weight of the catalyst. In some embodiments,
nickel is present in the catalyst in an amount in the range of 0.05 to 1.5 wt%, e.g.,
in the range of 0.1 to 1.5 wt%, or 0.3 to 1.5 wt%, or 0.5 to 1.5 wt%, based on the
total weight of the catalyst. In some embodiments, nickel is present in an amount
in the range of 0.05 to 1 wt%, e.g., in the range of 0.1 to 1 wt%, or 0.3 to 1 wt%,
or 0.5 to 1 wt%, based on the total weight of the catalyst. In some embodiments, nickel
is present in the catalyst in an amount in the range of 0.05 to 0.8 wt%, e.g., in
the range of 0.1 to 0.8 wt%, or 0.3 to 0.8 wt%, or 0.5 to 0.8 wt%, based on the total
weight of the catalyst.
[0042] The platinum, palladium, gold, and/or nickel and the metal can be provided in a variety
of weight ratios. For example, in some embodiments of the present disclosure as described
herein, the weight ratio of platinum, palladium, gold, and/or nickel to metal present
in the catalyst is at least 0.05:1. For example, in various embodiments, the weight
ratio of platinum, palladium, gold, and/or nickel to metal is at least 0.1:1. In various
embodiments of the present disclosure as described herein, the weight ratio of platinum,
palladium, gold, and/or nickel to metal present in the catalyst is at most 1:1. For
example, the weight ratio of platinum, palladium, gold, and/or nickel to metal is
at most 0.5:1. For example, in various embodiments, the weight ratio of platinum,
palladium, gold, and/or nickel to metal present in the catalyst is in the range of
0.05:1 to 1:1. For example, the weight ratio of platinum, palladium, gold, and/or
nickel to metal is in the range of 0.05:1 to 0.5:1, or 0.05:1 to 0.3:1, or 0.07:1
to 1:1, or 0.07:1 to 0.5:1, or 0.07:1 to 0.3:1, or 0.1:1 to 1:1, or 0.1:1 to 0.5:1,
or 0.1:1 to 0.3:1.
[0043] The present inventors have determined that suitable reverse water-gas shift catalysts
can be formed of one or more of cerium oxide, titanium oxide, aluminum oxide, zinc
oxide, and zirconium oxide as a support, with a metal and optionally with platinum,
palladium, gold, and/or nickel included in/on the catalyst. As would be understood
by the person of ordinary skill in the art, the amount of cerium, titanium, aluminum,
zinc, zirconium, metal, and platinum, palladium, gold, and nickel (if present) can
be quantified on a metallic basis regardless of the form in which these metals may
be present. For example, the amount of these metals can be calculated as a weight
percentage based on the total weight of metals in the catalysts (i.e., on a metallic
basis), without the inclusion of oxygen or non-metallic counterions in the calculation.
Accordingly, in various embodiments of the present disclosure as described herein,
the total amount of cerium, titanium, aluminum, zinc, zirconium, and metal in the
catalyst is at least 90 wt%, e.g., at least 95 wt%, or at least 98 wt% of the catalyst,
on a metallic basis. For example, in some particular embodiments, the total amount
of cerium and metal in the catalyst is at least 90 wt%, e.g., at least 95 wt%, or
at least 98 wt% of the catalyst, on a metallic basis. In other embodiments, the total
amount of titanium and metal in the catalyst is at least 90 wt%, e.g., at least 95
wt%, or at least 98 wt% of the catalyst, on a metallic basis. In other embodiments,
the total amount of aluminum and metal in the catalyst is at least 90 wt%, e.g., at
least 95 wt%, or at least 98 wt% of the catalyst, on a metallic basis. In other embodiments,
the total amount of zinc and metal in the catalyst is at least 90 wt%, e.g., at least
95 wt%, or at least 98 wt% of the catalyst, on a metallic basis. In other embodiments,
the total amount of zirconium and metal in the catalyst is at least 90 wt%, e.g.,
at least 95 wt%, or at least 98 wt% of the catalyst, on a metallic basis. In various
embodiments of the present disclosure as described herein, the total amount of cerium,
titanium, aluminum, zinc, zirconium, metal, platinum, palladium, gold, and nickel
in the catalyst is at least 90 wt%, e.g., at least 95 wt%, or at least 98 wt% of the
catalyst, on a metallic basis. For example, in some particular embodiments, the total
amount of cerium, metal, platinum, palladium, gold, and nickel in the catalyst is
at least 90 wt%, e.g., at least 95 wt%, or at least 98 wt% of the catalyst, on a metallic
basis. In other embodiments, the total amount of titanium, metal, platinum, palladium,
gold, and nickel in the catalyst is at least 90 wt%, e.g., at least 95 wt%, or at
least 98 wt% of the catalyst, on a metallic basis. In other embodiments, the total
amount of aluminum, metal, platinum, palladium, gold, and nickel in the catalyst is
at least 90 wt%, e.g., at least 95 wt%, or at least 98 wt% of the catalyst, on a metallic
basis. In other embodiments, the total amount of zinc, metal, platinum, palladium,
gold, and nickel in the catalyst is at least 90 wt%, e.g., at least 95 wt%, or at
least 98 wt% of the catalyst, on a metallic basis. In other embodiments, the total
amount of zirconium, metal, platinum, palladium, gold, and nickel in the catalyst
is at least 90 wt%, e.g., at least 95 wt%, or at least 98 wt% of the catalyst, on
a metallic basis.
[0044] As described above, the supported catalyst includes metals and optionally at least
one of platinum, palladium, gold, and nickel. Depending on the process of synthesis,
these species, which will typically be principally present in metallic form and/or
oxide form, can be disposed at a variety of different places on the support. For example,
they can be found in pores of the support and on the outer surface of the support.
They may be found substantially throughout the support, e.g., as when a large volume
of impregnation liquid is used, or only in a surface layer of the support, e.g., when
impregnation liquid does not infiltrate into the entirety of the support, such as
when using an incipient wetness technique.
[0045] Without intending to be bound by theory, it is believed that the active form of platinum
and palladium is typically a substantially metallic form. As described below, as platinum
and palladium may be present substantially in an oxide form after catalyst preparation
and during shipment and storage, it is typically desirable to activate the catalyst
by contacting it with a reductant, e.g., hydrogen gas, to convert a substantial fraction
of such oxide to metallic form. However, the person of ordinary skill in the art will
appreciate that the present disclosure contemplates the usefulness of a wide variety
of palladium and platinum forms in its catalysts, as these can be active or can be
conveniently transformed to active forms.
[0046] The metal will typically be provided in oxide form after catalyst preparation and
during shipment and storage. Without intending to be bound by theory, the present
inventors believe that the metal acts to improve the catalytic activity of the supported
platinum, palladium, gold, and/or nickel catalysts by reducing CO methanation that
can occur over the typical reverse water-gas shift reaction temperature range, which
impacts CO selectivity. The present inventors believe that the improved activity can
be attributed to the metal interfacing with the support (e.g., cerium oxide, titanium
oxide, aluminum oxide, zinc oxide, zirconium oxide, or a mixed oxide). Additionally,
when platinum, palladium, gold, and nickel are present in the catalyst, the present
inventors believe that the improved activity can be attributed to the metal interfacing
with both the noble metals and the support. The present inventors contemplate that
it is possible that some metal oxide is converted to metallic form during the activation
of the platinum, palladium, gold, and/or nickel species. However, the person of ordinary
skill in the art will appreciate that the present disclosure contemplates the usefulness
of a wide variety of metal forms in its catalysts, as these can provide a promoting
effect or can be conveniently transformed to forms that will.
[0047] The person of ordinary skill in the art will appreciate that the catalysts of the
disclosure can be provided in many forms, depending especially on the particular form
of the reactor system in which they are to be used, e.g., in a fixed bed or as a fluid
bed. The supports themselves can be provided as discrete bodies of material, e.g.,
as porous particles, pellets or shaped extrudates, with metal and optionally, palladium,
platinum, gold, and/or nickel provided thereon to provide the catalyst. However, in
other embodiments, a catalyst of the disclosure can itself be formed as a layer on
an underlying substrate. The underlying substrate is not particularly limited. It
can be formed of, e.g., a metal or metal oxide, and can itself be provided in a number
of forms, such as particles, pellets, shaped extrudates, or monoliths. The person
of ordinary skill in the art can, e.g., use coating or other forming techniques to
provide a layer of support on the substrate, then add metal and optionally, platinum,
palladium, gold, and/or nickel. Of course, as would be understood by the person of
ordinary skill in the art, other embodiments may be possible.
[0048] Another aspect of the present disclosure provides for a method of making the catalyst
as described herein. As described above, the method includes providing a support that
is a cerium oxide support, a titanium oxide support, an aluminum oxide support, a
zinc oxide support, a zirconium oxide support, or a mixed oxide support including
a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide,
and zirconium oxide; contacting the support with one or more liquids each comprising
one or more metal-containing compounds dispersed in a solvent(s), wherein the metal
is selected from manganese, copper, gallium, indium, lanthanum, titanium, niobium,
vanadium, and zirconium, and optionally one or more platinum-, palladium-, gold-,
or nickel-containing compounds; allowing the solvent(s) to evaporate to provide a
catalyst precursor; and calcining the catalyst precursor. The person of ordinary skill
in the art will appreciate, of course, that other methods can be used to make the
catalysts described herein.
[0049] In some embodiments of the present disclosure as described herein, contacting the
support with the liquid includes adding the liquid in an amount about equal to (i.e.,
within 25% of, or within 10% of) the pore volume of the support. In other embodiments,
contacting the support with the liquid includes adding the liquid in an amount greater
than the pore volume of the support. For example, in some embodiments, the ratio of
the amount of liquid to the amount of support on a mass basis is in the range of 0.75:1
to 5:1, e.g., in the range of 0.9:1 to 3:1. In some embodiments, contacting the support
with the liquid provides a slurry.
[0050] In various embodiments of the present disclosure as described herein, allowing the
solvent to evaporate is conducted at ambient temperature. In various embodiments,
allowing the solvent to evaporate is conducted at an elevated temperature for a drying
time. The person of ordinary skill in the art would be able to select appropriate
apparatuses or instruments to allow the solvent to evaporate, and such apparatuses
or instruments are not particularly limited. Additionally, the person of ordinary
skill in the art would understand that the elevated temperature that will allow the
solvent to evaporate depends on the boiling point of the solvent. As such, the person
of ordinary skill in the art would be able to select an appropriate elevated temperature.
For example, in some embodiments, the elevated temperature is in the range of 50-150
°C, e.g., in the range of 50-120 °C, or 50-100 °C, or 100-150 °C, or 100-120 °C. In
some embodiments, the drying time is in the range of 1 to 48 hours, e.g., in the range
of 10 to 36 hours, or 12 to 24 hours. For example, in particular embodiments, the
drying time is about 24 hours. In some embodiments, allowing the solvent to evaporate
is conducted under vacuum and at an elevated temperature for a drying time, as described
herein. In some embodiments, allowing the solvent to evaporate is conducted in a stirring
drybath at an elevated temperature, for example, in the range of 30-100 °C.
[0051] In some embodiments of the present disclosure as described herein, calcining the
catalyst precursor is conducted in a furnace for a calcining time and at a calcining
temperature. For example, in some embodiments, the calcining time is in the range
of 0.5 to 24 hours, or 0.5 to 15 hours, or 0.5 to 10 hours, or 0.5 to 5 hours. In
some embodiments, the calcining temperature is in the range of 100-600 °C, e.g., in
the range of 120-500 °C.
[0052] As described above, the method of making the catalyst as described herein includes
contacting the support with one or more liquids each including one or more metal-containing
compounds and optionally, one or more platinum-, palladium-, gold-, or nickel-containing
compounds dispersed in a solvent. The platinum-, palladium-, gold-, and metal-containing
compounds are not particularly limited and the person of ordinary skill in the art
would be able to choose appropriate compounds that are soluble in the solvent. For
example, in some embodiments of the disclosure as described herein, the platinum-,
palladium-, gold-, and metal-containing compounds may be selected from metal salts
(e.g., nitrates and acetates). The solvent is also not particularly limited and the
person of ordinary skill in the art would be able to choose an appropriate solvent
that can be absorbed by the support. For example, in some embodiments of the disclosure
as described herein, the solvent is water. As the person of ordinary skill in the
art will appreciate, these metal species are conveniently provided in the same liquid,
so that only one step of contacting the support with liquid is required. However,
other schemes are possible.
[0053] In another aspect, the present disclosure provides a catalyst as described herein
made by the methods as described herein.
Reverse Water-Gas Shift Reaction
[0054] Another aspect of the present disclosure provides a method for performing a reverse
water-gas shift reaction. As described above, the method includes contacting at a
temperature in the range of 250-1100 °C a catalyst as described herein with a feed
stream that includes CO
2 and H
2, wherein at least part of the CO
2 of the first feed stream is from biogas, a CO
2 emission source, and/or direct air capture, to provide a product stream that includes
CO and H
2, the product stream having a lower concentration of CO
2 and a higher concentration of CO than the feed stream. An example of such a method
is shown schematically in FIG. 1. In FIG. 1, the method 100 includes performing a
reverse water-gas shift reaction by providing a feed stream 111 comprising H
2 and CO
2, here, to a reaction zone, e.g., a reactor 110. A reverse water-gas shift catalyst
113, as described herein, is contacted at a temperature in the range of 250-1100 °C
with the feed stream 111 to provide a product stream 112 comprising CO and H
2. The product stream has a lower concentration of CO
2 and a higher concentration of CO than the feed stream.
[0055] As used herein, a "feed stream" is used to mean the total material input to a process
step, regardless of whether provided in a single physical stream or multiple physical
streams, and whether through a single inlet or multiple inlets. For example, H
2 and CO of the feed stream can be provided to the reverse water-gas shift catalyst
in a single physical stream (e.g., in a single pipe to reactor 110), or in multiple
physical streams (e.g., separate inlets for CO and H
2, or one inlet for fresh CO and H2 and another for recycled CO and/or H2). Similarly,
a "product stream" is used to mean the total material output from a process step,
regardless of whether provided in a single physical stream or multiple physical streams,
and whether through a single outlet or multiple outlets.
[0056] As described above, CO
2 is a substantial input to the claimed processes. Advantageously, the present inventors
have recognized that at least part of the CO
2 of the first feed stream (e.g., at least 50%, at least 75%, at least 90% or at least
95%) can come from renewable or otherwise environmentally responsible sources. Accordingly,
as described above, at least part of the CO
2 of the first feed stream is from biogas, a CO
2 emission source, and/or direct air capture.
[0057] In various embodiments, at least a portion of the CO
2 of the first feed stream is from biogas. Biogas is produced by anaerobic digestion
of organic matter (e.g., animal water, food waste, plant matter) by microorganisms
and includes substantial amounts of CO
2 and methane. In some embodiments as described herein, a majority (i.e., at least
50 mol%) the CO
2 of the first feed stream is from biogas. In some embodiments as described herein,
substantially all (e.g., at least 90 mol%) of the CO
2 of the first feed stream is from biogas. For example, in some embodiments, the CO
2 of the first feed stream comprises at least 50 mol% (e.g., at least 75 mol%, at least
90 mol%, or at least 95 mol%) CO
2 from biogas. In various embodiments, such as when at least part of the CO
2 of the first feed stream is from biogas, the process as described herein may operate
with significant amounts of unreacted methane. For example, in various embodiments
wherein the first feed stream comprises methane, such as from biogas, the first feed
stream comprises methane in an amount in the range of 10-70 mol%, or 10-50 mol%, or
20-70 mol%, or 20-50 mol%, or 30-70 mol%, or 30-50 mol%.. In other embodiments as
described herein, when the first feed stream comprises biogas, the methane in the
biogas may be separated out before being added to the first feed stream. Accordingly,
in some embodiments, the process as described herein may operate with low amounts
of unreacted methane. For example, in certain embodiments as otherwise described herein,
the first feed stream comprises methane in an amount in the range of 0.1 to 10 mol%,
or 0.1 to 5 mol%, or 0.1 to 1 mol%.
[0058] In various embodiments, at least a portion of the CO
2 of the first feed stream is from direct air capture. Carbon dioxide is a common waste
material, and often desirable to be removed from waste streams rather than be vented
to the atmosphere. Such capture of carbon dioxide is critical to the implementation
of many renewable initiatives as it serves to lower the carbon footprint of the associated
process. Advantageously, the carbon dioxide utilized in the processes described herein
may be carbon dioxide collected from the atmosphere or that would otherwise have been
released into the atmosphere, e.g., from a combustion or other industrial process.
The carbon dioxide may be captured, where it is collected or absorbed after release
from an industrial process, or harvested directly from the atmosphere. By using captured
carbon dioxide, the eventual hydrocarbon product can be substantially carbon-neutral
or of lower carbon intensity. Methods of carbon dioxide capture are known to those
of skill in the art. In various embodiments, at least a portion of the CO
2 of the first feed stream is from direct air capture. In some embodiments as described
herein, a majority (i.e., at least 50 mol%) the CO
2 of the first feed stream is from direct air capture. In some embodiments as described
herein, substantially all (e.g., at least 90 mol%) of the CO
2 of the first feed stream is from direct air capture. For example, in some embodiments,
the CO
2 of the first feed stream comprises at least 50 mol% (e.g., at least 75 mol%, at least
90 mol%, or at least 95 mol%) CO
2 from direct air capture.
[0059] In various embodiments as described herein, at least part of the CO
2 of the first feed stream is from a CO
2 emission source. Additionally or alternatively, carbon dioxide is often scrubbed
from industrial effluent, especially processes that generate large amounts of carbon
dioxide as a byproduct. As used herein, the source of this carbon dioxide byproduct
from industrial processes is referred to as a CO
2 emission source. In some embodiments as described herein, a majority (i.e., at least50
mol%) the CO
2 of the first feed stream is from a CO
2 emission source. In some embodiments as described herein, substantially all (e.g.,
at least 90 mol%) of the CO
2 of the first feed stream is from a CO
2 emission source. For example, in some embodiments, the CO
2 of the first feed stream comprises at least 50 mol% (e.g., at least 75 mol%, at least
90 mol%, or at least 95 mol%) CO
2 from a CO
2 emission source. The CO
2 emission source is not particularly limited and may derived from any industrial production
known in the art. For example, in some embodiments as described herein, the CO
2 emission source is a manufacturing plant, a bioethanol plant, a CO
2 producing fermentation plant, a steel plant, or a cement plant. Accordingly, in various
embodiments as otherwise described herein, at least part of the CO
2 of the first feed stream (e.g., at least 50%, at least 75%, at least 90% or at least
95%) is captured from a manufacturing plant, e.g., a bioethanol plant (e.g., CO
2 produced fermentation), a steel plant or a cement plant. In some embodiments as described
herein, the CO
2 emission source is a point source from a fermentation, manufacturing, or other industrial
process. The point source may be in the form of a chimney or vent or other structure
for containing and/or transporting CO
2 known in the art.
[0060] Accordingly, the rWGS-Fischer Tropsch integrated processes of the disclosure as described
herein can be not only carbon neutral, but in some cases a net consumer of carbon
dioxide. These benefits in particular make the integrated processes highly attractive
for decarbonizing transportation fuels, for both automotive and aviation sectors,
since the carbon monoxide produced in the rWGS reaction can be readily utilized by
well-established technologies to synthesize liquid hydrocarbon fuels by Fischer-Tropsch
processes.
[0061] For example, in various embodiments of the present disclosure as described herein,
the reverse water-gas shift reaction has a CO selectivity of at least 50%, e.g., at
least 50%. In various embodiments, the reverse water-gas shift reaction has a CO selectivity
of at least 70%, e.g., of at least 80%. In various embodiments, the reverse water-gas
shift reaction has a CO selectivity of at least 85%, e.g., or at least 90%. In various
embodiments, the reverse water-gas shift reaction has a CO selectivity of at least
95%, e.g., or at least 96%. As used herein, a "selectivity" for a given reaction product
is the molar fraction of the converted feed (here, the CO
2 that is converted to products other than CO
2) that is converted to the identified product (for "CO selectivity," CO). The present
inventors have determined that the present catalysts, even when operating at lower
temperatures (e.g., less than 900 °C) than many conventional reverse water-gas shift
catalysts, can provide excellent selectivity for CO, despite the potential for competition
by the Sabatier reaction and the methanation of CO. For example, in various embodiments
of the present disclosure as described herein, the reverse water-gas shift reaction
has a CO selectivity in the range of 50-99 wt%, e.g., 60-99%, or 70-99%, or 80-99%,
or 90-99%, or 95-99%. In various embodiments, the reverse water-gas shift reaction
has a CO selectivity in the range of 50-90%, e.g., 60-90%, or 70-90%, or 50-80%, or
60-80%, or 50-70%.
[0062] Notably, even over a broad range of temperatures in the range of 200-1100 °C, the
catalysts described herein can be operated to provide carbon monoxide with only a
very minor degree of methane formation. For example, in various embodiments of the
present disclosure as described herein, the reverse water-gas shift reaction has a
methane selectivity of no more than 40%, e.g., no more than 35%, or 30%, or 25%, or
20%. For example, in various embodiments of the present disclosure as described herein,
the reverse water-gas shift reaction has a methane selectivity of no more than 15%,
e.g., no more than 12%, or 10%, or 8%. For example, in various embodiments of the
present disclosure as otherwise described herein, the reverse water-gas shift reaction
has a methane selectivity of no more than 5%, e.g., no more than 4%. For example,
in some embodiments, the reverse water-gas shift reaction has a methane selectivity
of no more than 2%, e.g., no more than 1%. In some embodiments, the reverse water-gas
shift reaction has a methane selectivity of no more than 0.5%, e.g., no more than
0.2%.
[0063] The present inventors have determined that the catalysts described here can provide
desirably high CO selectivity and desirably low methane selectivity at commercially
relevant conversion rates. As used herein, a "conversion" is a molar fraction of a
feed that is reacted (be it to desirable products or undesirable species). In various
embodiments of the present disclosure as described herein, the reverse water-gas shift
reaction has a CO
2 conversion of at least 5%, e.g., at least 10%, or 20%. For example, in some embodiments,
the reverse water-gas shift reaction has a CO
2 conversion of at least 30%, e.g., at least 40%, or 50%, or 60%. In various embodiments
of the present disclosure as described herein, the reverse water-gas shift reaction
has a CO
2 conversion of no more than 90%, e.g., no more than 80%, or no more than 70%. For
example, in some embodiments, the reverse water-gas shift reaction has a CO
2 conversion of no more than 65%, e.g., no more than 60%. For example, in various embodiments
as otherwise described herein, the CO
2 conversion is in the range of 10-90%, e.g., 10-80%, 10-70%, or 10-60%, or 10-65%,
or 20-90%, or 20-80%, or 20-70%, or 20-60%, or 20-65%, or 30-90%, or 30-80%, or 30-70%,
or 30-60%, or 30-65%, or 40-90%, or 40-80%, or 40-70%, or 40-60%, or 40-65%. The person
of ordinary skill in the art will, based on the disclosure herein, operate at a degree
of conversion that provides a desirable product. And of course, in other embodiments,
e.g., when in a stacked-bed or mixed-bed system, the CO
2 conversion may be even higher than described here.
[0064] Advantageously, the processes described herein can be performed at temperatures that
are lower than temperatures used in many conventional reverse water-gas shift processes.
As described above, various processes of the disclosure can be performed in a temperature
range of 200-1100°C, e.g., in the range of 200-1050 °C, or 200-1000 °C, or 200-950
°C, or 250-1050 °C, or 250-1000 °C, or 250-950 °C. For example, in some embodiments,
the method for performing the reverse water-gas shift reaction is conducted at a temperature
in the range of 250-900 °C, e.g., in the range of 250-850 °C, 250-800 °C, or 250-750
°C, or 250-700 °C, or 250-650 °C, or 250-600 °C. In some embodiments as described
herein, the method for performing the reverse water-gas shift reaction is conducted
at a temperature in the range of 300-1100 °C, e.g., in the range of 300-1050 °C, or
300-1000 °C, or 300-950 °C. In some embodiments of the present disclosure as described
herein, the method for performing the reverse water-gas shift reaction is conducted
at a temperature in the range of 300-900 °C, e.g., in the range of 300-850 °C, or
300-800 °C, or 300-750 °C, or 300-700 °C, or 300-650 °C, or 300-600 °C. In some embodiments
as described herein, the method for performing the reverse water-gas shift reaction
is conducted at a temperature in the range of 350-1100 °C, e.g., in the range of 350-1050
°C, or 350-1000 °C , or 350-950 °C. In some embodiments of the present disclosure
as described herein, the method for performing the reverse water-gas shift reaction
is conducted at a temperature in the range of 350-900 °C, e.g., in the range of 350-850
°C , or 350-800 °C , or 350-750 °C, or 350-700 °C, or 350-650 °C, or 350-600 °C. In
some embodiments as described herein, the method for performing the reverse water-gas
shift reaction is conducted at a temperature in the range of 400-1100 °C, e.g., in
the range of 400-1050 °C, or 400-1000 °C , or 400-950 °C. In some embodiments, the
method for performing the reverse water-gas shift reaction is conducted at a temperature
in the range of 400-900 °C, e.g., in the range of 400-850 °C, or 400-800 °C , or 400-750
°C, or 400-700 °C, or 400-650 °C, or 400-600 °C. In some embodiments as described
herein, the method for performing the reverse water-gas shift reaction is conducted
at a temperature in the range of 450-1100 °C, e.g., in the range of 450-1050 °C, or
450-1000 °C, or 450-950 °C. In some embodiments, the method for performing the reverse
water-gas shift reaction is conducted at a temperature in the range of 450-900 °C,
e.g., in the range of 450-850 °C , or 450-800 °C, or 450-750 °C, or 450-700 °C, or
450-650 °C, or 450-600 °C. In some embodiments as described herein, the method for
performing the reverse water-gas shift reaction is conducted at a temperature in the
range of 500-1100 °C, e.g., in the range of 500-1050 °C, or 500-1000 °C, or 500-950
°C. In some embodiments, the method for performing the reverse water-gas shift reaction
is conducted at a temperature in the range of 500-900 °C, e.g., in the range of 500-850
°C, or 500-800 °C, or 500-750 °C , or 500-700 °C, or 500-650 °C, or 500-600 °C. In
some embodiments as described herein, the method for performing the reverse water-gas
shift reaction is conducted at a temperature in the range of 550-1100 °C, e.g., in
the range of 550-1050 °C, or 550-1000 °C, or 550-950 °C. In some embodiments, the
method for performing the reverse water-gas shift reaction is conducted at a temperature
in the range of 550-900 °C, e.g., in the range of 550-850 °C, or 550-800 °C, or 550-750°C,
or 550-700 °C, or 550-650 °C, or 550-600 °C. In some embodiments as described herein,
the method for performing the reverse water-gas shift reaction is conducted at a temperature
in the range of 600-1100 °C, e.g., in the range of 600-1050 °C, or 600-1000 °C, or
600-950 °C. In some embodiments, the method for performing the reverse water-gas shift
reaction is conducted at a temperature in the range of 600-900 °C, e.g., in the range
of 600-850 °C, or 600-800 °C, or 600-750°C, or 600-700 °C, or 600-650 °C. In some
embodiments as described herein, the method for performing the reverse water-gas shift
reaction is conducted at a temperature in the range of 650-1100 °C, e.g., in the range
of 650-1050 °C, or 650-1000 °C, or 650-950 °C. In some embodiments, the method for
performing the reverse water-gas shift reaction is conducted at a temperature in the
range of 650-900 °C, e.g., in the range of 650-850 °C, or 650-800 °C, or 650-750°C,
or 650-700 °C. In some embodiments as described herein, the method for performing
the reverse water-gas shift reaction is conducted at a temperature in the range of
700-1100 °C, e.g., in the range of 700-1050 °C, or 700-1000 °C, or 700-950 °C. In
some embodiments, the method for performing the reverse water-gas shift reaction is
conducted at a temperature in the range of 700-900 °C, e.g., in the range of 700-850
°C, or 700-800 °C, or 700-750°C.
[0065] In some embodiments, the reverse water-gas shift reaction is conducted at a temperature
in the range of 200-500 °C, e.g., 200-450 °C, or 200-400 °C, or 200-350 °C, or 250-500
°C, or 250-450 °C, or 250-400 °C, or 250-350 °C. The present inventors have noted
that operation at these temperatures can provide for lower energy demand, as well
as for facile integration with a subsequent Fischer-Tropsch process step.
[0066] As described above, the feed stream includes CO
2 and H
2. Advantageously, the present inventors have recognized that both of these can come
from renewable or otherwise environmentally responsible sources. For example, at least
part of the H
2 can be so-called "green" hydrogen, e.g., produced from the electrolysis of water
operated using renewable electricity (such as wind, solar, or hydroelectric power).
In other embodiments, at least part of the H
2 may be from a so-called "blue" source, e.g., from a natural gas reforming process
with carbon capture. Of course, other sources of hydrogen can be used in part or in
full. For example, in some embodiments, at least a portion of the H
2 of the feed stream is grey hydrogen, black hydrogen, brown hydrogen, pink hydrogen,
turquoise hydrogen, yellow hydrogen, and/or white hydrogen. CO
2 can be captured from the environment generally, or more directly from processes that
form CO
2 (especially in difficult-to-abate sectors), making a product that is later made from
the CO at least carbon-neutral. For example, in some embodiments, at least part of
the CO
2 is from direct air capture, or from a manufacturing plant such as a bioethanol plant
(e.g., CO
2 produced fermentation), a steel plant, or a cement plant. Accordingly, the rWGS reaction
can be not only carbon neutral, but in some cases a net consumer of carbon dioxide.
These benefits in particular makes the rWGS reaction highly attractive for decarbonizing
transportation fuels, for both automotive and aviation sectors, since the carbon monoxide
produced in the reaction can be readily utilized by well-established technologies
to synthesize liquid hydrocarbon fuels.
[0067] The feed stream contains both H
2 and CO
2 (e.g., provided to a reaction zone in a single physical stream or multiple physical
streams). As used herein, the feed stream includes all feeds to the process, regardless
of whether provided as a mixture of gases or as gases provided individually to a reaction
zone. In various embodiments as otherwise described herein, the molar ratio of H
2 to CO
2 in the feed stream is at least 0.1:1, e.g., at least 0.5:1. In some embodiments,
the molar ratio of H
2 to CO
2 in the feed stream is at least 0.9:1, e.g., at 1:1 or least 1.5:1. In some embodiments,
the molar ratio of H
2 to CO
2 in the feed stream is at least 2:1, e.g., at least 2.5:1. In some embodiments, the
molar ratio of H
2 to CO
2 in the feed stream is no more than 100:1, e.g., no more than 75:1, or 50:1. In some
embodiments, the molar ratio of H
2 to CO
2 in the feed stream is no more than 20:1, e.g., no more than 15:1, or 10:1. For example,
in some embodiments, the molar ratio of H
2 to CO
2 in the feed stream is in the range of 0.5:1 to 10:1. The person of ordinary skill
in the art will provide a desired ratio of H
2:CO
2 in the feed stream, based on the disclosure herein, that provides a desirable conversion
and selectivity; excess H
2 can, if consistent with a desirable conversion and selectivity, be provided to flow
through the system and provide a product stream with a desirable ratio of H
2 to CO for a downstream process.
[0068] Other gases may also be included in the feed stream. For example, in some embodiments,
the feed stream further comprises CO. In various embodiments as described herein,
the first feed stream comprises no more than 20 mol%, no more than 10 mol%, or no
more than 5 mol%, or no more than 3 mol%, or no more than 1 mol%, of CO. In some embodiments
of the disclosure as otherwise described herein, the feed stream further comprises
one or more inert gases. For example, in some embodiments, the feed stream further
comprises nitrogen and/or methane. In various embodiments as described herein, the
first feed stream comprises no more than 10 mol%, no more than 6 mol%, or no more
than 2 mol%, of nitrogen. In various embodiments as described herein, the gases of
first feed steam may be separated out to provide the amounts of carbon dioxide, methane,
and/or nitrogen as described herein. For example, in some embodiments as described
herein, methane is separated from the first feed stream to provide a first feed stream
comprising at least 50 mol% carbon dioxide, e.g., at least 60 mol% carbon dioxide,
at least 70 mol% carbon dioxide, at least 80 mol% carbon dioxide, or at least 90 mol%
carbon dioxide.
[0069] The processes described herein can be performed at a variety of pressures, as would
be appreciated by the person of ordinary skill in the art. In various embodiments
of the present disclosure, the method for performing the reverse water-gas shift reaction
is conducted at a pressure in the range of 1 to 100 barg. For example, the method
is conducted at a pressure in the range of 1 to 70 barg, or 1 to 50 barg, or 1 to
40 barg, or 1 to 35 barg, or 5 to 70 barg, or 5 to 50 barg, or 5 to 40 barg, or 5
to 35 barg, or 10 to 70 barg, 10 to 50 barg, or 10 to 40 barg, or 10 to 35 barg, or
20 to 70 barg, 20 to 50 barg, or 20 to 40 barg, or 20 to 35 barg, or 25 to 70 barg,
25 to 50 barg, or 25 to 40 barg, or 25 to 35 barg.
[0070] The processes described herein can be performed at a variety of GHSV (gas hourly
space velocity), as would be appreciated by the person of ordinary skill in the art.
As such, the GHSV for performing the reverse water-gas shift reaction is not particularly
limited. For example, in some embodiments of the present disclosure, the method for
performing the reverse water-gas shift reaction is conducted at a GHSV in the range
of 1,000 to 2,000,000 h
-1. In various embodiments, the method for performing the reverse water-gas shift reaction
is conducted at a GHSV in the range of 1,000 to 1,200,000 h
-1, or 1,000 to 500,000 h
-1, or 1,000 to 100,000 h
-1, or 5,000 to 1,200,000 h
-1, or 5,000 to 500,000 h
-1, or 5,000 to 100,000 h
-1, or 10,000 to 1,200,000 h
-1, or 10,000 to 500,000 h
-1, or 10,000 to 100,000 h
-1. In various embodiments of the present disclose, the method for performing the reverse
water-gas shift reaction is conducted at a GHSV in the range of 1,000 to 50,000 h
-1, or 2,000 to 50,000 h
-1, or 5,000 to 50,000 h
-1, or 10,000 to 50,000, or 1,000 to 40,000 h
-1, or 2,000 to 40,000 h
-1, or 5,000 to 40,000 h
-1, or 10,000 to 40,000 h
-1, or 1,000 to 30,000 h
-1, or 2,000 to 30,000 h
-1, or 5,000 to 30,000 h
-1, or 10,000 to 30,000 h
-1.
[0071] The rWGS catalyst described herein is based in part on platinum, palladium, gold,
and/or nickel. It will typically be desirable to activate the rWGS catalyst, e.g.,
before contacting with the feed stream. Thus in some embodiments of the present disclosure
as described herein, the method comprises activating the rWGS catalyst prior to contacting
the catalyst with the feed stream. For example, in some embodiments, activating the
catalyst comprises contacting the catalyst with a reducing stream comprising a reductive
gas, e.g., hydrogen. In various embodiments of the present disclose, the reducing
stream comprises hydrogen in an amount of at least 25 mol%, e.g., at least 50 mol%,
or 75 mol%, or 90 mol%. The person of ordinary skill in the art will determine suitable
conditions for activation of the rWGS catalyst. As such, the person or ordinary skill
in the art would be able to choose an appropriate temperature, pressure, and time
for activating the rWGS catalyst. For example, in various embodiments activating the
catalyst is conducted at a temperature in the range of 200 °C to 1000 °C. In some
embodiment, activating the catalyst is conducted at a temperature in the range of
250 °C to 1000 °C, or 300 °C to 1000 °C, 200 °C to 900 °C, or 250 °C to 900 °C, or
300 °C to 900 °C, 200 °C to 800 °C, or 250 °C to 800 °C, or 300 °C to 800 °C, or 200
°C to 700 °C, or 250 °C to 800 °C, or 300 °C to 700 °C. In some embodiments of the
present disclosure as described herein, activating the catalyst provides a catalyst
that is at least 10% reduced (e.g., at least 25%, or at least 50% reduced).
[0072] The present inventors have found that contacting the rWGS catalysts as described
herein with a feed stream can provide a product stream with advantageously high CO
selectivity and low methane selectivity. The amount of CO in the product stream can
be further controlled by the rWGS reaction conditions, as described above. But in
general, the methods for performing the rWGS reaction as described herein, provide
a product stream comprising H
2 and CO, with the product stream having a lower concentration of CO
2 and a higher concentration of CO than the feed stream, as is consistent with the
degrees of conversion described herein. For example, in various embodiments, the product
stream includes no more than 95 mol% CO
2, or no more than 90 mol% CO
2. In some embodiments, the product stream includes no more than 85 mol% CO
2, or no more than 80 mol% CO
2. In other examples, the product stream includes no more than 75 mol%, or no more
than 70 mol% CO
2. However, as described above, the present inventors have determined that it can be
desirable to perform the processes at intermediate degrees of conversion to provide
desirably high CO selectivities and desirably low methane selectivities. Accordingly,
in various embodiments as otherwise described herein, the product stream includes
an amount of CO
2 together with the CO.
[0073] Other gases may also be included in the product stream. In some embodiments of the
disclosure as otherwise described herein, the product stream further comprises one
or more inert gases. These inert gases may be included from the feed stream or provided
from a source other than the feed stream. For example, in some embodiments, the product
stream further comprises nitrogen and/or methane.
[0074] Depending on, inter alia, the degree of conversion, the CO selectivity, the relative
amounts of H
2 and CO
2 in the feed stream, and the reaction conditions, the product stream can include H
2 in combination with CO, in a variety of ratios. For example, in some embodiments,
the ratio of H
2:CO in the product stream is in the range of 0.1:1 to 100:1 (e.g., in the range of
0.1:1 to 50:1, or 0.1:1 to 25:1, or 0.1:1 to 10:1, or 0.1:1 to 5:1, or 1:1 to 100:1,
or 1:1 to 50:1, or 1:1 to 25:1, or 1:1 to 10:1, or 1:1 to 5:1).
[0075] The person of ordinary skill in the art would appreciate that, based on the methods
as described herein, the product stream may include H
2, CO, and CO
2 and other components in various amounts. Components of the product stream may be
separated and used for various purposes in the rWGS process.
[0076] For example, in various embodiments of the present disclosure as described herein,
the method further comprises separating the product stream to recycle at least a portion
(e.g., at least 5 mol%, at least 10 mol%, at least 25 mol%, at least 50 mol%, at least
75 mol%, or at least 90 mol%) of one or more components of the product stream to the
feed stream. For example, when the product stream includes CO
2, the method can include recycling at least a portion (e.g., at least 5 mol%, at least
10 mol%, at least 25 mol%, at least 50 mol%. at least 75 mol%, or at least 90 mol%)
of the CO
2 of the product stream to the feed stream. The product stream may also include H
2; in some embodiments, the method further includes recycling at least a portion of
H
2 of the product stream (e.g., at least 5 mol%, at least 10 mol%, at least 25 mol%,
at least 50 mol%, at least 75 mol%, or at least 90 mol%) to the feed stream.
[0077] Such recycling is shown in the process 100 of FIG. 1 (and of FIG. 2). Here, the process
100 includes separating from the product stream 112 at least a portion of CO
2 (stream 114) to recycle to the feed stream 111. Similarly, the process 100 includes
separating from the product stream 112 at least a portion of H
2 (stream 115) to recycle to the product stream 111. While stream 115 is depicted as
entering reactor 110 through a different inlet than the rest of the feed stream 111,
it is considered to be part of the feed stream, as it is part of the material input
to the process step.
[0078] As noted above, one competing reaction in the reverse water-gas shift reaction is
the Sabatier reaction, which makes methane. While in various embodiments the reverse
water-gas shift processes described herein can be performed without forming large
amounts of methane, in some embodiments there can be some methane formed. Accordingly,
in various embodiments of the method as described herein, the product stream comprises
one or more light hydrocarbons. For example, in some embodiments, the product stream
may include one or more of methane, ethane, propane, or combinations thereof. When
the first product steam includes methane, a substantial fraction of such methane may
be from biogas provided to the first feed stream (e.g., at least 50%, at least 75%,
or at least 90%). As would be understood by the person of ordinary skill in the art,
it may be desirable to operate the reverse water-gas shift reaction to provide higher
amounts of light hydrocarbons in the product feed. For example, such light hydrocarbons
may be inert in further processing of the product stream and so may be acceptable
at higher amounts, especially when biogas is used in the first feed stream. The person
of ordinary skill in the art would be able to select appropriate reaction conditions
(e.g., temperature, pressure, feed stream composition) to provide a product stream
that includes methane at a desired amount. For example, in various embodiments as
otherwise described herein, the product stream includes no more than 20 mol% methane
or no more than 15 mol%. As noted above, when lower amounts of methane are desired
in the product stream, the catalysts of the disclosure can provide very low methane
selectivity. Additionally, when biogas is present in the first feed stream, methane
may be separated before contacting with the reverse water-gas shift catalyst to provide
a first feed stream and a first product stream with low amounts of methane. Accordingly,
in various embodiments as otherwise described herein, the product stream includes
no more than 10 mol% methane. For example, in various embodiments, the product stream
includes no more than 5 mol%, or 1 mol%, or 0.5 mol%, or no more than 0.1 mol% methane.
In general, light hydrocarbons (e.g., C
1-C
5 hydrocarbons) may be present in the product stream. For example, in various embodiments
as otherwise described herein, the product stream includes no more than 20 mol% light
hydrocarbons (e.g., no more than 15 mol%, no more than 10 mol%, no more than 5 mol%,
no more than 1 mol%, no more than 0.5 mol%, or no more than 0.1 no mol% light hydrocarbons).
[0079] These light hydrocarbons (e.g., C
1-C
5 hydrocarbons) of the product stream can be separated and used for other purposes.
For example, in various embodiments, the method further includes separating at least
a portion of one or more light hydrocarbons from the product stream to provide a light
hydrocarbon stream. For example, in method 100 of FIG. 1, at least a portion of one
or more light hydrocarbons are separated from the product stream 112 to provide a
light hydrocarbon stream 116. The light hydrocarbon stream, for example, can be used
to provide other products, can be partially oxidized to form CO, can be steam reformed
to provide hydrogen, and/or can be burned to provide heat or other energy (e.g., electricity
for electrolysis) for use in the rWGS method or otherwise. In some embodiments as
described herein, the light hydrocarbon stream comprises methane from biogas which
can be burned to provide energy (e.g., heat energy or electrical energy) for use in
the integrated process (e.g., for heating the first feed stream).
Of course, as would be understood by the ordinary skill in the art, the light hydrocarbon
stream may be used in other processes as well. For example, as would be understood
by the person of ordinary skill in the art, some rWGS catalysts can have reforming
capability. Without being bound by theory, the present inventors hypothesize that
one explanation for the low methane production observed using the rWGS catalysts as
described herein is that methane is formed but then immediately reformed into CO and
H
2. Accordingly, in some embodiments as described herein, the light hydrocarbons of
the process stream is recycled to the feed stream for the rWGS reaction. These light
hydrocarbons can be separated and used for other purposes. For example, in various
embodiments, the process further includes separating at least a portion of one or
more light hydrocarbons from the first product stream to provide a light hydrocarbon
stream. For example, in process 100 of FIG. 2, at least a portion of one or more light
hydrocarbons are separated from the first product stream 112 to provide a light hydrocarbon
stream 118. The light hydrocarbon stream, for example, can be used to provide other
products, can be partially oxidized to form CO, can be steam reformed to provide hydrogen,
and/or can be burned to provide heat or other energy (e.g., electricity for electrolysis)
for use in the integrated process or otherwise. Of course, as would be understood
by the person of ordinary skill in the art, the light hydrocarbon stream may be used
in other processes as well.
Integrated Fischer-Tropsch Processes
[0080] In some embodiments as described herein, the supported reverse water-gas can be used
in a rWGS process integrated with an FT process. The embodiments related to the reverse
water-gas shift portion of the integrated FT process are as described above in the
previous section. For example, the feed stream of the rWGS process corresponds to
the first feed stream in the integrated FT process and the product stream of the rWGS
process corresponds to the first product stream in the integrated FT process.
[0081] Another aspect of the present disclosure provides a process for performing an integrated
Fischer-Tropsch process (i.e., integrated with an rWGS process). The process includes
providing a first feed stream comprising H
2 and CO
2, wherein at least part of the CO
2 of the first feed stream is from biogas, a CO
2 emission source, and/or direct air capture; contacting at a first temperature in
the range of 200-1100 °C and at a first pressure a reverse water-gas shift catalyst,
as described herein, with the first feed stream to perform a reverse water-gas shift
reaction to provide a first product stream comprising CO and H
2, the first product stream having a lower concentration of CO
2 and a higher concentration of CO than the first stream feed stream. An example of
such a process is shown schematically in FIG. 2. In FIG. 2, the process 100 includes
performing a reverse water-gas shift reaction by providing a first feed stream 111
comprising H
2 and CO
2, here, to a first reaction zone, e.g., a reactor 110. A reverse water-gas shift catalyst
113, as described herein, is contacted at a first temperature in the range of 250-1100
°C and at a first pressure with the feed stream 111 to provide a first product stream
112 comprising CO and H
2. The first product stream has a lower concentration of CO
2 and a higher concentration of CO than the first feed stream. The process of this
aspect of the disclosure also includes contacting at a second temperature and at a
second pressure a Fischer-Tropsch catalyst with a second feed stream comprising H
2 and at least a portion of CO of the first product stream to provide a second product
stream comprising C
5+ hydrocarbons, In the process 100 of FIG. 2, at least a portion of CO of the first
product stream 112 is included in second feed stream 121, which is contacted with
Fischer-Tropsch catalyst 123, here, in a second reaction zone (e.g., a reactor 120).
This provides a second product stream 122, which includes C
5+ hydrocarbons.
[0082] The present inventors have found that contacting the rWGS catalysts as described
herein with a first feed stream can provide a first product stream with advantageously
high CO selectivity and low methane selectivity. The amount of CO in the first product
stream can be further controlled by the rWGS reaction conditions, as described above.
However, as described above, the present inventors have determined that it can be
desirable to perform the processes at intermediate degrees of conversion to provide
desirably high CO selectivities and desirably low methane selectivities. Moreover,
the present inventors have noted that it can be advantageous to perform the downstream
Fischer-Tropsch process with a relatively high level of inerts, and thus contemplate
that passing a significant amount of CO
2 to the Fischer-Tropsch process step can be beneficial. Accordingly, in various embodiments
as otherwise described herein, the first product stream includes an amount of CO
2 together with the CO. In various embodiments, the first product stream comprises
in the range of 5-95 mol% CO
2, e.g., 5-90 mol%, or 5-85 mol%, or 5-80 mol%, or 5-75 mol%, or 5-70 mol%, or 10-95
mol%, or 10-90 mol%, or 10-85 mol%, or 10-80 mol%, or 10-75 mol%, or 10-70 mol%, or
20-95 mol%, or 20-90 mol%, or 20-85 mol%, or 20-80 mol%, or 20-75 mol%, or 20-70 mol%,
or 30-95 mol%, or 30-90 mol%, or 30-85 mol%, or 30-80 mol%, or 30-75 mol%, or 30-70
mol% CO
2.
[0083] Moreover, as described below, Fischer-Tropsch catalysts typically require activation
by a reducing gas. As would be understood by the person of skill in the art, different
Fischer-Tropsch catalysts required different activation conditions (e.g., gas composition,
temperature, pressure, time). For example, iron based Fischer-Tropsch catalysts require
activation with both H
2 and CO, while cobalt based Fischer-Tropsch catalysts require activation with just
H
2. As such, H
2 and CO or just H
2 from the first product stream can be used to perform this activation. Accordingly,
in various embodiments as otherwise described herein, the process includes separating
at least a portion of H
2 and CO (desirably in a ratio of at least 1:1 or at least 3:1) from the first product
stream and contacting it with the Fischer-Tropsch catalyst to activate the Fischer-Tropsch
catalyst. In various other embodiments as otherwise described herein, the process
includes separating at least a portion of H
2 from the first product stream and contacting it with the Fischer-Tropsch catalyst
to activate the Fischer-Tropsch catalyst. For example, in the process of FIG. 2, stream
125 separates H
2 or H
2 and CO and conducts it to reactor 120. This separation need not be continuous; rather,
it need only be performed for a time desirable to provide reducing gas to the Fischer-Tropsch
catalyst for activation. Of course, as would be understood by the person of skill
in the art, other sources of H
2 or CO may be used to provide reducing gas to the Fischer-Tropsch catalyst for activation.
[0084] As shown above, water is a product of the reverse water-gas shift reaction. Accordingly,
the first product stream will generally contain water. In many cases it can be desirable
to reduce the amount of water that is provided to the Fischer-Tropsch process step.
Accordingly, in various embodiments as otherwise described herein, the process further
includes removing at least a portion (e.g., at least 25%, at least 50%, or at least
75%) of water from the first product stream. In the embodiment of FIG. 2, a water
removal zone 116 is used to remove water and provide a water-containing stream 117.
The person of ordinary skill in the art will appreciate that a variety of processes
can be used to remove water from the first product stream. For example, the first
product stream can be contacted with a water scavenger to remove water therefrom.
For example, a molecular sieve guard bed can be used to remove water from the first
product stream; water can be recovered from the molecular sieves of the guard bed,
e.g., by heating and vacuum. In other embodiments, a knockout vessel can be used.
However, use of a knockout vessel can in some cases cool the first product stream
enough so that it is desirably reheated for introduction to the Fischer-Tropsch process
step. Water removed from the first product stream can be used, e.g., as feed water
for electrolysis processes described herein.
[0085] As noted above, the reverse water-gas shift process can be provided at a wide variety
of temperatures. In some cases, those temperatures can be relatively close to the
temperature of the subsequent Fischer-Tropsch process step (often 150-400 °C, e.g.,
200-350 °C, or other temperatures as described below). In other cases, the reverse
water-gas shift process can be performed at temperatures significantly higher than
the temperature of the Fischer-Tropsch step. The present inventors have noted that
it can be desirable to provide for heat exchange with a relatively hot first product
stream to cool the first product stream to a temperature more appropriate for the
Fischer Tropsch step and to provide heat elsewhere to the integrated process. For
example, in various embodiments of the processes as otherwise described herein, the
process further comprises exchanging heat between at least a portion of the first
product stream and at least a portion of the first feed stream, thereby cooling at
least a portion of the first product stream and heating at least a portion of the
first feed stream. An example of such a process is shown schematically in FIG. 3.
In FIG. 3, the process 200, first reactor 210, first feed stream 211, first product
stream 212, reverse water-gas shift catalyst 213, second reactor 220, second feed
stream 221, second product stream 222 and Fischer-Tropsch catalyst 223 are generally
as described above. Here, the process 200 includes exchanging heat between at least
a portion of the first product stream 212 and a least a portion of the first feed
stream 211 in a first heat exchange zone 230, thereby cooling at least a portion of
the first product stream 212 and heating at least a portion of the first feed stream
211. The person of ordinary skill in the art will appreciate that a wide variety of
heat exchangers can be used for this purpose.
[0086] Of course, any excess heat in the first product stream can be additionally or alternatively
used for other purposes. For example, in various embodiments the process further comprises
exchanging heat between at least a portion of the first product stream and a steam
generation zone, thereby cooling at least a portion of the first product stream and
providing heat to the steam generation zone. This is shown in FIG. 3. Here, after
heat exchange with the first feed stream 211, the first product stream 212 is conducted
to steam generation zone 232, to cool the first product stream 212 and provide heat
to the steam generation zone 232. Steam can be generated from the heat provided, and
electricity can be generated from the steam. For example, in the embodiment of FIG.
3, electricity stream 264 is provided by the generation of electricity using steam
generated in the steam generation zone 232. Of course, as would be understood to the
person of ordinary skill in the art, the steam generated in the steam generation zone
may be used in other processes. In various embodiments, the steam may be used to heat
the first feed stream. For example, in the embodiment of FIG. 3, the steam stream
266 generated in the steam generation zone 232 is conducted to the heat exchange zone
290 to heat the first feed stream 211.
[0087] As noted above, at least a portion of the CO of the first product stream is included
in the second feed stream, for reaction in a Fischer-Tropsch process. For example,
in various embodiments as otherwise described herein, at least 25% of the CO of the
first product stream, e.g., at least 50% of the CO, at least 75% of the CO, or at
least 90% of the CO of the first product stream is included in the second feed stream.
Of course, as noted above, some of the CO of the first product stream can be used
for other purposes, e.g., catalyst activation as described herein.
[0088] In some embodiments, substantially all of the CO of the second feed stream comes
from the first product stream. However, in other embodiments, CO can be provided to
the second feed stream from other sources, fossil-derived or otherwise. For example,
in various embodiments, CO is provided to the second feed stream from a CO source
other than the first product stream. In FIG. 3, a stream of CO 226a from some other
source is included in the second feed stream 221. The person of ordinary skill in
the art will appreciate that CO can be provided from a variety of sources, e.g., gasification,
reforming, or electrochemical CO
2 reduction. Moreover, as described in more detail below, CO can be recycled to the
second feed stream from the second product stream; and/or can be provided by reaction
of a light hydrocarbon stream, e.g., by partial oxidation or reforming (e.g., steam
reforming and/or autothermal reforming)..
[0089] As noted above, the second feed stream includes H
2. Notably, the first product stream will often include H
2, e.g., unreacted from the first feed stream. In various embodiments, the first product
stream includes H
2 wherein the second feed stream includes at least a portion of the H
2 of the first product stream. For example, in various embodiments as otherwise described
herein, at least 25% of the H
2 of the first product stream, e.g., at least 50% of the H
2, at least 75% of the H
2, or at least 90% of the H
2 of the first product stream is included in the second feed stream. Of course, as
noted above, some of the H
2 of the first product stream can be used for other purposes, e.g., catalyst activation
as described herein.
[0090] In some embodiments, substantially all of the H
2 of the second feed stream comes from the first product stream. In fact, the person
of ordinary skill in the art can provide more H
2 than necessary for the reverse water-gas shift reaction in the first feed stream,
to provide excess H
2 in the first product stream that can then provide a desired amount of H
2 to the second feed stream for the Fischer-Tropsch process step. However, in other
embodiments, H
2 can be provided to the second feed stream from other sources. For example, in various
embodiments, H
2 is provided to the second feed stream from a H
2 source other than the first product stream. In FIG. 3, a stream of H
2 226b from some other source is included in the second feed stream 221. The person
of ordinary skill in the art will appreciate that H
2 can be provided from a variety of sources, e.g., gasification, reforming, or H
2O electrolysis (including the electrolysis described herein). Moreover, as described
in more detail below, H
2 can be recycled to the second feed stream from the second product stream.
[0091] The person of ordinary skill in the art can, based on the disclosure herein, adjust
the relative amounts of H
2 and CO in the second feed stream to provide a desired ratio. For example, more or
less H
2 of the first feed stream and/or more or less H
2 from electrolysis can be included in the second feed stream. Similarly, more or less
CO of the first feed stream and more or less CO from other sources (e.g., partial
oxidation and reforming as described below) can be included in the second feed stream.
[0092] As noted above, it can be desirable to perform the Fischer-Tropsch process step in
the presence of a significant level of inerts. One such inert, CO
2, can come from the reverse water-gas shift, e.g., via the first product stream. Accordingly,
in various embodiments as otherwise described herein, the second feed stream includes
at least a portion of CO
2 of the first product stream. For example, in various embodiments, at least 10% of
the CO
2 of the first product stream, e.g., at least 25% of the CO
2, at least 50% of the CO
2, at least 75% of the CO
2, or at least 90% of the CO
2 of the first product stream is included in the second feed stream. Of course, in
other embodiments, the second feed stream may not include any substantial amount of
CO
2 of the first product stream. Accordingly, in various embodiments, the second feed
stream does not include a substantial amount of CO
2 of the first product stream. While it can be desirable generally to recycle CO
2 to the first feed stream for use in the reverse water-gas shift reaction, as described
in more detail below, unreacted CO
2 can be recycled from the second product stream to the first feed stream.
[0093] But it can additionally or alternatively be desirable to include additional inert
content to the second feed stream, be it CO
2 or other inerts such as nitrogen and methane. For example, in various embodiments,
one or more inerts (e.g., CO
2, nitrogen and/or methane) are provided to the second feed stream from a source other
than the first product stream. In FIG. 3, a stream of inert(s) 226c from some other
source is included in the second feed stream 221. The person of ordinary skill in
the art will appreciate that inerts can be provided from a variety of sources. Moreover,
as described in more detail below, inerts can be recycled to the second feed stream
from the second product stream.
[0094] As noted above, it can be desirable to perform the Fischer-Tropsch process step in
the presence of inerts. Accordingly, in various embodiments as otherwise described
herein, the portion of the first product stream that is included in the second feed
stream has a CO
2 content in the range of 10-95 mol% CO
2, e.g., 10-90 mol%, or 10-85 mol%, or 10-80 mol%, or 10-75 mol%, or 10-70 mol%, or
20-95 mol%, or 20-90 mol%, or 20-85 mol%, or 20-80 mol%, or 20-75 mol%, or 20-70 mol%,
or 30-95 mol%, or 30-90 mol%, or 30-85 mol%, or 30-80 mol%, or 30-75 mol%, or 30-70
mol% CO
2.
[0095] Other gases may also be included in the second feed stream, as described above. For
example, as noted above, it can be desirable to perform the Fischer-Tropsch process
step in the presence of a significant amount of inerts (i.e., components that are
not H
2 or CO). For example, in various embodiments, the second feed stream includes up to
80 mol% of one or more inerts, e.g., in the range of 3-80 mol%, or 5-80 mol%, or 10-80
mol%, or 15-80 mol%, or 30-80 mol% of one or more inerts. In various embodiments,
the second feed stream includes up to 70 mol% inerts, up to 60 mol% inerts, or up
to 50 mol% inerts, e.g., 3-70 mol%, or 5-70 mol%, or 10-70 mol%, or 15-70 mol%, or
30-70 mol%, or 3-60 mol%, or 5-60 mol%, or 10-60 mol%, or 15-60 mol%, or 30-60 mol%,
or 3-50 mol%, or 5-50 mol%, or 10-50 mol%, or 15-50 mol%, or 30-50 mol% inerts. In
various embodiments, the second feed stream includes up to 80% of one or more inerts
selected from CO
2, methane and nitrogen, e.g., up to 70 mol%, up to 60 mol%, or up to 50 mol%, or 15-70
mol%, or 30-70 mol%, or 15-60 mol%, or 30-60 mol%, or 15-50 mol%, or 30-50 mol%. In
various embodiments, the second feed stream includes up to 80 mol% of CO
2, e.g., up to 70 mol%, up to 60 mol%, or up to 50 mol%, or 15-70 mol%, or 30-70 mol%,
or 15-60 mol%, or 30-60 mol%, or 15-50 mol%, or 30-50 mol%.
[0096] The person of ordinary skill in the art can tune the portion of the first product
stream that is included in the second feed stream to provide a desirable H
2:CO ratio. For example in various embodiments, the portion of the first product stream
that is included in the second feed stream has a H
2:CO ratio in the range of 0.5:1 to 10:1, e.g., in the range of 1:1 to 2.5:1. Of course,
whatever the H
2:CO ratio of the portion of the first product stream that is included in the second
feed stream, the person of ordinary skill in the art can add H
2 or CO as described above as necessary to provide the desired ratio overall in the
second feed stream.
[0097] As described above, the second feed stream contains both H
2 and CO and the second feed stream includes all feeds to the Fischer Tropsch reactor,
regardless of whether the second feed stream is provided as a mixture of feeds or
as feeds provided individually to a reaction zone. In various embodiments of the present
disclosure as described herein, the second feed stream has a H
2:CO ratio in the range of 0.5:1 to 6:1. In some embodiments, the second feed stream
has a H
2:CO ratio in the range of 1:1 to 3:1, or 1:1 to 2.5:1. In some embodiments, the second
feed stream has a H
2:CO ratio of at least 1.4:1. For example, in some embodiments, the second feed stream
has a H
2:CO ratio in the range of 1.4:1 to 3:1, or 1.4:1 to 2:1. The person of ordinary skill
in the art will provide a desired ratio of H
2:CO in the second feed stream, based on the disclosure herein that provides a desirable
conversion and selectivity in the Fischer-Tropsch process.
[0098] As noted above it can be desirable to reduce the amount of water that is conducted
to the Fischer-Tropsch process step. Accordingly, in various embodiments as otherwise
described herein, the portion of the first product stream that is included in the
second feed stream has a water content of no more than 10 mol%, e.g., or no more than
2 mol%, or no more than 0.5 mol%.
[0099] And as noted above, it can be desirable to perform the Fischer-Tropsch process with
a relatively small amount of water present. Accordingly, in various embodiments, the
second feed stream has a water content of no more than 10 mol%, e.g., or no more than
2 mol%, or no more than 0.5 mol%.
[0100] The processes as described here include contacting a Fischer-Tropsch catalyst with
the second feed stream as described herein. The Fischer-Tropsch catalyst for use in
the processes as described herein is not particularly limited and the person of ordinary
skill in the art would be able to choose a catalyst as appropriate for their desired
Fischer-Tropsch product. In some embodiments, the Fischer-Tropsch catalyst includes
cobalt, iron, rhodium, ruthenium, or a combination thereof.
[0101] For example, in some embodiments of the present disclosure as described herein, the
Fischer-Tropsch catalyst comprises cobalt, e.g., in an amount in the range of 5-25
wt%, calculated as Co(0). "Calculated as Co(0)" and analogous terms mean that the
weight of cobalt atoms/ions themselves are used in the calculation, and not the total
amount of any compound or polynuclear ion in which those cobalt atoms/ions might be
bound. For example, in various embodiments, the Fischer-Tropsch catalyst comprises
cobalt in an amount in the range of 7-25 wt%, or 10-25 wt%, or 5-20 wt%, or 7-20 wt%,
or 10-20 wt%, calculated as Co(0). As the person of ordinary skill in the art will
appreciate, cobalt-based catalysts are often provided to the reaction zone in the
form of cobalt oxide on a support; the cobalt can be reductively activated (e.g.,
with H
2) in situ to provide an active catalyst species with a significant concentration of
Co(0).
[0102] In some embodiments, the Fischer-Tropsch catalyst comprises iron, e.g., in an amount
in the range of 5-95 wt%, calculated as Fe(0). For example, in various embodiments,
the Fischer-Tropsch catalyst comprises iron in the range of 10-95 wt%, or 25-95 wt%,
or 50-95 wt%, or 5-85 wt%, or 10-85 wt%, or 25-85 wt%, or 50-85 wt%, or 5-75 wt%,
or 10-75 wt%, or 25-75 wt%, calculated as Fe(0). As the person of ordinary skill in
the art will appreciate, iron-based catalysts are often provided to the reaction zone
in the form of metallic iron or iron oxide, optionally on a support; the iron can
be activated (e.g., by reaction with H
2 and CO) to provide an active catalyst species with a significant concentration of
iron carbide.
[0103] In various embodiments of the disclosure as described herein, especially when the
catalyst is a cobalt-based catalyst, the Fischer-Tropsch catalyst further includes
manganese. For example, in various embodiments, the Fischer-Tropsch catalyst includes
manganese in an amount up to 15 wt%, e.g., up to 12 wt%, or up to 10 wt%, or up to
7 wt%, calculated as Mn(0). In certain such embodiments, a catalyst material includes
manganese in an amount in the range of 0.1-15 wt%, e.g., 0.1-10 wt%, or 0.1-5 wt%,
0.5-15 wt%, or 0.5-10 wt%, or 0.5-5 wt%, or calculated as Mn(0). Of course, in other
embodiments substantially no manganese is present (e.g., less than 0.1 wt% or less
than 0.5 wt% manganese is present).
[0104] The Fischer-Tropsch catalysts suitable for use in the process as described herein
can be a variety of forms and are not particularly limited. For example, the Fischer-Tropsch
catalyst may be a supported or unsupported catalyst. While the form of the catalyst
is not particularly limited, in various desirable embodiments, the Fischer-Tropsch
catalyst is a supported catalyst, wherein the support comprises at least one of titanium
oxide, zirconium oxide, cerium oxide, aluminum oxide, silicon oxide and zinc oxide.
For example, in various embodiments, the support comprises at least one or titanium
oxide, aluminum oxide, and silicon oxide. In some embodiments of the present disclosure
as described herein, the support is a titanium dioxide support.
[0105] The person of ordinary skill in the art will appreciate that the Fischer-Tropsch
catalysts of the disclosure can be provided in many forms, depending especially on
the particular form of the reactor system in which they are to be used, e.g., in a
fixed bed or as a fluidized bed. The supports of the Fischer-Tropsch catalysts can
be provided themselves as discrete bodies of material, e.g., as porous particles,
pellets or shaped extrudates, with the metals provided thereon to provide the Fischer-Tropsch
catalyst. However, in other embodiments, a Fischer-Tropsch catalyst of the disclosure
can itself be formed as a layer on an underlying substrate. The underlying substrate
is not particularly limited. It can be formed of, e.g., a metal or metal oxide, and
can itself be provided in a number of forms, such as particles, pellets, shaped extrudates,
or monoliths. The person of ordinary skill in the art will select an appropriate Fischer-Tropsch
catalyst for the particular reactor system.
[0106] As with the rWGS catalyst, Fischer-Tropsch catalysts are typically activated before
use, e.g., to provide cobalt(0) species on a cobalt-based catalyst, or iron carbide
species on an iron-based catalyst. Such activation can be performed prior to contacting
the Fischer-Tropsch catalyst with a second feed stream.
[0107] For example, in some embodiments, the Fischer-Tropsch catalyst is activated by contact
with a reducing gas. For example, hydrogen can be an especially suitable gas for activating
Fischer-Tropsch catalyst, e.g., when the activation is a reduction to metal(0) species,
e.g., as for many cobalt-based catalysts. In various embodiments of the present disclosure
as otherwise described herein, the reducing gas comprises at least a portion of H
2 from the first product stream. For example, in some embodiments, the process further
comprises separating at least a portion of H
2 of the first product stream and contacting it with the Fischer-Tropsch catalyst to
activate Fischer-Tropsch catalyst. In the process 100 shown schematically in FIG.
2, at least a portion of hydrogen stream 125 is separated from the first product stream
112 and contacted with the Fischer-Tropsch catalyst 123 to activate it. In other embodiments,
H
2 present in the second feed stream can be used to activate the catalyst. As would
be understood by the person of ordinary skill in the art, activation temperatures
can vary depending on the Fischer-Tropsch catalyst used. As such, the person of ordinary
skill in the art would be able to select an appropriate temperature for activating
the catalyst, e.g., in the range of 200-400 °C.
[0108] In various embodiments, the Fischer-Tropsch catalyst is activated by contact with
H
2 and CO. This can be especially suitable when the activation provides conversion to
carbide, e.g., as for many iron-based catalysts. In various embodiments of the present
disclosure as otherwise described herein, the reducing gas comprises at least a portion
of H
2 and CO from the first product stream. For example, in some embodiments, the process
further comprises separating at least a portion of H
2 and at least a portion of CO of the first product stream and contacting it with the
Fischer-Tropsch catalyst to activate Fischer-Tropsch catalyst. In the process 200
shown schematically in FIG. 3, at least a portion of H
2 and CO stream 227 is separated from the first product stream 212 and contacted with
the Fischer-Tropsch catalyst 223 to activate it. In other embodiments, H
2 and CO present in the second feed stream can be used to activate the catalyst. Activation
temperatures can vary, e.g., in the range of 200-400 °C.
[0109] As described above, the process includes contacting at a second temperature and at
a second pressure a Fischer-Tropsch catalyst with a second feed stream. The person
of ordinary skill in the art will select appropriate reaction conditions in conjunction
with the particular feed and catalyst used to provide desired Fischer-Tropsch processes.
In some embodiments of the disclosure as described herein, the second temperature
is in the range of 150-400 °C. For example, in various embodiments, the second temperature
is in the range of 150-350 °C, or 150-300 °C, or 150-250°C, or 150-200°C, or 200-400
°C, or 200-350 °C, or 200-300°C, or 200-250 °C, or 250-400 °C, or 250-350 °C, or 250-300
°C, or 300-400 °C. In some particular embodiments, the second temperature is in the
range of 200-350 °C.
[0110] Notably, in many embodiments, the first temperature and the second temperature can
be relatively close to one another. The present inventors have noted that the reverse
water-gas shift catalysts described herein can provide suitable activity and CO selectivity
even at relatively low temperatures. Accordingly, the first product stream can be
provided with a temperature that is suitable for, or at least close to suitable for,
the Fischer-Tropsch reaction step. This can desirably provide for increased process
integration. For example, in various embodiments, the first temperature is within
100 °C of the second temperature, e.g., within 50 °C of the second temperature, or
within 25 °C of the second temperature.
[0111] However, in other embodiments, the first temperature and the second temperature are
less close to one another. The present inventors have noted that in many cases a desirable
reverse water-gas shift process temperature will be significantly greater than a desirable
Fischer-Tropsch process temperature. For example, in various embodiments, the first
temperature is at least 100 °C greater than the second temperature, e.g., at least
150 °C greater than the second temperature, or at least 200 °C greater than the second
temperature. The excess heat in the first product stream can be used for a number
of purposes, for example, to preheat at least part of the first feed stream or to
generate steam for use in generating electricity, as described above.
[0112] In some embodiments of the disclosure as described herein, the second pressure is
in the range of 10-50 barg. For example, in various embodiments, the second pressure
is in the range of 20-50 barg, or 25-50 barg, or 10-40 barg, or 20-40 barg, or 25-40
barg or 10-35 barg, or 20-35 barg, or 25-35 barg. In some embodiments, the second
pressure is in the range of 20-50 barg.
[0113] The Fischer-Tropsch processes described herein can be performed at a variety of GHSV
(gas hourly space velocity) values, as would be appreciated by the person of ordinary
skill in the art. As such, the GHSV for performing the Fischer-Tropsch reaction is
not particularly limited. For example, in some embodiments of the present disclosure,
the process for performing the Fischer-Tropsch reaction is conducted at a GHSV in
the range of 1,000 to 2,000,000 h
-1. In various embodiments, the process for performing the reverse water-gas shift reaction
is conducted at a GHSV in the range of 1,000 to 1,200,000 h
-1, or 1,000 to 500,000 h
-1, or 1,000 to 100,000 h
-1, or 5,000 to 1,200,000 h
-1, or 5,000 to 500,000 h
-1, or 5,000 to 100,000 h
-1, or 10,000 to 1,200,000 h
-1, or 10,000 to 500,000 h
-1, or 10,000 to 100,000 h
-1. In various embodiments of the present disclose, the process for performing the Fischer-Tropsch
reaction is conducted at a GHSV in the range of 1,000 to 50,000 h
-1, or 2,000 to 50,000 h
-1, or 5,000 to 50,000 h
-1, or 10,000 to 50,000, or 1,000 to 40,000 h
-1, or 2,000 to 40,000 h
-1, or 5,000 to 40,000 h
-1, or 10,000 to 40,000 h
-1, or 1,000 to 30,000 h
-1, or 2,000 to 30,000 h
-1, or 5,000 to 30,000 h
-1, or 10,000 to 30,000 h
-1.
[0114] The Fischer-Tropsch process is typically used to make C
5+ hydrocarbons, for example, unsubstituted C
5+ hydrocarbons (e.g., alkanes and alkenes) and oxygenated C
5+ hydrocarbons (e.g., C
5+ alcohols, aldehydes, ketones, carboxylic acids). In various embodiments of the disclosure
as described herein, contacting the Fischer-Tropsch catalyst with the second feed
stream to provide the second product stream is performed with a C
5+ selectivity (i.e., for all C
5+ species) of at least 30%, e.g., at least 50%, or at least 70%. For example, in some
embodiments, the selectivity for C
5+ alkanes is at least 30%, e.g., at least 50%, or at least 70%. In some embodiments,
the selectivity for C
5+ alkanes and C
5+ alcohols is at least 30%, e.g., at least 50%, or at least 70%.
[0115] Additional components may be in present in the second product stream. For example,
in some embodiments, the second product stream includes water, which is another product
of the Fischer-Tropsch reaction. Also present can be one or more light hydrocarbons
(i.e., C
1-C
4) as a side product. CO and/or H
2 can be present, e.g., unreacted from the second feed stream. CO
2 or other inerts as described herein can also be present. Such components of the second
product stream can be separated and/or recycled in various manners. When the second
product steam includes methane, such methane may be substantially from biogas provided
to the first feed stream (e.g., at least 50%, at least 75%, or at least 90%).
[0116] For example, in various embodiments, the process further comprises separating at
least a portion of water from the second product stream. This is shown schematically
in FIG. 4. In the embodiment of FIG. 4, the reverse water-gas shift catalyst 313 and
the Fischer-Tropsch catalyst 323 are provided in separate beds in the same reactor.
Thus, the first reaction zone 310 is a volume of the reactor 305 that includes the
bed 314 containing the reverse water-gas shift catalyst 313, and the second reaction
zone 320 is a volume of the reactor 305 that includes the bed 324 containing the Fischer-Tropsch
catalyst 323. First feed stream 311 is contacted with the reverse water-gas shift
catalyst 313 to provide first product stream 312, which is passed directly as the
second feed stream 321 to the Fischer-Tropsch catalyst 323 to provide second product
stream 322. Here, the process also optionally includes separating at least a portion
of water (e.g., at least 50%, at least 75%, or at least 90%) from the second product
stream 322 to provide water-containing stream 334.
[0117] Light hydrocarbons, while often not a desired portion of a Fischer-Tropsch product
to be used as a fuel or a lubricant, can themselves be useful for a number of purposes.
Accordingly, in various embodiments, the process further includes separating at least
a portion of C
1-C
4 hydrocarbons from the second product stream to provide a light hydrocarbon stream.
The light hydrocarbon stream can, for example, be recycled to the first feed stream
or the second feed stream. For example, in the process 200 of FIG. 3, light hydrocarbons
can be provided as part of the recycle stream 236, which becomes part of the second
feed stream 221. In the process 300 of FIG. 4, light hydrocarbons can be provided
as part of the recycle stream 336, which becomes part of the first feed stream 311.
In the process 400 of FIG. 5, light hydrocarbons are recycled via recycle stream 442
to first feed stream 411.
[0118] There are other uses for the light hydrocarbon stream. For example, in some embodiments,
the process further comprises oxidizing at least a portion of the light hydrocarbon
stream to provide a CO- and/or CO
2-containing partial oxidation (pOX) stream, and including at least a portion of the
pOX stream in the first feed stream and/or the second feed stream. In some embodiments
as described herein, the light hydrocarbon stream comprises methane from biogas. In
some embodiments herein, at least 50% of methane of the light hydrocarbon stream is
methane from biogas. An example of such a process is shown schematically in FIG. 5,
in which the process 400, the first feed stream 411, the first product stream 412,
the reverse water-gas shift catalyst 413, the second feed stream 421, the second product
stream 422 and the Fischer-Tropsch catalyst 423 can be as otherwise described herein.
Here, the process includes oxidizing at least a portion of the light hydrocarbon stream
450) in a partial oxidation reaction zone 452 to provide a CO- and/or CO
2 containing pOX stream, and including at least a portion of the pOX stream 454 stream
in the first feed stream 411 and/or the second feed stream 421.
[0119] As described above, at least part of the CO
2 of the first feed stream may be from biogas. In some embodiments as described herein,
the process includes providing a biogas comprising CO
2 and methane, and providing at least a portion of the CO
2 to the first feed stream, and at least a portion of the methane to the oxidation
of at least a portion of the light hydrocarbon stream as shown in the embodiment of
FIG. 6.
[0120] Other methods can be used to provide CO and/or CO
2 from the light hydrocarbon stream. For example, reforming techniques such as steam
reforming and autothermal reforming can be used to provide CO by reaction of hydrocarbons
with water. Accordingly, in various embodiments, the process further comprises reforming
(e.g., steam reforming and/or autothermal reforming) at least a portion of the light
hydrocarbon stream to provide a CO- and/or CO
2-containing reformed stream, and including at least a portion of the reformed stream
in the first feed stream and/or the second feed stream. Water separated from the first
and/or second product streams can be provided as part of a feed to the reforming described
herein.
[0121] Moreover, the light hydrocarbon stream can be burned to provide heat energy, which
can be used to heat various process streams, or to generate electricity. Accordingly,
in various embodiments, the process includes burning at least a portion of the light
hydrocarbon stream to provide energy, e.g., heat energy or electrical energy. For
example, in the process 400 of FIG. 5, a portion of light hydrocarbon stream 450 is
burned in a power generation zone (here, in an electrical generator 470), to generate
electricity stream 472. In various embodiments, the heat energy may be used to provide
the needed heat duty for the reverse water-gas shift process. For example, in the
process 400 of FIG. 5, a portion of the light hydrocarbon stream 450 is burned in
a power generation zone (here, in a heat generator 480), to generate heat stream 482.
The heat stream 482 is conducted to a heat exchange zone 490 to heat the first feed
stream 411. Heat energy can similarly be provided to the Fischer-Tropsch reaction.
And as the person of ordinary skill in the art will appreciate, other treatments of
the light hydrocarbon stream (e.g., partial oxidation) can also provide energy, which
can be used, e.g., as described herein.
[0122] As with the first product stream, heat can be exchanged from the second product stream
to provide heat to, for example, a feed stream or a steam generation zone. For example,
in various embodiments, the process further comprises exchanging heat between at least
a portion of the second product stream and at least a portion of the first feed stream,
thereby cooling at least a portion of the second product stream and heating at least
a portion of the first feed stream. In process 300 of FIG. 4, heat is exchanged between
at least a portion of the second product stream 322 and first feed stream 311 in a
second heat exchange zone 330, thereby cooling the second product stream 322 and heating
the first feed stream 311. Of course, heat can also be exchanged from the second product
stream to the second feed stream. For example, in various embodiments, the process
further comprises exchanging heat between at least a portion of the second product
stream and at least a portion of the second feed stream, thereby cooling at least
a portion of the second product stream and heating at least a portion of the second
feed stream. In process 400 of FIG. 5, heat is exchanged between at least a portion
of the second product stream 422 and second feed stream 421 in a second heat exchange
zone 430, thereby cooling the second product stream 422 and heating the second feed
stream 421. The person of ordinary skill in the art will appreciate that a wide variety
of heat exchangers can be used for this purpose.
[0123] Of course, any excess heat in the second product stream can be additionally or alternatively
used for other purposes. For example, in various embodiments the process further comprises
exchanging heat between at least a portion of the second product stream and a steam
generation zone, thereby cooling at least a portion of the second product stream and
providing heat to the steam generation zone. This is shown in FIG. 4. Here, after
heat exchange with the first feed stream 311, the second product stream 322 is conducted
to steam generation zone 332, to cool the second product stream 322 and provide heat
to the steam generation zone 332. Steam can be generated from the heat provided, and
electricity can be generated from the steam (not shown here).
[0124] It can be desirable to recycle hydrogen from the second product stream, for example,
to the first feed stream and/or the second feed stream. For example, in various embodiments,
the process includes recycling at least a portion of H
2 of the second product stream to the second feed stream. For example, in the process
of FIG. 3, at least a portion of H
2 of the second product stream (e.g., at least 25%, at least 50%, or at least 75%)
can be recycled to the second feed stream 221 via recycle stream 236. In various embodiments,
the process includes recycling at least a portion of H
2 of the second product stream to the first feed stream. For example, in the process
of FIG. 4, at least a portion of H
2 of the second product stream (e.g., at least 25%, at least 50%, or at least 75%)
can be recycled to the first feed stream 311 via recycle stream 336. In various embodiments,
at least 25%, e.g., at least 50% of H
2 of the second product stream is recycled to the first feed stream or the second feed
stream. In various embodiments, at least 75%, e.g., at least 90% of H
2 of the second product stream is recycled to the first feed stream or the second feed
stream.
[0125] In some cases, e.g., when H
2 is provided to the second feed stream from an H
2 source other than the first product stream, H
2 from the second product stream can make up most of the H
2 of the first feed stream, e.g., at least 90%, at least 95%, or at least 98% of the
H
2 of the first feed stream. This is shown, e.g., in FIG. 5. Here, the primary H
2 input to the process is through stream 440, which becomes part of the second feed
stream 421. H
2 of the second product stream is included in recycle stream 442, which becomes part
of first feed stream 411.
[0126] Similarly, it can be desirable to recycle CO of the second product stream, for example,
to the first feed stream and/or the second feed stream. For example, in various embodiments,
the process includes recycling at least a portion of CO of the second product stream
to the second feed stream. For example, in the process of FIG. 3, at least a portion
of CO of the second product stream (e.g., at least 25%, at least 50%, or at least
75%) can be recycled to the second feed stream 221 via recycle stream 236. In various
embodiments, the process includes recycling at least a portion of CO of the second
product stream to the first feed stream. For example, in the process of FIG. 4, at
least a portion of CO of the second product stream (e.g., at least 25%, at least 50%,
or at least 75%) can be recycled to the first feed stream 311 via recycle stream 336.
In various embodiments, at least 25%, e.g., at least 50% of CO of the second product
stream is recycled to the first feed stream or the second feed stream. In various
embodiments, at least 75%, e.g., at least 90% of CO of the second product stream is
recycled to the first feed stream or the second feed stream.
[0127] In many cases, both CO and H
2 of the second product stream will be recycled.
[0128] Moreover, when one or more inerts are used in the Fischer-Tropsch process step, it
can be desirable to recycle these. For example, in various embodiments, the process
includes recycling at least a portion of inerts of the second product stream to the
second feed stream. For example, in the process of FIG. 3, at least a portion of inerts
of the second product stream (e.g., at least 25%, at least 50%, or at least 75%) can
be recycled to the second feed stream 221 via recycle stream 236. In various embodiments,
the process includes recycling at least a portion of inerts of the second product
stream to the first feed stream. For example, in the process of FIG. 4, at least a
portion of inerts of the second product stream (e.g., at least 25%, at least 50%,
or at least 75%) can be recycled to the first feed stream 311 via recycle stream 336.
In various embodiments, at least 25%, e.g., at least 50% of inerts of the second product
stream is recycled to the first feed stream or the second feed stream. In various
embodiments, at least 75%, e.g., at least 90% of inerts of the second product stream
is recycled to the first feed stream or the second feed stream. In various embodiments,
a purge stream can be incorporated with the recycle stream to prevent uncontrolled
accumulation of inerts in the recycle stream (not shown here).
[0129] Specifically, as CO
2 is the carbon source for the reverse water-gas shift process step, it can be especially
desirable to recycle CO
2 to the first feed stream. Accordingly, in various embodiments, the process includes
recycling at least a portion (e.g., at least 50%, at least 75%, or at least 90%) of
CO
2 of the second product stream to the first feed stream. For example, in the process
of FIG. 4, at least a portion of CO
2 of the second product stream (e.g., at least 50%, at least 75%, or at least 90%)
can be recycled to the first feed stream 311 via recycle stream 336.
[0130] In some cases, e.g., when CO
2 is provided to the second feed stream from a CO
2 source other than the first product stream, CO
2 from the second product stream can make up most of the CO
2 of the first feed stream, e.g., at least 90%, at least 95%, or at least 98% of the
CO
2 of the first feed stream. This is shown, e.g., in FIG. 5. Here, the primary CO
2 input to the process is through stream 440, which becomes part of the second feed
stream 421. CO
2 of the second product stream is included in recycle stream 442, which becomes part
of first feed stream 411.
[0131] As noted above, the Fischer-Tropsch process step provides a second product stream
that includes C
5+ hydrocarbons (e.g., unsubstituted hydrocarbons like alkanes and alkenes, and/or oxygenated
hydrocarbons such as alcohols). Accordingly, in various embodiments, one or more products
are provided from at least a portion of C
5+ hydrocarbons of the second product stream. The C
5+ hydrocarbons can be used as the basis of a variety of fuels, e.g., gasoline, diesel,
aviation fuel. Other products, like waxes and lubricants, can also be made. And alkenes
and oxygenates can be used as feedstocks in a variety of other processes.
[0132] The person of ordinary skill in the art will use conventional post-processing techniques
to convert the C
5+ hydrocarbon-containing product to desirable products such as desirable fuels. For
example, in various embodiments, the process further includes hydroprocessing at least
a portion of C
5+ hydrocarbons of the second product stream. As the person of ordinary skill in the
art will appreciate, hydroprocessing is a treatment of the hydrocarbon stream with
hydrogen in the presence of a suitable catalyst. A wide variety of hydroprocessing
techniques are known, and the person of ordinary skill in the art will apply them
here. For example, in the process 300 of FIG. 4, second product stream 322 is hydroprocessed
in hydroprocessing reactor 350, to provide a hydroprocessed product stream 352.
[0133] As described above, CO
2 and H
2 are substantial inputs to the claimed processes. Advantageously, the present inventors
have recognized that each of these can come from renewable or otherwise environmentally
responsible sources. As described above, a least a part of the CO
2 of the first feed stream is from biogas, a CO
2 emission source, and/or direct air capture. A part of the CO
2 of the second feed stream may also be from biogas, a CO
2 emission source, and/or direct air capture.
[0134] Accordingly, in some embodiments of the disclosure as described herein, at least
a part of the CO
2 of the first feed stream and/or the second feed stream is from a renewable source.
In some embodiments, at least part (e.g., at least 25%, at least 50%, or at least
75%) of the CO
2 of the first feed stream and/or the second feed stream is from direct air capture.
In some embodiments, at least part (e.g., at least 25%, at least 50%, or at least
75%) of the CO
2 of the first feed stream and/or the second feed stream is from a manufacturing plant
such as a bioethanol plant (e.g., CO
2 produced fermentation), a steel plant, or a cement plant. Accordingly, the rWGS-Fischer
Tropsch integrated processes of the disclosure as described herein can be not only
carbon neutral, but in some cases a net consumer of carbon dioxide. These benefits
in particular make the integrated processes highly attractive for decarbonizing transportation
fuels, for both automotive and aviation sectors, since the carbon monoxide produced
in the rWGS reaction can be readily utilized by well-established technologies to synthesize
liquid hydrocarbon fuels by Fischer-Tropsch processes.
[0135] Similarly, H
2 can be provided from environmentally-responsible sources. In some embodiments, at
least a part of the H
2 of the first feed stream and/or the second feed stream is from a renewable source.
For example, in various embodiments, at least part (e.g., at least 25%, at least 50%,
or at least 75%) of the H
2 of the first feed stream and/or the second feed stream can be so-called "green" hydrogen,
e.g., produced from the electrolysis of water operated using renewable electricity
(such as wind, solar, or hydro-electric power). In some embodiments, at least part
(e.g., at least 25%, at least 50%, or at least 75%) of the H
2 of the first feed stream and/or the second feed stream may be from a so-called "blue"
source, e.g., from a natural gas reforming process with carbon capture. Of course,
other sources of H
2 can be used in part or in full. For example, in some embodiments, at least part (e.g.,
at least 25%, at least 50%, or at least 75%) of the H
2 of the first feed stream and/or the second feed stream is grey hydrogen, black hydrogen,
brown hydrogen, pink hydrogen, turquoise hydrogen, yellow hydrogen, and/or white hydrogen.
[0136] The present inventors have noted that electrolysis of water is a desirable way to
provide hydrogen to the claimed processes. Accordingly, in some embodiments, the process
includes providing at least a portion of H
2 to the first feed stream and/or the second feed stream by electrolysis of water.
In some embodiments, the electrolysis of water is performed using at least partially
electricity from a renewable source, e.g., to provide so-called "green hydrogen."
However, the present inventors have noted that electricity can be generated as part
of the claimed process, e.g., using heat exchange from the first or second product
stream, or by burning light hydrocarbons as described above. In some embodiments,
the electrolysis of water is performed using at least partially electricity generated
according to the processes as described herein. For example, in the process 200 of
FIG. 3, water 262 separated from the first product stream is electrolyzed in electrolyzer
260, using electricity 264 generated from steam made in the steam generation zone
232 by heat exchange from the first product stream. H
2 generated in the electrolysis is provided via stream 265 to the first feed stream.
In some embodiments, at least a portion of O
2 generated in the electrolysis is provided to a partial oxidation reaction zone as
described herein and as shown in the embodiment of FIG. 7. Hydrogen from electrolysis
can also burned to provide heat energy, e.g., which can be used to heat the first
feed stream.
[0137] The processes described herein can be operated in a wide variety of reactor systems.
In some embodiments, the first reaction zone (i.e., in which the reverse water-gas
shift process step is performed) comprises a first reactor in which a reverse water-gas
shift catalyst is disposed, and the second reaction zone (i.e., in which the Fischer-Tropsch
process step is performed) comprises a second reactor in which the Fischer-Tropsch
catalyst is disposed. Examples of such processes are shown schematically in FIGS.
1, 2, and 4. In these examples, the process (100, 200, 400) is performed in a reactor
system that includes a first reactor (110, 210, 410) in which a reverse water-gas
shift catalyst (113, 213, 413) is disposed, and a second reactor (120, 220, 420) in
which the Fischer-Tropsch catalyst (123, 223, 423) is disposed. The reactors used
for the integrated process of the present disclosure as described herein are not particularly
limited, and the person of ordinary skill in the art will be able to select an appropriate
reactor.
[0138] But other embodiments are possible. For example, in some embodiments, the process
is performed in a reactor system comprising first catalyst bed in which the reverse
water-gas shift catalyst is disposed, and wherein the second reaction zone comprises
a second catalyst bed in which the Fischer-Tropsch catalyst is disposed. In some embodiments,
the first reactor bed and the second reactor bed are disposed within the same reactor.
Such a configuration is shown in FIG. 4, in which the reverse water-gas shift catalyst
313 is disposed in a first catalyst bed 314, and the Fischer-Tropsch catalyst 323
is disposed in a second catalyst bed 324. Here, the catalyst beds 314 and 324 are
in the same reactor 305, with process gases flowing between them. Such a configuration
can be especially desirable when the first temperature and the second temperature
are relatively close to one another.
[0139] In various embodiments, the process is performed in a reactor system comprising one
or more first catalyst containers in which the reverse water-gas shift catalyst is
disposed, and wherein the second reaction zone comprises one or more second catalyst
containers in which the Fischer-Tropsch catalyst is disposed. These can be provided
in the same reactor, such as described above with respect to catalyst beds.
[0140] As noted above, the reverse water-gas shift process step using the palladium and
platinum catalysts described herein and the Fischer-Tropsch process step can be performed
under similar conditions. Accordingly, in various embodiments, the reverse water-gas
shift catalyst and the Fischer-Tropsch catalyst can be provided together in the same
catalyst bed, e.g., mixed together. Such an embodiment is shown in FIG. 6. Here, the
process 500 is performed in a reactor system that includes a reactor 505 in which
the reverse water-gas shift catalyst 513 and the Fischer-Tropsch catalyst 523 are
mixed together in a single catalyst bed 524. Here, first feed stream 511 and second
product stream 522 can be substantially as described herein. The first product stream
and the second feed stream are understood to be the mixture of process gases within
the mixed catalysts.
[0141] In the embodiments particularly-described above, separate rWGS and Fischer-Tropsch
catalysts are used, e.g., in separate reactors, in separate regions of the same reactor,
or even comingled in the same region of a reactor.
[0142] However, the present inventors also note that there are certain commonalities between
the rWGS catalysts described herein and certain Fischer-Tropsch catalysts. For example,
as the person of ordinary skill in the art would appreciate, manganese is a common
modifier used in Fischer-Tropsch catalysts, especially those based on cobalt. The
present inventors also note that similar supports can be used for each.
[0143] Accordingly, in addition to the configurations described above, the present inventors
contemplate the provision of a single bifunctional catalyst with both reverse water-gas
shift activity and Fischer-Tropsch activity. Such a bifunctional catalyst includes
both rWGS-active catalyst metal and the Fischer-Tropsch active catalyst metal in the
same body. The person or ordinary skill in the art will appreciate that both the rWGS
catalysts and the Fischer-Tropsch catalysts are supported catalyst, e.g., metal oxide
supported catalyst. As such, in various embodiments of the present disclosure, the
rWGS-active catalyst metals and Fischer-Tropsch active catalyst metals can be provided
together on the same support to provide a bifunctional catalyst. For example, in some
embodiments, the supports of bifunctional catalyst are provided themselves as discrete
body of material, e.g., as porous particles, pellets, or shaped extrudates, with the
rWGS-active catalyst metals and the FT-active catalyst metals provided thereon to
provide a bifunctional catalyst. The rWGS-active catalyst metals and the FT-active
catalyst metals may be homogenous distributed throughout the support or may be distributed
in discrete areas throughout the support. However, in other embodiments, the bifunctional
catalyst of the disclosure can itself be formed as a layer on an underlying substrate.
For example, in some embodiments, the bifunctional catalyst is formed from a layer
of rWGS-active catalyst metals and a layer of FT-active catalyst metals on an underlying
substrate. The rWGS-active catalyst metals and the FT-active catalyst metals may be
homogeneously distributed on the underlying substrate. In other embodiments, the rWGS-active
catalyst metals and the FT-active catalyst metals may be in discrete areas on the
underlying substrate. The underlying substrate is not particularly limited. It can
be formed of, e.g., a metal or metal oxide, and can itself be provided in a number
of forms, such as particles, pellets, shaped extrudates, or monoliths.
[0144] The bifunctional catalyst includes a support material, the rWGS-active catalyst metals
as described herein, and the Fischer-Tropsch active catalyst metals as described herein.
For example, the bifunctional catalyst includes a support that is a metal oxide support
as described herein, at least one of platinum, palladium, gold, and metal as described
herein, and at least one of cobalt, iron, rhodium, and ruthenium. In some embodiments
of present disclosure, the bifunctional catalyst includes a support that is a metal
oxide support as described herein, at least one of platinum, palladium, gold, metal
as described herein, and cobalt. In some embodiments of the present disclosure, the
bifunctional catalyst includes a support comprising at least one of titanium oxide,
zirconium oxide, cerium oxide, or aluminum oxide, at least one of platinum, palladium,
gold, and nickel, metals as described herein, and cobalt. In some embodiments, the
bifunctional catalyst includes a titanium oxide support, at least one of platinum,
palladium, gold, and nickel, metal as described herein, and cobalt. In some embodiments,
the bifunctional catalyst includes a titanium oxide support, platinum, metal as described
herein, and cobalt. In some embodiments, the bifunctional catalyst includes a titanium
oxide support, palladium, metals as described herein, and cobalt. In some embodiments,
the bifunctional catalyst includes a titanium oxide support, gold, metals as described
herein, and cobalt. For example, in some embodiments, the bifunctional catalyst includes
a titanium oxide support, at least one of platinum, palladium, gold, and nickel, present
in an amount in the range of 0.05 to 10 wt%, metal as described herein, present in
an amount in the range of 0.5 to 20 wt%, and cobalt, present in an amount in the range
of 7-25 wt%. In some embodiments, the bifunctional catalyst includes a titanium oxide
support, platinum, present in an amount in the range of 0.05 to 10 wt%, metal as described
herein, present in an amount in the range of 0.5 to 20 wt%, and cobalt, present in
an amount in the range of 7-25 wt%. In some embodiments, the bifunctional catalyst
includes a titanium oxide support, palladium, present in an amount in the range of
0.05 to 10 wt%, metal as described herein, present in an amount in the range of 0.5
to 20 wt%, and cobalt, present in an amount in the range of 7-25 wt%. In some embodiments,
the bifunctional catalyst includes a titanium oxide support, gold, present in an amount
in the range of 0.05 to 10 wt%, metal as described herein, present in an amount in
the range of 0.5 to 20 wt%, and cobalt, present in an amount in the range of 7-25
wt%.
[0145] The ratio of rWGS-active catalyst metals to FT-active catalyst metals in the bifunctional
catalyst is not particularly limited and the person of ordinary skill in the art would
be able to select an appropriate ratio. For example, in some embodiments, the ratio
of rWGS-active catalyst metals to FT-active catalyst metals in the bifunctional catalyst
is at least 0.1:1. In various embodiments, the ratio of rWGS-active catalyst metals
to FT-active catalyst metals in the bifunctional catalyst is at least 0.2:1, or 0.5,
or 1:1.
[0146] Such catalysts can be used in embodiments like those described with respect to FIG.
6. The person of ordinary skill in the art will select reaction conditions that provide
the appropriate balance of reverse water-gas shift activity and Fischer-Tropsch activity.
[0147] FIG. 7 is a schematic depiction of another integrated process according to the disclosure.
Here, the reverse water-gas shift and Fischer-Tropsch process steps are integrated
together with partial oxidation of light hydrocarbons to provide CO and H
2 to the Fischer-Tropsch process step; electrolysis to provide H
2 for the reverse water-gas shift process step and O
2 for the partial oxidation; and various recycles and optional feeds, as described
throughout the present specification.
[0148] Additional aspects of the disclosure are provided by the following enumerated embodiments,
which may be combined in any number and in any combination that is not logically or
technically inconsistent.
Embodiment 1. A supported reverse water-gas shift catalyst comprising:
a support that is a cerium oxide support, a titanium oxide support, an aluminum oxide
support, zinc oxide support, a zirconium oxide support, or a mixed oxide support comprising
a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide
and zirconium oxide;
a metal selected from at least one of manganese, copper, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium, present in an amount in the range of 0.5
to 20 wt% of the catalyst, based on the total weight of the catalyst; and
optionally, at least one of platinum, palladium, gold, and nickel, present in an amount
in the range of 0.05 to 10 wt% of the catalyst, based on the total weight of the catalyst.
Embodiment 2. The catalyst of embodiment 1, wherein the support makes up at least
70 wt% (e.g., at least 75 wt%, or 80 wt%, or 85 wt%, or 90 wt%) of the catalyst, on
an oxide basis.
Embodiment 3. The catalyst of embodiment 1 or embodiment 2, wherein the support is
a cerium oxide support.
Embodiment 4. The catalyst of embodiment 3, wherein at least a surface layer of the
cerium oxide support comprises at least 60 wt% cerium oxide, e.g., at least 70 wt%
cerium oxide or at least 80 wt% cerium oxide, on an oxide basis.
Embodiment 5. The catalyst of embodiment 3, wherein at least a surface layer of the
cerium oxide support comprises at least 90 wt% cerium oxide, e.g., at least 95 wt%
cerium oxide, or at least 98 wt% cerium oxide, on an oxide basis.
Embodiment 6. The catalyst of any of embodiments 3-5, wherein the cerium oxide support
comprises at least 50 wt% cerium oxide, e.g., at least 60 wt% cerium oxide, or at
least 70 wt% cerium oxide, or at least 80 wt% cerium oxide, on an oxide basis.
Embodiment 7. The catalyst of any of embodiments 3-5, wherein the cerium oxide support
comprises at least 90 wt% cerium oxide, e.g., at least 95 wt% cerium oxide, or at
least 98 wt% cerium oxide, on an oxide basis.
Embodiment 8. The catalyst of embodiment 1 or embodiment 2, wherein the support is
a titanium oxide support.
Embodiment 9. The catalyst of embodiment 8, wherein at least a surface layer of the
titanium oxide support comprises at least 60 wt% titanium oxide, e.g., at least 70
wt% titanium oxide, or at least 80 wt% titanium oxide, on an oxide basis.
Embodiment 10. The catalyst of embodiment 8, wherein at least a surface layer of the
titanium oxide support comprises at least 90 wt% titanium oxide, e.g., at least 95
wt% titanium oxide, or at least 98 wt% titanium oxide, on an oxide basis.
Embodiment 11. The catalyst of any of embodiments 8-10, wherein the titanium oxide
support comprises at least 50 wt% titanium oxide, e.g., at least 60 wt% titanium oxide,
or at least 70 wt% titanium oxide, or at least 80 wt% titanium oxide, on an oxide
basis.
Embodiment 12. The catalyst of any of embodiments 8-10, wherein the titanium oxide
support comprises at least 90 wt% titanium oxide, e.g., at least 95 wt% titanium oxide,
or at least 98 wt% titanium oxide, on an oxide basis.
Embodiment 14. The catalyst of embodiment 1 or embodiment 2, wherein the support is
an aluminum oxide support.
Embodiment 15. The catalyst of embodiment 14, wherein at least a surface layer of
the aluminum oxide support comprises at least 60 wt% aluminum oxide, e.g., at least
70 wt% aluminum oxide or at least 80 wt% aluminum oxide, on an oxide basis.
Embodiment 16. The catalyst of embodiment 14, wherein at least a surface layer of
the aluminum oxide support comprises at least 90 wt% aluminum oxide, e.g., at least
95 wt% aluminum oxide, or at least 98 wt% aluminum oxide, on an oxide basis.
Embodiment 17. The catalyst of any of embodiments 14-16, wherein the aluminum oxide
support comprises at least 50 wt% aluminum oxide, e.g., at least 60 wt% aluminum oxide,
or at least 70 wt% aluminum oxide, or at least 80 wt% aluminum oxide, on an oxide
basis.
Embodiment 18. The catalyst of any of embodiments 14-16, wherein the aluminum oxide
support comprises at least 90 wt% aluminum oxide, e.g., at least 95 wt% aluminum oxide,
or at least 98 wt% aluminum oxide, on an oxide basis.
Embodiment 19. The catalyst of embodiment 1 or embodiment 2, wherein the support is
a zinc oxide support.
Embodiment 20. The catalyst of embodiment 19, wherein at least a surface layer of
the zinc oxide support comprises at least 60 wt% zinc oxide, e.g., at least 70 wt%
zirconium oxide or at least 80 wt% zinc oxide, on an oxide basis.
Embodiment 21. The catalyst of embodiment 19, wherein at least a surface layer of
the zinc oxide support comprises at least 90 wt% zinc oxide, e.g., at least 95 wt%
zinc oxide, or at least 98 wt% zinc oxide, on an oxide basis.
Embodiment 22. The catalyst of any of embodiments 19-21, wherein the zinc oxide support
comprises at least 50 wt% zinc oxide, e.g., at least 60 wt% zinc oxide, or at least
70 wt% zinc oxide, or at least 80 wt% zinc oxide, on an oxide basis.
Embodiment 23. The catalyst of any of embodiments 19-22, wherein the zinc oxide support
comprises at least 90 wt% zinc oxide, e.g., at least 95 wt% zinc oxide, or at least
98 wt% zinc oxide, on an oxide basis.
Embodiment 24. The catalyst of embodiment 1 or embodiment 2, wherein the support is
a zirconium oxide support.
Embodiment 25. The catalyst of embodiment 24, wherein at least a surface layer of
the zirconium oxide support comprises at least 60 wt% zirconium oxide, e.g., at least
70 wt% zirconium oxide or at least 80 wt% zirconium oxide, on an oxide basis.
Embodiment 26. The catalyst of embodiment 24, wherein at least a surface layer of
the zirconium oxide support comprises at least 90 wt% zirconium oxide, e.g., at least
95 wt% zirconium oxide, or at least 98 wt% zirconium oxide, on an oxide basis.
Embodiment 27. The catalyst of any of embodiments 24-26, wherein the zirconium oxide
support comprises at least 50 wt% zirconium oxide, e.g., at least 60 wt% zirconium
oxide, or at least 70 wt% zirconium oxide, or at least 80 wt% zirconium oxide, on
an oxide basis.
Embodiment 28. The catalyst of any of embodiments 24-27, wherein the zirconium oxide
support comprises at least 90 wt% zirconium oxide, e.g., at least 95 wt% zirconium
oxide, or at least 98 wt% zirconium oxide, on an oxide basis.
Embodiment 29. The catalyst of embodiment 1 or embodiment 2, wherein the support is
a mixed oxide support having at least a surface layer comprising at least 50 wt% of
two or more of cerium oxide, titanium oxide, aluminum oxide, zinc oxide, and zirconium
oxide, on an oxide basis.
Embodiment 30. The catalyst of any of embodiments 1-29, wherein the support does not
include additional metals in a total amount of additional metals in excess of 2 wt%,
e.g., in excess of 1 wt% or in excess of 0.5 wt%, on an oxide basis.
Embodiment 31. The catalyst of any of embodiments 1-29, wherein the support includes
at least one additional metal.
Embodiment 32. The catalyst of embodiment 31, wherein the total amount of the at least
one additional metal is in the range of 0.5-20 wt%, e.g., 1-20 wt%, or 2-20 wt%, or
0.5-15 wt%, or 1-15 wt%, or 2-15 wt%, or 0.5-10 wt%, or 1-10 wt%, or 2-10 wt%, or
0.5-5 wt%, or 1-5 wt%, on an oxide basis.
Embodiment 33. The catalyst of any of embodiments 1-32, wherein the support has a
pore volume of at least 0.05 mL/g.
Embodiment 34. The catalyst of any of embodiments 1-33, wherein the support has a
pore volume of at most 1.5 mL/g.
Embodiment 35. The catalyst of any of embodiments 1-34, wherein the support has a
pore volume in the range of 0.05-1.5 mL/g.
Embodiment 36. The catalyst of any of embodiments 1-35, wherein the metal is manganese.
Embodiment 37. The catalyst of embodiment 36, wherein manganese is present in the
catalyst in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to
12 wt% or 0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 38. The catalyst of embodiment 36, wherein manganese is present in the
catalyst in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%,
or 1 to 12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 39. The catalyst of embodiment 36, wherein manganese is present in the
catalyst in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%,
or 2 to 12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 40. The catalyst of embodiment 36, wherein manganese is present in the
catalyst in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%,
or 4 to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 41. The catalyst of any of embodiments 1-35, wherein the metal is copper.
Embodiment 42. The catalyst of embodiment 41, wherein copper is present in the catalyst
in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to 12 wt% or
0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 43. The catalyst of embodiment 41, wherein copper is present in the catalyst
in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%, or 1 to
12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 44. The catalyst of embodiment 41, wherein copper is present in the catalyst
in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%, or 2 to
12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 45. The catalyst of embodiment 41, wherein copper is present in the catalyst
in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4
to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 46. The catalyst of any of embodiments 1-35, wherein the metal is gallium.
Embodiment 47. The catalyst of embodiment 46, wherein gallium is present in the catalyst
in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to 12 wt% or
0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 48. The catalyst of embodiment 46, wherein gallium is present in the catalyst
in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%, or 1 to
12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 49. The catalyst of embodiment 46, wherein gallium is present in the catalyst
in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%, or 2 to
12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 50. The catalyst of embodiment 46, wherein gallium is present in the catalyst
in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4
to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 51. The catalyst of any of embodiments 1-35, wherein the is indium.
Embodiment 52. The catalyst of embodiment 51, wherein indium is present in the catalyst
in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to 12 wt% or
0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 53. The catalyst of embodiment 51, wherein indium is present in the catalyst
in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%, or 1 to
12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 54. The catalyst of embodiment 51, wherein indium is present in the catalyst
in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%, or 2 to
12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 55. The catalyst of embodiment 51, wherein indium is present in the catalyst
in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4
to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 56. The catalyst of any of embodiments 1-35, wherein the metal is lanthanum.
Embodiment 57. The catalyst of embodiment 56, wherein lanthanum is present in the
catalyst in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to
12 wt% or 0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 58. The catalyst of embodiment 56, wherein lanthanum is present in the
catalyst in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%,
or 1 to 12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 59. The catalyst of embodiment 56, wherein lanthanum is present in the
catalyst in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%,
or 2 to 12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 60. The catalyst of embodiment 56, wherein lanthanum is present in the
catalyst in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%,
or 4 to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 61. The catalyst of any of embodiments 1-35, wherein the metal is titanium.
Embodiment 62. The catalyst of embodiment 61, wherein titanium is present in the catalyst
in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to 12 wt% or
0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 63. The catalyst of embodiment 61, wherein titanium is present in the catalyst
in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to 15 wt%, or 1
to 12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 64. The catalyst of embodiment 61, wherein titanium is present in the catalyst
in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to 15 wt%, or 2
to 12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 65. The catalyst of embodiment 61, wherein titanium is present in the catalyst
in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4
to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 66. The catalyst of any of embodiments 1-35, wherein the metal is niobium.
Embodiment 67. The catalyst of embodiment 66, wherein niobium is present in the catalyst
in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to 12 wt% or
0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 68. The catalyst of embodiment 66, wherein niobium is present in the catalyst
in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%, or 1 to
12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 69. The catalyst of embodiment 66, wherein niobium is present in the catalyst
in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%, or 2 to
12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 70. The catalyst of embodiment 66, wherein niobium is present in the catalyst
in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4
to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 71. The catalyst of any of embodiments 1-35, wherein the metal is vanadium.
Embodiment 72. The catalyst of embodiment 71, wherein vanadium is present in the catalyst
in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to 12 wt% or
0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 73. The catalyst of embodiment 71, wherein vanadium is present in the catalyst
in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%, or 1 to
12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 74. The catalyst of embodiment 71, wherein vanadium is present in the catalyst
in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%, or 2 to
12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 75. The catalyst of embodiment 71, wherein vanadium is present in the catalyst
in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%, or 4
to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 76. The catalyst of any of embodiments 1-35, wherein the metal is zirconium.
Embodiment 77. The catalyst of embodiment 76, wherein zirconium is present in the
catalyst in an amount in the range of 0.5 to 15 wt%, e.g., in the range of 0.5 to
12 wt% or 0.5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 78. The catalyst of embodiment 76, wherein zirconium is present in the
catalyst in an amount in the range of 1 to 20 wt%, e.g., in the range of 1 to15 wt%,
or 1 to 12 wt%, or 1 to 10 wt%, based on the total weight of the catalyst.
Embodiment 79. The catalyst of embodiment 76, wherein zirconium is present in the
catalyst in an amount in the range of 2 to 20 wt%, e.g., in the range of 2 to15 wt%,
or 2 to 12 wt%, or 2 to 10 wt%, based on the total weight of the catalyst.
Embodiment 80. The catalyst of embodiment 76, wherein zirconium is present in the
catalyst in an amount in the range of 4 to 20 wt%, e.g., in the range of 4 to 15 wt%,
or 4 to 12 wt%, or 4 to 10 wt%, based on the total weight of the catalyst.
Embodiment 81. The catalyst of any of embodiments 1-80, wherein the total amount of
cerium, titanium, aluminum, zirconium, metal (e.g., manganese, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium), in the catalyst is at least 90 wt%, e.g.,
at least 95 wt% or at least 98 wt% of the catalyst, on a metallic basis.
Embodiment 82. The catalyst of any of embodiments 1-81, wherein platinum, palladium,
gold, or nickel is present in the catalyst.
Embodiment 83. A supported reverse water-gas shift catalyst comprising:
a support that is a cerium oxide support, a titanium oxide support, a zirconium oxide
support, or a mixed oxide support comprising a mixture of two or more of cerium oxide,
titanium oxide, aluminum oxide, zinc oxide, and zirconium oxide;
a metal selected from at least one of manganese, copper, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium, present in an amount in the range of 0.5
to 20 wt% of the catalyst, based on the total weight of the catalyst; and
at least one of platinum, palladium, gold, and nickel present in an amount in the
range of 0.05 to 10 wt% of the catalyst, based on the total weight of the catalyst.
Embodiment 84. The catalyst of embodiment 83, wherein the support is as described
in any of embodiments 2-35.
Embodiment 85. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
manganese and is present in the amounts as described in embodiments 36-40.
Embodiment 86. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
copper and is present in the amounts as described in embodiments 41-45.
Embodiment 87. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
gallium and is present in the amounts as described in embodiments 46-50.
Embodiment 88. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
indium and is present in the amounts as described in embodiments 51-55.
Embodiment 89. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
lanthanum and is present in the amounts as described in embodiments 56-60. Embodiment
90. The catalyst of embodiment 83 or embodiment 84, wherein the metal is titanium
and is present in the amounts as described in embodiments 61-65.
Embodiment 91. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
niobium and is present in the amounts as described in embodiments 66-70.
Embodiment 92. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
vanadium and is present in the amounts as described in embodiments 71-75.
Embodiment 93. The catalyst of embodiment 83 or embodiment 84, wherein the metal is
zirconium and is present in the amounts as described in embodiments 76-80.
Embodiment 94. The catalyst of any of embodiments 83-93, wherein platinum is present
in the catalyst.
Embodiment 95. The catalyst of embodiment 94, wherein platinum is present in the catalyst
in an amount in the range of 0.1 to 10 wt%, e.g., in the range of 0.5 to 10 wt%, or
1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 96. The catalyst of embodiment 94, wherein platinum is present in the catalyst
in an amount in the range of 0.05 to 7 wt%, e.g., in the range of 0.1 to 7 wt%, or
0.5 to 7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total weight of the catalyst.
Embodiment 97. The catalyst of embodiment 94, wherein platinum is present in the catalyst
in an amount in the range of 0.05 to 5 wt%, e.g., in the range of 0.1 to 5 wt%, or
0.5 to 5 wt%, or 1 to 5 wt%, or 2 to 5 wt%, based on the total weight of the catalyst.
Embodiment 98. The catalyst of embodiment 94, wherein platinum is present in the catalyst
in an amount in a range of 0.05 to 2 wt%, e.g., in the range of 0.1 to 2 wt%, or 0.3
to 2 wt%, or 0.5 to 2 wt%, or 1 to 2 wt%, based on the total weight of the catalyst.
Embodiment 99. The catalyst of embodiment 94, wherein platinum is present in the catalyst
in an amount in a range of 0.05 to 1.5 wt%, e.g., in the range of 0.1 to 1.5 wt%,
or 0.3 to 1.5 wt%, or 0.5 to 1.5 wt%, based on the total weight of the catalyst.
Embodiment 100. The catalyst of embodiment 94, wherein platinum is present in the
catalyst in an amount in the range of 0.05 to 1 wt%, e.g., in the range of 0.1 to
1 wt%, or 0.3 to 1 wt%, or 0.5 to 1 wt%, based on the total weight of the catalyst.
Embodiment 101. The catalyst of embodiment 94, wherein platinum is present in the
catalyst in an amount in the range of 0.05 to 0.8 wt%, e.g., in the range of 0.1 to
0.8 wt%, or 0.3 to 0.8 wt%, or 0.5 to 0.8 wt%, based on the total weight of the catalyst.
Embodiment 102. The catalyst of any of embodiments 83-93, wherein palladium is present
in the catalyst.
Embodiment 103. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in the range of 0.1 to 10 wt%, e.g., in the range of 0.5 to
10 wt%, or 1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight
of the catalyst.
Embodiment 104. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in the range of 0.05 to 7 wt%, e.g., in the range of 0.1 to
7 wt%, or 0.5 to 7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total weight of
the catalyst.
Embodiment 105. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in the range of 0.05 to 5 wt%, e.g., in the range of 0.1 to
5 wt%, or 0.5 to 5 wt%, or 1 to 5 wt%, or 2 to 5 wt%, based on the total weight of
the catalyst.
Embodiment 106. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in a range of 0.05 to 2 wt%, e.g., in the range of 0.1 to 2
wt%, or 0.3 to 2 wt%, or 0.5 to 2 wt%, based on the total weight of the catalyst.
Embodiment 107. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in a range of 0.05 to 1.5 wt%, e.g., in the range of 0.1 to
1.5 wt%, or 0.3 to 1.5 wt%, or 0.5 to 1.5 wt%, based on the total weight of the catalyst.
Embodiment 108. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in the range of 0.05 to 1 wt%, e.g., in the range of 0.1 to
1 wt%, or 0.3 to 1 wt%, or 0.5 to 1 wt%, based on the total weight of the catalyst.
Embodiment 109. The catalyst of embodiment 102, wherein palladium is present in the
catalyst in an amount in the range of 0.05 to 0.8 wt%, e.g., in the range of 0.1 to
0.8 wt%, or 0.3 to 0.8 wt%, or 0.5 to 0.8 wt%, based on the total weight of the catalyst.
Embodiment 110. The catalyst of any of embodiments 82-93, wherein gold is present
in the catalyst.
Embodiment 111. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in the range of 0.1 to 10 wt%, e.g., in the range of 0.5 to 10 wt%, or
1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 112. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in the range of 0.05 to 7 wt%, e.g., in the range of 0.1 to 7 wt%, or
0.5 to 7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total weight of the catalyst.
Embodiment 113. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in the range of 0.05 to 5 wt%, e.g., in the range of 0.1 to 5 wt%, or
0.5 to 5 wt%, or 1 to 5 wt%, or 2 to 5 wt%, based on the total weight of the catalyst.
Embodiment 114. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in a range of 0.05 to 2 wt%, e.g., in the range of 0.1 to 2 wt%, or 0.3
to 2 wt%, or 0.5 to 2 wt%, based on the total weight of the catalyst.
Embodiment 115. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in a range of 0.05 to 1.5 wt%, e.g., in the range of 0.1 to 1.5 wt%,
or 0.3 to 1.5 wt%, or 0.5 to 1.5 wt%, based on the total weight of the catalyst.
Embodiment 116. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in the range of 0.05 to 1 wt%, e.g., in the range of 0.1 to 1 wt%, or
0.3 to 1 wt%, or 0.5 to 1 wt%, based on the total weight of the catalyst.
Embodiment 117. The catalyst of embodiment 110, wherein gold is present in the catalyst
in an amount in the range of 0.05 to 0.8 wt%, e.g., in the range of 0.1 to 0.8 wt%,
or 0.3 to 0.8 wt%, or 0.5 to 0.8 wt%, based on the total weight of the catalyst.
Embodiment 118. The catalyst of any of embodiments 82-93, wherein nickel is present
in the catalyst.
Embodiment 119. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in the range of 0.1 to 10 wt%, e.g., in the range of 0.5 to 10 wt%, or
1 to 10 wt%, or 2 to 10 wt%, or 5 to 10 wt%, based on the total weight of the catalyst.
Embodiment 120. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in the range of 0.05 to 7 wt%, e.g., in the range of 0.1 to 7 wt%, or
0.5 to 7 wt%, or 1 to 7 wt%, or 2 to 7 wt%, based on the total weight of the catalyst.
Embodiment 121. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in the range of 0.05 to 5 wt%, e.g., in the range of 0.1 to 5 wt%, or
0.5 to 5 wt%, or 1 to 5 wt%, or 2 to 5 wt%, based on the total weight of the catalyst.
Embodiment 122. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in a range of 0.05 to 2 wt%, e.g., in the range of 0.1 to 2 wt%, or 0.3
to 2 wt%, or 0.5 to 2 wt%, based on the total weight of the catalyst.
Embodiment 123. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in a range of 0.05 to 1.5 wt%, e.g., in the range of 0.1 to 1.5 wt%,
or 0.3 to 1.5 wt%, or 0.5 to 1.5 wt%, based on the total weight of the catalyst.
Embodiment 124. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in the range of 0.05 to 1 wt%, e.g., in the range of 0.1 to 1 wt%, or
0.3 to 1 wt%, or 0.5 to 1 wt%, based on the total weight of the catalyst.
Embodiment 125. The catalyst of embodiment 118, wherein nickel is present in the catalyst
in an amount in the range of 0.05 to 0.8 wt%, e.g., in the range of 0.1 to 0.8 wt%,
or 0.3 to 0.8 wt%, or 0.5 to 0.8 wt%, based on the total weight of the catalyst.
Embodiment 126. The catalyst of any of embodiments 83-125, wherein a weight ratio
of platinum, palladium, gold, and/or nickel to the metal (e.g., manganese, gallium,
indium, lanthanum, titanium, niobium, vanadium, and zirconium) is at least 0.05:1,
e.g., at least 0.1:1.
Embodiment 127. The catalyst of any of embodiments 83-126, wherein a weight ratio
of platinum, palladium, gold, and/or nickel to the metal (e.g., manganese, gallium,
indium, lanthanum, titanium, niobium, vanadium, and zirconium) is at most 5:1, e.g.,
at most 2:1, or 1:1, or 0.5:1.
Embodiment 128. The catalyst of any of embodiments 83-127, wherein a ratio of platinum,
palladium, gold, and/or nickel to the metal (e.g., manganese, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium) is in the range of 0.05:1 to 1:1 (e.g.,
in the range of 0.05:1 to 2:1, or 0.05:1 to 1:1, or 0.05:1 to 0.5:1, or 0.05:1 to
0.3:1, or 0.07:1 to 5:1, or 0.07:1 to 2:1, or 0.07:1 to 1:1, or 0.07:1 to 0.5:1, or
0.07:1 to 0.3:1, or 0.1:1 to 5:1, or 0.1:1 to 2:1, or 0.1:1 to 1:1, or 0.1:1 to 0.5:1,
or 0.1:1 to 0.3:1).
Embodiment 129. The catalyst of any of embodiments 83-128, wherein the total amount
of cerium, titanium, zinc, zirconium, metal (e.g., manganese, copper, gallium, indium,
lanthanum, titanium, niobium, vanadium, and zirconium), platinum, palladium, gold,
and nickel in the catalyst is at least 90 wt%, e.g., at least 95 wt% or at least 98
wt% of the catalyst, on a metallic basis.
Embodiment 130. A method for making the catalyst of any of embodiments 1-129, the
method comprising:
providing a support that is a cerium oxide support, a titanium oxide support, an aluminum
oxides support, a zinc oxide support, a zirconium oxide support, or a mixed oxide
support comprising a mixture of two or more of cerium oxide, titanium oxide, aluminum
oxide, zinc oxide, and zirconium oxide;
contacting the support with one or more liquids each comprising one or more metalcontaining
compounds dispersed in a solvent(s), wherein the metal is selected from manganese,
copper, gallium, indium, lanthanum, titanium, niobium, vanadium, and zirconium, and
optionally one or more platinum-, palladium-, gold-, or nickel- containing compounds;
allowing the solvent(s) to evaporate to provide a catalyst precursor; and calcining
the catalyst precursor.
Embodiment 131. The method of embodiment 130, wherein contacting the support with
the liquid comprises adding the liquid in an amount equal to the pore volume of the
support.
Embodiment 132. The method of embodiment 130, wherein contacting the support with
the liquid comprises adding the liquid in an amount greater than the pore volume of
the support.
Embodiment 133. The method of any of embodiments 130-132, wherein ratio of the amount
liquid to the amount of support on a mass basis is in the range of 1:1 to 5:1 (e.g.,
in the range of 1:1 to 3:1).
Embodiment 134. The method of any of embodiments 130-133, wherein contacting the support
with the liquid provides a slurry.
Embodiment 135. The method of any of embodiments 130-134, wherein allowing the solvent
to evaporate is conducted at ambient temperature.
Embodiment 136. The method of embodiments 130-135, wherein allowing the solvent to
evaporate is conducted at an elevated temperature (e.g., in the range of 50-150 °C)
for a drying time (e.g., 24 hours).
Embodiment 137. The method of embodiments 130-135, wherein allowing the solvent to
evaporate is conducted under vacuum and at an elevated temperature (e.g., in the range
of 50-150 °C) for a drying time (e.g., 24 hours).
Embodiment 138. The method of any of embodiments 130-135, wherein allowing the solvent
to evaporate is conducted in a stirring drybath at an elevated temperature (e.g.,
in the range of 30-100 °C).
Embodiment 139. The method of any of embodiments 130-138, wherein calcining the catalyst
precursor is conducted for a calcining time in the range of 0.5 to 24 hours (e.g.,
0.5 to 15 hours, or 0.5 to 10 hours, or 0.5 to 5 hours).
Embodiment 140. The method of any of embodiments 130-139, wherein calcining the catalyst
precursor is conducted for a calcining is in the range of 100-600 °C (e.g., in the
range of 120-500 °C).
Embodiment 141. The catalyst of any of embodiments 1-129, made by a method according
to embodiments 130-140.
Embodiment 142. A method for performing a reverse water-gas shift reaction, the method
comprising:
contacting at a temperature in the range of 100-1100 °C a catalyst according to any
of embodiments 1-104 and 116 with a feed stream comprising CO2 and H2,wherein at least part of the CO2 of the first feed stream is from biogas, a CO2 emission source, and/or direct air capture, to provide a product stream comprising
CO and H2, the product stream having a lower concentration of CO2 and a higher concentration of CO than the feed stream.
Embodiment 143. The method of embodiment 142, wherein the reverse water-gas shift
reaction has a CO selectivity of at least 50%, e.g., of at least 60%.
Embodiment 144. The method of embodiment 142, wherein the reverse water-gas shift
reaction has a CO selectivity of at least 70%, e.g., of at least 80%.
Embodiment 145. The method of embodiment 142, wherein the reverse water-gas shift
reaction has a CO selectivity of at least 85%, e.g., of at least 95%.
Embodiment 146. The method of embodiment 142, wherein the reverse water-gas shift
reaction has a CO selectivity of at least 85%, e.g., of at least 96%.
Embodiment 147. The method of embodiment 142, wherein the reverse water-gas shift
reaction has a CO selectivity of 50-99 wt%, e.g., 60-99%, or 70-99%, or 80-99%, or
90-99%, or 95-99%.
Embodiment 148. The method of embodiment 142, wherein the reverse water-gas shift
reaction has a CO selectivity of 50-90%, e.g., 60-90%, or 70-90%, or 50-80%, or 60-80%,
or 50-70%.
Embodiment 149. The method of any of embodiments 142-148, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 40%, e.g., no more than 35%,
or 30%, or 25%, or 20%.
Embodiment 150. The method of any of embodiments 142-148, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 15%, e.g., no more than 12%,
or 10%, or 8%.
Embodiment 151. The method of any of embodiments 142-148, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 5%, e.g., no more than 4%.
Embodiment 152. The method of any of embodiments 142-148, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 2%, e.g., no more than 1%.
Embodiment 153. The method of any of embodiments 142-148, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 0.5%, e.g., no more than
0.2%.
Embodiment 154. The method of any of embodiments 142-153, having a CO2 conversion of at least 5%, e.g., at least 10%, or 20%.
Embodiment 155. The method of any of embodiments 142-153, having a CO2 conversion of at least 30%, e.g., at least 40%.
Embodiment 156. The method of any of embodiments 142-155, having a CO2 conversion of no more than 90%, e.g., no more than 80%, or no more than 70%.
Embodiment 157. The method of any of embodiments 142-156, having a CO2 conversion of no more than 65%, e.g., no more than 60%.
Embodiment 158. The method of any of embodiments 142-157, conducted at a temperature
in the range of 250-1050 °C, e.g., in the range of 250-1000 °C, or 250-950 °C.
Embodiment 159. The method of any of embodiments 142-157, conducted at a temperature
in the range of 250-900 °C, e.g., in the range of 250-850 °C , or 250-800 °C, or 250-750
°C, or 250-700 °C, or 250-650 °C, or 250-600 °C.
Embodiment 160. The method of any of embodiments 142-157, conducted at a temperature
in the range of 300-1100 °C, e.g., in the range of 300-1050 °C, or 300-1000 °C, or
300-950 °C.
Embodiment 161. The method of any of embodiments 142-157, conducted at a temperature
in the range of 300-900 °C, e.g., in the range of 300-850 °C, or 300-800 °C, or 300-750
°C, or 300-700 °C, or 300-650 °C, or 300-600 °C.
Embodiment 162. The method of any of embodiments 142-157, conducted at a temperature
in the range of 350-1100 °C, e.g., in the range of 350-1050 °C, or 350-1000 °C , or
350-950 °C.
Embodiment 163. The method of any of embodiments 142-157, conducted at a temperature
in the range of 350-900 °C, e.g., in the range of 350-850 °C, or 350-800 °C , or 350-750
°C, or 350-700 °C, or 350-650 °C, or 350-600 °C.
Embodiment 164. The method of any of embodiments 142-157, conducted at a temperature
in the range of 400-1100 °C, e.g., in the range of 400-1050 °C, or 400-1000 °C , or
400-950 °C.
Embodiment 165. The method of any of embodiments 142-157, conducted at a temperature
in the range of 400-900 °C, e.g., in the range of 400-850 °C, or 400-800 °C , or 400-750
°C, or 400-700 °C, or 400-650 °C, or 400-600 °C.
Embodiment 166. The method of any of embodiments 142-157, conducted at a temperature
in the range of 450-1100 °C, e.g., in the range of 450-1050 °C, or 450-1000 °C, or
450-950 °C.
Embodiment 167. The method of any of embodiments 142-157, conducted at a temperature
in the range of 450-900 °C, e.g., in the range of 450-850 °C, or 450-800 °C, or 450-750
°C, or 450-700 °C, or 450-650 °C, or 450-600 °C.
Embodiment 168. The method of any of embodiments 142-157, conducted at a temperature
in the range of 500-1100 °C, e.g., in the range of 500-1050 °C, or 500-1000 °C, or
500-950 °C.
Embodiment 169. The method of any of embodiments 142-157, conducted at a temperature
in the range of 500-900 °C, e.g., in the range of 500-850 °C, or 500-800 °C, or 500-750
°C , or 500-700 °C, or 500-650 °C, or 500-600 °C.
Embodiment 170. The method of any of embodiments 142-157, conducted at a temperature
in the range of 550-1100 °C, e.g., in the range of 550-1050 °C, or 550-1000 °C, or
550-950°C.
Embodiment 171. The method of any of embodiments 142-157, conducted at a temperature
in the range of 550-900 °C, e.g., in the range of 550-850 °C, or 550-800 °C, or 550-750°C,
or 550-700 °C, or 550-650 °C, or 550-600 °C.
Embodiment 172. The method of any of embodiments 142-157, conducted at a temperature
in the range of 600-1100 °C, e.g., in the range of 600-1050 °C, or 600-1000 °C, or
600-950°C.
Embodiment 173. The method of any of embodiments 142-157, conducted at a temperature
in the range of 600-900 °C, e.g., in the range of 600-850 °C, or 600-800 °C, or 600-750°C,
or 600-700 °C, or 600-650 °C.
Embodiment 174. The method of any of embodiments 142-157, conducted at a temperature
in the range of 650-1100 °C, e.g., in the range of 650-1050 °C, or 650-1000 °C, or
650-950°C.
Embodiment 175. The method of any of embodiments 142-157, conducted at a temperature
in the range of 650-900 °C, e.g., in the range of 650-850 °C, or 650-800 °C, or 650-750°C,
or 650-700 °C.
Embodiment 176. The method of any of embodiments 142-157, conducted at a temperature
in the range of 700-1100 °C, e.g., in the range of 700-1050 °C, or 700-1000 °C, or
700-950°C.
Embodiment 177. The method of any of embodiments 142-157, conducted at a temperature
in the range of 700-900 °C, e.g., in the range of 700-850 °C, or 700-800 °C, or 700-750°C.
Embodiment 178. The method of any of embodiments 142-177, wherein at least part of
the H2 of the feed stream is from a renewable source.
Embodiment 179. The method of any of embodiments 142-178, wherein at least part of
the H2 of the feed stream is green hydrogen.
Embodiment 180. The method of any of embodiments 142-179, wherein at least part of
the H2 of the feed stream is blue hydrogen.
Embodiment 181. The method of any of embodiments 142-180, wherein at least a part
of the H2 of the feed stream is grey hydrogen, black hydrogen, brown hydrogen, pink hydrogen,
turquoise hydrogen, yellow hydrogen, and/or white hydrogen.
Embodiment 182. The process of embodiment 142-180, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from biogas, a CO2 emission source, and/or CO2 from direct air capture.
Embodiment 183. The process of claim 142-180, wherein at least part of the CO2 of the first feed stream is from biogas.
Embodiment 184. The process of embodiment 183, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from biogas.
Embodiment 185. The process of claim 142-180, wherein at least part of the CO2 of the first feed stream is from direct air capture.
Embodiment 186. The process of embodiment 185, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from direct air capture.
Embodiment 187. The process of embodiment 142-180, wherein at least part of the CO2 of the first feed stream is from a CO2 emission source (e.g., from a manufacturing plant, e.g., a bioethanol plant, a steel
plant, or a cement plant).
Embodiment 188. The process of embodiment 187, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from a CO2 emission source.
Embodiment 189. The method of any of embodiments 142-188, wherein the molar ratio
of H2 to CO2 in the feed stream is at least 0.1:1, e.g., at least 0.5:1.
Embodiment 190. The method of any of embodiments 142-189, wherein the molar ratio
of H2 to CO2 in the feed stream is at least 0.9:1, e.g., at least 1:1 or at least 1.5:1.
Embodiment 191. The method of any of embodiments 142-189, wherein the molar ratio
of H2 to CO2 in the feed stream is at least 2:1, e.g., at least 2.5:1.
Embodiment 192. The method of any of embodiments 142-191, wherein the molar ratio
of H2 to CO2 in the feed stream is no more than 100:1, e.g., no more than 75:1, or 50:1.
Embodiment 193. The method of any of embodiments 142-191, wherein the molar ratio
of H2 to CO2 in the feed stream is no more than 20:1, e.g., no more than 15:1, or 10:1.
Embodiment 194. The method of any of embodiments 142-191, wherein the molar ratio
of H2 to CO2 in the feed stream is in the range of 0.5:1 to 10:1.
Embodiment 195. The method of any of embodiments 142-194, conducted at a pressure
in the range of 1 to 100 barg (e.g., in the range of 1 to 70 barg, or 1 to 50 barg,
or 1 to 40 barg, or 1 to 35 barg, or 5 to 80 barg, or 5 to 50 barg, or 5 to 40 barg,
or 5 to 35 barg, or 10 to 70 barg, 10 to 50 barg, or 10 to 40 barg, or 10 to 35 barg,
or 20 to 70 barg, 20 to 50 barg, or 20 to 40 barg, or 20 to 35 barg, or 25 to 70 barg,
25 to 50 barg, or 25 to 40 barg, or 25 to 35 barg).
Embodiment 196. The method of any of embodiments 142-195, conducted at a GHSV in the
range of 1,000 to 2,000,000 h-1 (e.g., in the range of 1,000 to 1,200,000 h-1, or 1,000 to 500,000 h-1, or 1,000 to 100,000 h-1, or 5,000 to 1,200,000 h-1, or 5,000 to 500,000 h-1, or 5,000 to 100,000 h-1, or 10,000 to 1,200,000 h-1, or 10,000 to 500,000 h-1, or 10,000 to 100,000 h-1).
Embodiment 197. The method of any of embodiments 142-196, wherein the product stream
comprises no more than 95 mol% CO2 (e.g., no more than 90 mol% CO2).
Embodiment 198. The method of any of embodiments 142-196, wherein the product stream
comprises no more than 85 mol% CO2 (e.g., no more than 80 mol% CO2).
Embodiment 199. The method of any of embodiments 142-196, wherein the product stream
comprises no more than 75 mol% CO2 (e.g., no more than 70 mol% CO2).
Embodiment 200. The method of any of embodiments 142-199, wherein the product stream
further comprises CO2, and wherein the method further comprises recycling at least a portion of the CO2 of the product stream to the feed stream.
Embodiment 201. The method of any of embodiments 142-200, wherein the product stream
further comprises hydrogen and wherein the method further comprises recycling at least
a portion of the hydrogen of the product stream to the feed stream.
Embodiment 202. The method of any of embodiments 142-201, wherein a ratio of H2:CO in the product stream is in the range of 0.1:1 to 100:1. (e.g., in the range of
0.1:1 to 50:1, or 0.1:1 to 25:1, or 0.1:1 to 10:1, or 0.1:1 to 5:1, or 1:1 to 100:1,
or 1:1 to 50:1, or 1:1 to 25:1, or 1:1 to 10:1, or 1:1 to 5:1).
Embodiment 203. The method of any of embodiments 142-202, wherein the product stream
comprises no more than 20 mol% methane, e.g., no more than 15 mol% methane.
Embodiment 204. The method of any of embodiments 142-202, wherein the product stream
comprises no more than 10 mol% methane, e.g., no more than 5 mol%, or 1 mol%, or 0.5
mol%, or 0.1 mol% methane.
Embodiment 205. The method of any of embodiments 142-204, wherein the method comprises
activating the catalyst prior to contacting the catalyst with the feed stream.
Embodiment 206. The method of embodiment 205, wherein activating the catalyst comprises
contacting the catalyst with a reducing stream comprising a reductive gas (e.g., hydrogen).
Embodiment 207. The method of embodiment 205 or embodiment 206, wherein the reducing
stream comprises hydrogen in an amount of at least 25 mol% (e.g., at least 50 mol%,
or 75 mol%, or 90 mol%).
Embodiment 208. The method of any of embodiments 205-207, wherein activating the catalyst
is conducted at a temperature in the range of 200 to 1000 °C. (e.g., in the range
of 250 °C to 1000 °C, or 300 °C to 1000 °C, 200 °C to 900 °C, 250 °C to 900 °C, or
300 °C to 900 °C, 200 °C to 800 °C, or 250 °C to 800 °C, or 300 °C to 800 °C, or 200
°C to 700 °C, or 250 °C to 800 °C, or 300 °C to 700 °C).
Embodiment 209. The method of any of embodiments 207-208, wherein activating the catalyst
provides a catalyst that is at least 10% reduced (e.g., at least 25%, or 50%).
Embodiment 210. A process for performing an integrated Fischer-Tropsch process, the
process comprising:
providing a first feed stream comprising H2 and CO2, wherein at least part of the CO2 of the first feed stream is from biogas, a CO2 emission source, and/or direct air capture;
contacting at a first temperature in the range of 200-1100 °C and at a first pressure
a reverse water-gas shift catalyst with the first feed stream to perform a reverse
water-gas shift reaction to provide a first product stream comprising CO and H2, the first product stream having a lower concentration of CO2 and a higher concentration of CO than the first feed stream;
contacting at a second temperature and at a second pressure a Fischer-Tropsch catalyst
with a second feed stream comprising H2 and at least a portion of CO of the first product stream to provide a second product
stream comprising C5+ hydrocarbons,
wherein the reverse water-gas shift catalyst is a supported reverse water-gas shift
catalyst comprising:
a support that is a cerium oxide support, a titanium oxide support, an aluminum oxide
support, a zinc oxide support, a zirconium oxide support, or a mixed oxide support
comprising a mixture of two or more of cerium oxide, titanium oxide, aluminum oxide,
zinc oxide, and zirconium oxide;
a metal selected from at least one of manganese, copper, gallium, indium, lanthanum,
titanium, niobium, vanadium, and zirconium, present in an amount in the range of 0.5
to 20 wt% of the catalyst, based on the total weight of the catalyst; and
optionally, at least one of platinum, palladium, gold, and nickel present in an amount
in the range of 0.05 to 10 wt% of the catalyst, based on the total weight of the catalyst.
Embodiment 211. The process of embodiment 210, wherein the reverse water-gas shift
catalyst is as described in any embodiments 1 to 129.
Embodiment 212. The process of any embodiment 210, wherein the reverse water-gas shift
catalyst is made by the method of any of embodiments 130 to 141.
Embodiment 213. The process of any of embodiments 210-212, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from biogas, a CO2 emission source, and/or CO2 from direct air capture.
Embodiment 214. The process of any of embodiments 210-212, wherein at least part of
the CO2 of the first feed stream is from biogas.
Embodiment 215. The process of embodiment 214, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from biogas.
Embodiment 216. The process of any of embodiments 210-212, wherein at least part of
the CO2 of the first feed stream is from direct air capture.
Embodiment 217. The process of embodiment 216, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from direct air capture.
Embodiment 218. The process of any of embodiments 210-212, wherein at least part of
the CO2 of the first feed stream is from a CO2 emission source (e.g., from a manufacturing plant, e.g., a bioethanol plant, a steel
plant, or a cement plant).
Embodiment 219. The process of embodiment 218, wherein the CO2 of the first feed stream comprises at least 50 vol% (e.g., at least 75 vol%, at least
90 vol%, or at least 95 vol%) CO2 from a CO2 emission source.
Embodiment 220. The process of any of embodiments 210-219, wherein the molar ratio
of H2 to CO2 in the first feed stream is at least 0.1:1, e.g., at least 0.5:1.
Embodiment 221. The process of any of embodiments 210-219, wherein the molar ratio
of H2 to CO2 in the first feed stream is at least 0.9:1, e.g., at least 1:1 or at least 1.5:1.
Embodiment 222. The process of any of embodiments 210-219, wherein the molar ratio
of H2 to CO2 in the first feed stream is at least 2:1, e.g., at least 2.5:1.
Embodiment 223. The process of any of embodiments 210-222, wherein the molar ratio
of H2 to CO2 in the first feed stream is no more than 100:1, e.g., no more than 75:1, or 50:1.
Embodiment 224. The process of any of embodiments 210-222, wherein the molar ratio
of H2 to CO2 in the first feed stream is no more than 20:1, e.g., no more than 15:1, or 10:1.
Embodiment 225. The process of any of embodiments 210-224, wherein the molar ratio
of H2 to CO2 in the first feed stream is in the range of 0.5:1 to 10:1.
Embodiment 226. The process according to any of embodiments 210-225, wherein the first
feed stream further comprises CO.
Embodiment 227. The process according to any of embodiments 210-226, wherein the first
feed stream comprises no more than 20 mol% (e.g., no more than 10 mol%, or no more
than 5 mol%, or no more than 3 mol%, or no more than 1 mol%) of CO.
Embodiment 228. The process according to any of embodiments 210-227,wherein the first
feed stream further comprises one or more inert gases (e.g., nitrogen and/or methane).
Embodiment 229. The process according to embodiment 228, wherein the first feed stream
comprise no more than 50 mol% (e.g., no more than 30 mol%, no more than 20 vml%, or
no more than 10 mol%) of methane.
Embodiment 230. The process according to embodiment 228 or embodiment 229, wherein
the first feed stream comprises no more than 10 mol% (e.g., no more than 6 mol%, or
no more than 2 mol%) of nitrogen.
Embodiment 231. The method of any of embodiments 210-230, wherein the reverse water-gas
shift reaction has a CO selectivity of at least 50%, e.g., of at least 60%.
Embodiment 232. The method of any of embodiments 210-231, wherein the reverse water-gas
shift reaction has a CO selectivity of at least 70%, e.g., of at least 80%.
Embodiment 233. The method of any of embodiments210-231, wherein the reverse water-gas
shift reaction has a CO selectivity of at least 85%, e.g., of at least 95%.
Embodiment 234. The method of any of embodiments 210-231, wherein the reverse water-gas
shift reaction has a CO selectivity of at least 85%, e.g., of at least 96%.
Embodiment 235. The method of any of embodiments 210-231, wherein the reverse water-gas
shift reaction has a CO selectivity of 50-99 wt%, e.g., 60-99%, or 70-99%, or 80-99%,
or 90-99%, or 95-99%.
Embodiment 236. The method of any of embodiments 210-231, wherein the reverse water-gas
shift reaction has a CO selectivity of 50-90%, e.g., 60-90%, or 70-90%, or 50-80%,
or 60-80%, or 50-70%.
Embodiment 237. The method of any of embodiments 210-236, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 40%, e.g., no more than 35%,
or 30%, or 25%, or 20%.
Embodiment 238. The method of any of embodiments 210-236, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 15%, e.g., no more than 12%,
or 10%, or 8%.
Embodiment 239. The process of any of embodiments 210-236, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 5%, e.g., no more than 4%.
Embodiment 240. The process of any of embodiments 210-236, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 2%, e.g., no more than 1%.
Embodiment 241. The process of any of embodiments 210-236, wherein the reverse water-gas
shift reaction has a methane selectivity of no more than 0.5%, e.g., no more than
0.2%.
Embodiment 242. The process of any of embodiments 210-241, wherein the reverse water-gas
shift reaction has a CO2 conversion of at least 5%, e.g., at least 10%, or 20%.
Embodiment 243. The process of any of embodiments 210-241, wherein the reverse water-gas
shift reaction has a CO2 conversion of at least 30%, e.g., at least 40%.
Embodiment 244. The process of any of embodiments 210-243, wherein the reverse water-gas
shift reaction has a CO2 conversion of no more than 90%, e.g., no more than 80%, or no more than 70%.
Embodiment 245. The process of any of embodiments 210-243, wherein the reverse water-gas
shift reaction has a CO2 conversion of no more than 65%, e.g., no more than 60%.
Embodiment 246. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 250-1050 °C, e.g., in
the range of 250-1000 °C, or 250-950 °C.
Embodiment 247. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 250-900 °C, e.g., in
the range of 250-850 °C , or 250-800 °C, or 250-750 °C, or 250-700 °C, or 250-650
°C, or 250-600 °C.
Embodiment 248. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 300-1100 °C, e.g., in
the range of 300-1050 °C, or 300-1000 °C, or 300-950 °C.
Embodiment 249. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 300-900 °C, e.g., in
the range of 300-850 °C, or 300-800 °C, or 300-750 °C, or 300-700 °C, or 300-650 °C,
or 300-600 °C.
Embodiment 250. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 350-1100 °C, e.g., in
the range of 350-1050 °C, or 350-1000 °C , or 350-950 °C.
Embodiment 251. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 350-900 °C, e.g., in
the range of 350-850 °C, or 350-800 °C , or 350-750 °C, or 350-700 °C, or 350-650
°C, or 350-600 °C.
Embodiment 252. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 400-1100 °C, e.g., in
the range of 400-1050 °C, or 400-1000 °C , or 400-950 °C.
Embodiment 253. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 400-900 °C, e.g., in
the range of 400-850 °C, or 400-800 °C , or 400-750 °C, or 400-700 °C, or 400-650
°C, or 400-600 °C.
Embodiment 254. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 450-1100 °C, e.g., in
the range of 450-1050 °C, or 450-1000 °C, or 450-950 °C.
Embodiment 255. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 450-900 °C, e.g., in
the range of 450-850 °C, or 450-800 °C, or 450-750 °C, or 450-700 °C, or 450-650 °C,
or 450-600 °C.
Embodiment 256. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 500-1100 °C, e.g., in
the range of 500-1050 °C, or 500-1000 °C, or 500-950 °C.
Embodiment 257. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 500-900 °C, e.g., in
the range of 500-850 °C, or 500-800 °C, or 500-750 °C , or 500-700 °C, or 500-650
°C, or 500-600 °C.
Embodiment 258. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 550-1100 °C, e.g., in
the range of 550-1050 °C, or 550-1000 °C, or 550-950°C.
Embodiment 259. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 550-900 °C, e.g., in
the range of 550-850 °C, or 550-800 °C, or 550-750°C, or 550-700 °C, or 550-650 °C,
or 550-600 °C.
Embodiment 260. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 600-1100 °C, e.g., in
the range of 600-1050 °C, or 600-1000 °C, or 600-950°C.
Embodiment 261. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 600-900 °C, e.g., in
the range of 600-850 °C, or 600-800 °C, or 600-750°C, or 600-700 °C, or 600-650 °C.
Embodiment 262. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 650-1100 °C, e.g., in
the range of 650-1050 °C, or 650-1000 °C, or 650-950°C.
Embodiment 263. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 650-900 °C, e.g., in
the range of 650-850 °C, or 650-800 °C, or 650-750°C, or 650-700 °C.
Embodiment 264. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 700-1100 °C, e.g., in
the range of 700-1050 °C, or 700-1000 °C, or 700-950°C.
Embodiment 265. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 700-900 °C, e.g., in
the range of 700-850 °C, or 700-800 °C, or 700-750°C.
Embodiment 266. The process of any of embodiments 210-245, wherein the reverse water-gas
shift reaction is conducted at a temperature in the range of 200-500 °C, e.g., 200-450
°C, or 200-400 °C, or 200-350 °C, or 250-500 °C, e.g., 250-450 °C, or 250-400 °C,
or 250-350 °C.
Embodiment 267. The process of any of embodiments 210-266, wherein the reverse water-gas
shift reaction is conducted at a pressure in the range of 1 to 100 barg (e.g., in
the range of 1 to 70 barg, or 1 to 50 barg, or 1 to 40 barg, or 1 to 35 barg, or 5
to 80 barg, or 5 to 50 barg, or 5 to 40 barg, or 5 to 35 barg, or 10 to 70 barg, 10
to 50 barg, or 10 to 40 barg, or 10 to 35 barg, or 20 to 70 barg, 20 to 50 barg, or
20 to 40 barg, or 20 to 35 barg, or 25 to 70 barg, 25 to 50 barg, or 25 to 40 barg,
or 25 to 35 barg).
Embodiment 268. The process of any of embodiments 210-267, wherein the reverse water-gas
shift reaction is conducted at a GHSV in the range of 1,000 to 2,000,000 h-1 (e.g., in the range of 1,000 to 1,200,000 h-1, or 1,000 to 500,000 h-1, or 1,000 to 100,000 h-1, or 5,000 to 1,200,000 h-1, or 5,000 to 500,000 h-1, or 5,000 to 100,000 h-1, or 10,000 to 1,200,000 h-1, or 10,000 to 500,000 h-1, or 10,000 to 100,000 h-1).
Embodiment 269. The process of any of embodiments 210-268, wherein the process comprises
activating the reverse water-gas shift catalyst, e.g., prior to contacting the reverse
water-gas shift catalyst with the first feed stream.
Embodiment 270. The process of embodiment 269, wherein activating the rWGS catalyst
comprises contacting the rWGS catalyst with a reducing stream comprising a reductive
gas (e.g., hydrogen).
Embodiment 271. The process of embodiment 269 or embodiment 270, wherein the reducing
stream comprises hydrogen in an amount of at least 25 mol% (e.g., at least 50 mol%,
or 75 mol%, or 90 mol%).
Embodiment 272. The process of any of embodiments 269-271, wherein activating the
rWGS catalyst is conducted at a temperature in the range of 200 °C to 1000 °C. (e.g.,
in the range of 250 °C to 1000 °C, or 300 °C to 1000 °C, 200 °C to 900 °C, 250 °C
to 900 °C, or 300 °C to 900 °C, 200 °C to 800 °C, or 250 °C to 800 °C, or 300 °C to
800 °C, or 200 °C to 700 °C, or 250 °C to 700 °C, or 300 °C to 700 °C).
Embodiment 273. The process of any of embodiments 269-272, wherein activating the
rWGS catalyst provides a catalyst that is at least 10% reduced (e.g., at least 25%,
or 50%).
Embodiment 274. The process of any of embodiments 210-273, wherein the first product
stream comprises no more than 95 mol% CO2 (e.g., no more than 90 mol% CO2).
Embodiment 275. The process of any of embodiments 210-273, wherein the first product
stream comprises no more than 85 mol% CO2 (e.g., no more than 80 mol% CO2).
Embodiment 276. The process of any of embodiments 210-273, wherein the first product
stream comprises no more than 75 mol% CO2 (e.g., no more than 70 mol% CO2).
Embodiment 277. The process of any of embodiments 210-276, wherein the first product
stream comprises in the range of 5-95 mol% CO2, e.g., 5-90 mol%, or 5-85 mol%, or 5-80 mol%, or 5-75 mol%, or 5-70 mol%, or 10-95
mol%, or 10-90 mol%, or 10-85 mol%, or 10-80 mol%, or 10-75 mol%, or 10-70 mol%, or
20-95 mol%, or 20-90 mol%, or 20-85 mol%, or 20-80 mol%, or 20-75 mol%, or 20-70 mol%,
or 30-95 mol%, or 30-90 mol%, or 30-85 mol%, or 30-80 mol%, or 30-75 mol%, or 30-70
mol% CO2.
Embodiment 278. The process of any of embodiments 210-277, wherein the first product
stream comprises methane in an amount in the range of 10-70 mol% (e.g., in the range
of 10-50 mol%, or 20-70 mol%, or 20-50 mol%, or 30-70 mol%, or 30-50 mol%).
Embodiment 279. The process of any of embodiments 210-277, wherein the first product
stream comprises no more than 20 mol% methane, e.g., no more than 15 mol% methane.
Embodiment 280. The process of any of embodiments 210-277, wherein the first product
stream comprises no more than 10 mol% methane, e.g., no more than 5 mol% or 1 mol%,
or 0.5 mol%, or 0.1 mol% methane.
Embodiment 281. The process of any of embodiments 210-280, wherein a ratio of H2:CO in the first product stream is up to 100:1, e.g., up to 50:1, or up to 25:1, or
up to 10:1.
Embodiment 282. The process of any of embodiments 210-280, wherein a ratio of H2:CO in the first product stream is in the range of 0.1:1 to 100:1 (e.g., in the range
of 0.1:1 to 50:1, or 0.1:1 to 25:1, or 0.1:1 to 10:1, or 0.1:1 to 5:1, or 1:1 to 100:1,
or 1:1 to 50:1, or 1:1 to 25:1, or 1:1 to 10:1, or 1:1 to 5:1).
Embodiment 283. The process of any of embodiments 210-282, wherein the process further
comprises separating the first product stream to recycle at least a portion of one
or more components of the first product stream to the first feed stream.
Embodiment 284. The process of any of embodiments 210-283, wherein the process further
comprises separating the first product stream to recycle at least a portion (e.g.,
at least 5 mol%, at least 10 mol%, at least 25 mol%, at least 50 mol%, at least 75
mol%, or at least 90 mol%) of CO2 of the first product stream to the first feed stream.
Embodiment 285. The process of any of embodiments 210-284, wherein the process further
comprises separating the first product stream to recycle at least a portion of H2 (e.g., at least 5 mol%, at leat10 mol%, at least 25 mol%, at least 50 mol%, at least
75 mol%, or at least 90 mol%) to the first feed stream.
Embodiment 286. The process of any of embodiments 210-285, wherein the process further
comprises separating at least a portion of H2 and/or CO from the first product stream and contacting it with the Fischer-Tropsch
catalyst to activate the Fischer-Tropsch catalyst.
Embodiment 287. The process of any of embodiments 210-286, wherein the process further
comprises removing at least a portion (e.g., at least 25%, at least 50%, or at least
75%) of water from the first product stream.
Embodiment 288. The process according to any of embodiments 210-287, wherein the first
product stream further comprises one or more light hydrocarbons (e.g., methane, ethane,
propane).
Embodiment 289. The process according to embodiment 288, further comprising separating
at least a portion of the one or more light hydrocarbons from the first product stream
to provide a light hydrocarbon stream.
Embodiment 290. The process according to embodiment 288 or 289, wherein the light
hydrocarbon stream comprises methane from biogas.
Embodiment 291. The process according to embodiment 290, further comprising burning
at least a portion of the light hydrocarbon stream to provide energy, e.g., heat energy
or electrical energy.
Embodiment 292. The process according to embodiment 291, wherein the heat energy is
used to heat the first feed stream.
Embodiment 293. The process of any of embodiments 210-292, wherein the process further
comprises exchanging heat between at least a portion of the first product stream and
at least a portion of the first feed stream, thereby cooling at least a portion of
the first product stream and heating at least a portion of the first feed stream.
Embodiment 294. The process of any of embodiments 210-293, wherein the process further
comprises exchanging heat between at least a portion of the first product stream and
a steam generation zone, thereby cooling at least a portion of the first product stream
and providing heat to the steam generation zone.
Embodiment 295. The process of embodiment 294, further comprising generating steam
from the heat provided to the steam generation zone, and generating electricity from
the steam.
Embodiment 296. The process of embodiment 294 or 295, wherein steam is used to heat
the first feed stream and/or the second feed stream.
Embodiment 297. The process of any of embodiments 210-296, wherein at least 25% of
the CO of the first product stream, e.g., at least 50% of the CO, at least 75% of
the CO, or at least 90% of the CO of the first product stream is included in the second
feed stream.
Embodiment 298. The process of any of embodiments 210-297, wherein CO is provided
to the second feed stream from a CO source other than the first product stream.
Embodiment 299. The process of any of embodiments 210-298, wherein the first product
stream includes H2, and wherein the second feed stream includes at least a portion of the H2 of the first product stream.
Embodiment 300. The process of any of embodiments 210-299, wherein at least 25% of
the H2 of the first product stream, e.g., at least 50% of the H2, at least 75% of the H2, or at least 90% of the H2 of the first product stream is included in the second feed stream.
Embodiment 301. The process of any of embodiments 210-300, wherein H2 is provided to the second feed stream from a hydrogen source other than the first
product stream.
Embodiment 302. The process of any of embodiments 210-301, wherein the second feed
stream includes at least a portion of CO2 of the first product stream.
Embodiment 303. The process of any of embodiments 210-302, wherein at least 10% of
the CO2 of the first product stream, e.g., at least 25% of the CO2, at least 50% of the CO2, at least 75% of the CO2, or at least 90% of the CO2 of the first product stream is included in the second feed stream.
Embodiment 304. The process of any of embodiments 210-302, wherein the second feed
stream does not include a substantial amount of CO2 of the first product stream.
Embodiment 305. The process of any of embodiments 210-304, wherein the portion of
the first product stream that is included in the second feed stream has a H2:CO ratio in the range of 0.5:1 to 10:1, e.g., in the range of 1:1 to 3:1.
Embodiment 306. The process of any of embodiments 210-305, wherein the portion of
the first product stream that is included in the second feed stream has a water content
of no more than 10 mol%, e.g., or no more than 2 mol%, or no more than 0.5 mol%.
Embodiment 307. The process of any of embodiments 210-306, wherein the portion of
the first product stream that is included in the second feed stream has a CO2 content in the range of 10-95 mol% CO2, e.g., 10-90 mol%, or 10-85 mol%, or 10-80 mol%, or 10-75 mol%, or 10-70 mol%, or
20-95 mol%, or 20-90 mol%, or 20-85 mol%, or 20-80 mol%, or 20-75 mol%, or 20-70 mol%,
or 30-95 mol%, or 30-90 mol%, or 30-85 mol%, or 30-80 mol%, or 30-75 mol%, or 30-70
mol% CO2.
Embodiment 308. The process of any of embodiments 210-307, wherein the second feed
stream has a H2:CO ratio in the range of 0.5:1 to 6:1.
Embodiment 309. The process of any of embodiments 210-307, wherein the second feed
stream has a H2:CO ratio in the range of 1:1 to 3:1, e.g., 1:1 to 2.5:1.
Embodiment 310. The process of any of embodiments 210-307, wherein the second feed
stream has a H2:CO ratio of at least 1.4:1, e.g., in the range of 1.4:1 to 3:1, or 1.4:1 to 2.5:1.
Embodiment 311. The process of any of embodiments 210-310, wherein the second feed
stream includes up to 80% of one or more inerts, e.g., up to 70 mol%, up to 60 mol%,
or up to 50 mol%, or 15-70 mol%, or 30-70 mol%, or 15-60 mol%, or 30-60 mol%, or 15-50
mol%, or 30-50 mol%.
Embodiment 312. The process of any of embodiments 210-310, wherein the second feed
stream includes up to 80% of one or more inerts selected from CO2, methane and nitrogen, e.g., up to 70 mol%, up to 60 mol%, or up to 50 mol%, or 15-70
mol%, or 30-70 mol%, or 15-60 mol%, or 30-60 mol%, or 15-50 mol%, or 30-50 mol%.
Embodiment 313. The process of any of embodiments 210-312, wherein the second feed
stream includes up to 80% of CO2, e.g., up to 70 mol%, up to 60 mol%, or up to 50 mol%, or 15-70 mol%, or 30-70 mol%,
or 15-60 mol%, or 30-60 mol%, or 15-50 mol%, or 30-50 mol%.
Embodiment 314. The process of any of embodiments 210-313, wherein the second feed
stream has a water content of no more than 10 mol%, e.g., or no more than 2 mol%,
or no more than 0.5 mol%.
Embodiment 315. The process of any of embodiments 210-314, wherein the Fischer-Tropsch
catalyst comprises cobalt, iron, rhodium, ruthenium, or a combination thereof.
Embodiment 316. The process of any of embodiments 210-314, wherein the Fischer-Tropsch
catalyst comprises cobalt, for example, in an amount in the range of 5-25 wt%, e.g.,
7-25 wt%, or 10-25 wt%, or 5-20 wt%, or 7-20 wt%, or 10-20 wt%, calculated as Co(0).
Embodiment 317. The process of any of embodiments 210-314, wherein the Fischer-Tropsch
catalyst comprises iron, for example, in an amount in the range of 5-95 wt%, e.g.,
10-95 wt%, or 25-95 wt%, or 50-95 wt%, or 5-85 wt%, or 10-85 wt%, or 25-85 wt%, or
50-85 wt%, or 5-75 wt%, or 10-75 wt%, or 25-75 wt%, calculated as Fe(0).
Embodiment 318. The process of any of embodiments 313-317, wherein the Fischer-Tropsch
catalyst further comprises manganese.
Embodiment 319. The process of embodiment 318, wherein the manganese is present in
an amount up to 15 wt%, e.g., up to 12 wt%, or up to 10 wt%, or up to 7 wt%, or in
the range of 0.1-15 wt%, e.g., 0.1-10 wt%, or 0.1-5 wt%, 0.5-15 wt%, or 0.5-10 wt%,
or 0.5-5 wt%, calculated as Mn(0).
Embodiment 320. The process of any of embodiments 210-319, wherein the Fischer-Tropsch
catalyst is a supported catalyst, wherein the support comprises at least one of titanium
oxide, zirconium oxide, cerium oxide, aluminum oxide, silicon oxide and zinc oxide.
Embodiment 321. The process of any of embodiments 210-319, wherein the Fischer-Tropsch
catalyst is a supported catalyst, wherein the support comprises at least one of titanium
oxide, aluminum oxide, and silicon oxide.
Embodiment 322. The process of any of embodiments 210-319, wherein the Fischer-Tropsch
catalyst is a supported catalyst, wherein the support is a titanium dioxide support.
Embodiment 323. The process of any of embodiments 185210-322, wherein the Fischer-Tropsch
catalyst is activated by contact with a reducing gas, e.g., hydrogen.
Embodiment 324. The process of embodiment 323, wherein the reducing gas comprises
at least a portion of hydrogen from the first product stream.
Embodiment 325. The process of any of embodiments 210-324, wherein the Fischer-Tropsch
catalyst is activated by contact with H2 and CO.
Embodiment 326. The process of embodiment 325, wherein the reducing gas comprises
at least a portion of H2 and CO from the first product stream.
Embodiment 327. The process of any of embodiments 210-326, wherein the activation
is performed at a temperature in the range of 200-400 °C
Embodiment 328. The process of any of embodiments 210-327, wherein the second temperature
is in the range of 150-400 °C (e.g., in the range of 150-350 °C, or 150-300 °C, or
150-250°C, or 150-200°C, or 200-400 °C, or 200-350 °C, or 200-300°C, or 200-250 °C,
or 250-400 °C, or 250-350 °C, or 250-300 °C, or 300-400 °C).
Embodiment 329. The process of any of embodiments 210-328, wherein the second temperature
is in the range of 200-350 °C.
Embodiment 330. The process of any of embodiments 210-329, wherein the first temperature
is within 100 °C of the second temperature, e.g., within 50 °C of the second temperature,
or within 25 °C of the second temperature.
Embodiment 331. The process of any of embodiments 210-330, wherein the first temperature
is at least 100 °C greater than the second temperature, e.g., at least 150 °C greater
than the second temperature, or at least 200 °C greater than the second temperature.
Embodiment 332. The process of any of embodiments 210-331, wherein the second pressure
is in the range of 10-50 barg (e.g., 20-50 barg, or 25-50 barg, or 10-40 barg, or
20-40 barg, or 25-40 barg or 10-35 barg, or 20-35 barg, or 25-35 barg).
Embodiment 333. The process of any of embodiments 210-332, wherein the second pressure
is in the range of 20-50 barg.
Embodiment 334. The process of any of embodiments 210-333, wherein the Fischer-Tropsch
reaction is conducted at a GHSV in the range of 1,000 to 2,000,000 h-1 (e.g., in the range of 1,000 to 1,200,000 h-1, or 1,000 to 500,000 h-1, or 1,000 to 100,000 h-1, or 5,000 to 1,200,000 h-1, or 5,000 to 500,000 h-1, or 5,000 to 100,000 h-1, or 10,000 to 1,200,000 h-1, or 10,000 to 500,000 h-1, or 10,000 to 100,000 h-1).
Embodiment 335. The process of any of embodiments 210-334, wherein the contacting
of the Fischer-Tropsch catalyst with the second feed stream to provide the second
product stream is performed with a C5+ selectivity of at least 30%, e.g., at least 50%, or at least 70%.
Embodiment 336. The process of any of embodiments 210-335, wherein the contacting
of the Fischer-Tropsch catalyst with the second feed stream to provide the second
product stream is performed with a selectivity for C5+ alkanes of at least 30%, e.g., at least 50%, or at least 70%.
Embodiment 337. The process of any of embodiments 210-336, wherein the contacting
of the Fischer-Tropsch catalyst with the second feed stream to provide the second
product stream is performed with a selectivity for C5+ alkanes and C5+ alcohols of at least 30%, e.g., at least 50%, or at least 70%.
Embodiment 338. The process of any of embodiments 210-337, further comprising separating
at least a portion of water from the second product stream.
Embodiment 339. The process of any of embodiments 210-338, further comprising separating
at least a portion of C1-C4 hydrocarbons from the second product stream to provide a light hydrocarbon stream.
Embodiment 340. The process of embodiment 339, further comprising including at least
a portion of the light hydrocarbon stream in the first feed stream and/or the second
feed stream.
Embodiment 341. The process of embodiment 339 or embodiment 340, further comprising
oxidizing at least a portion of the light hydrocarbon stream to provide a CO- and/or
CO2-containing pOX stream, and including at least a portion of the pOX stream in the
first feed stream and/or the second stream.
Embodiment 342. The process of any of embodiments 339-341, wherein the light hydrocarbon
stream comprises methane from biogas.
Embodiment 343. The process of embodiment 342, comprising providing a biogas comprising
CO2 and methane, and providing at least a portion of the CO2 to the first feed stream, and at least a portion of the methane to the oxidation
of at least a portion of the light hydrocarbon stream.
Embodiment 344. The process of any of embodiments 339-343, further comprising reforming
(e.g., steam reforming and/or autothermal reforming) at least a portion of the light
hydrocarbon stream to provide a CO- and/or CO2-containing reformed stream, and including at least a portion of the reformed stream
in the first feed stream and/or the second feed stream.
Embodiment 345. The process of any of embodiments 341-344, wherein the oxidation or
the reforming provides energy, heat energy or electrical energy.
Embodiment 346. The process of any of embodiments 339-345, further comprising burning
at least a portion of the light hydrocarbon stream to provide energy, e.g., heat energy
or electrical energy.
Embodiment 347. The process of embodiment 346, wherein heat energy is provided, and
the heat energy is used to heat the first feed stream.
Embodiment 348. The process of any of embodiments 210-347, wherein the process further
comprises exchanging heat between at least a portion of the second product stream
and a steam generation zone, thereby cooling at least a portion of the first feed
stream and providing heat to the steam generation zone.
Embodiment 349. The process of embodiment 348, further comprising generating steam
from the heat provided to the steam generation zone, and generating electricity from
the steam.
Embodiment 350. The process of embodiment 348 or 349, wherein steam is used to heat
the first feed stream and/or the second feed stream.
Embodiment 351. The process of any of embodiments 210-350, wherein the process further
comprises exchanging heat between at least a portion of the second product stream
and at least a portion of the second feed stream, thereby cooling at least a portion
of the second product stream and heating at least a portion of the second feed stream.
Embodiment 352. The process of any of embodiments 210-351, further comprising recycling
at least a portion of H2 of the second product stream to the second feed stream.
Embodiment 353. The process of any of embodiments 210-352, further comprising recycling
at least a portion of H2 of the second product stream to the first feed stream.
Embodiment 354. The process of embodiment 353, further comprising providing H2 to the second feed stream from a H2 source other than the first product stream.
Embodiment 355. The process of embodiment 354, when H2 from the second product stream makes up most of the H2 of the first feed stream, e.g., at least 90%, at least 95%, or at least 98% of the
H2 of the first feed stream.
Embodiment 356. The process of any of embodiments 210-355, further comprising recycling
at least a portion of CO of the second product stream to the second feed stream.
Embodiment 357. The process of any of embodiments 210-356, further comprising recycling
at least a portion of CO of the second product stream to the first feed stream.
Embodiment 358. The process of any of embodiments 210-357, further comprising recycling
at least a portion of inerts of the second product stream to the second feed stream.
Embodiment 359. The process of any of embodiments 210-358, further comprising recycling
at least a portion of inerts of the second product stream to the first feed stream.
Embodiment 360. The process of any of embodiments 210-359, further comprising recycling
at least a portion of CO2 of the second product stream to the first feed stream.
Embodiment 361. The process of embodiment 360, further comprising providing CO2 to the second feed stream from a CO2 source other than the first product stream.
Embodiment 362. The process of embodiment 361, when CO2 from the second product stream makes up most of the CO2 of the first feed stream, e.g., at least 90%, at least 95%, or at least 98% of the
CO2 of the first product stream.
Embodiment 363. The process of any of embodiments 210-362, wherein one or more products
are provided from at least a portion of C5+ hydrocarbons of the second product stream.
Embodiment 364. The process of embodiment 363, wherein the one or more products include
fuels (e.g., gasoline, diesel fuel, aviation fuel), lubricants and waxes.
Embodiment 365. The process of any of embodiments 210-364, further comprising hydroprocessing
at least a portion of C5+ hydrocarbons of the second product stream. Embodiment 366.
The process of any of embodiments 210-365, wherein at least part of the CO2 of the second feed stream is from a renewable source.
Embodiment 367. The process of any of embodiments 210-365, wherein at least part of
the CO2 of the second feed stream is from biogas.
Embodiment 368. The process of any of embodiments 210-365, wherein at least part of
the CO2 of the second feed stream is from direct air capture.
Embodiment 369. The process of any of embodiments 210-365, wherein at least part of
the CO2 of the second feed stream is from a CO2 emission source (e.g., from a manufacturing plant, e.g., a bioethanol plant, a steel
plant, or a cement plant).
Embodiment 370. The process of any of embodiments 210-369, wherein at least part of
the H2 of the first feed stream or the second feed stream is from a renewable source.
Embodiment 371. The process of any of embodiment 210-370, wherein at least a portion
of the hydrogen of the first feed stream or the second feed stream is green hydrogen.
Embodiment 372. The process of any of embodiment 210-371, wherein at least a portion
of the hydrogen of the first feed stream or the second feed stream is blue hydrogen.
Embodiment 373. The process of any of embodiment 210-372, wherein at least a portion
of the hydrogen of the first feed stream or the second feed stream is grey hydrogen,
black hydrogen, brown hydrogen, pink hydrogen, turquoise hydrogen, yellow hydrogen,
and/or white hydrogen.
Embodiment 374. The process of any of embodiments 210-373, further comprising providing
at least a portion of H2 to the first feed stream and/or the second feed stream by electrolysis of water.
Embodiment 375. The process of embodiment 374, wherein the electrolysis of water is
performed using at least partially electricity from a renewable source.
Embodiment 376. The process of embodiment 374 or embodiment 375, wherein the electrolysis
of water is performed using at least partially electricity generated from steam made
by heat exchange from the first product stream and/or the second product stream, or
by burning a light hydrocarbon stream.
Embodiment 377. The process of any of embodiments 372-376, further comprising providing
at least a portion of O2 generated in the electrolysis to a partial oxidation.
Embodiment 378. The process of any of embodiments 210-377, wherein the process is
performed in a reactor system comprising a first reactor in which the reverse water-gas
shift catalyst is disposed, and a second reactor in which the Fischer-Tropsch catalyst
is disposed.
Embodiment 379. The process of any of embodiments 210-377, wherein the process is
performed in a reactor system comprising a first catalyst bed in which the reverse
water-gas shift catalyst is disposed and a second catalyst bed in which the Fischer-Tropsch
catalyst is disposed.
Embodiment 380. The process of embodiment 379, wherein the first reactor bed and the
second reactor bed are disposed within the same reactor.
Embodiment 381. The process of any of embodiments 210-380, wherein the process is
performed in a reactor system comprising one or more first catalyst containers in
which the reverse water-gas shift catalyst is disposed, and wherein the second reaction
zone comprises one or more second catalyst containers in which the Fischer-Tropsch
catalyst is disposed.
Embodiment 382. The process of embodiment 381, wherein the one or more first catalyst
containers and the one or more second catalyst containers are disposed within the
same reactor.
Embodiment 383. The process of any of embodiments 210-382, wherein the process is
performed in a reactor system comprising a reactor in which the reverse water-gas
shift catalyst and the Fischer-Tropsch catalyst are disposed, e.g., in admixture.
[0149] The particulars shown herein are by way of example and for purposes of illustrative
discussion of the preferred embodiments of the present invention only and are presented
in the cause of providing what is believed to be the most useful and readily understood
description of the principles and conceptual aspects of various embodiments of the
invention. In this regard, no attempt is made to show structural details of the invention
in more detail than is necessary for the fundamental understanding of the invention,
the description taken with the drawings and/or examples making apparent to those skilled
in the art how the several forms of the invention may be embodied in practice. Thus,
before the disclosed processes and devices are described, it is to be understood that
the aspects described herein are not limited to specific embodiments, apparatuses,
or configurations, and as such can, of course, vary. It is also to be understood that
the terminology used herein is for the purpose of describing particular aspects only
and, unless specifically defined herein, is not intended to be limiting.
[0150] The terms "a," "an," "the" and similar referents used in the context of describing
the invention (especially in the context of the following claims) are to be construed
to cover both the singular and the plural, unless otherwise indicated herein or clearly
contradicted by context. Recitation of ranges of values herein is merely intended
to serve as a shorthand process of referring individually to each separate value falling
within the range. Unless otherwise indicated herein, each individual value is incorporated
into the specification as if it were individually recited herein. It will be further
understood that the endpoints of each of the ranges are significant both in relation
to the other endpoint, and independently of the other endpoint.
[0151] All processes described herein can be performed in any suitable order of steps unless
otherwise indicated herein or otherwise clearly contradicted by context. The use of
any and all examples, or exemplary language (e.g., "such as") provided herein is intended
merely to better illuminate the invention and does not pose a limitation on the scope
of the invention otherwise claimed. No language in the specification should be construed
as indicating any non-claimed element essential to the practice of the invention.
[0152] Unless the context clearly requires otherwise, throughout the description and the
claims, the words 'comprise', 'comprising', and the like are to be construed in an
inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in
the sense of "including, but not limited to". Words using the singular or plural number
also include the plural and singular number, respectively. Additionally, the words
"herein," "above," and "below" and words of similar import, when used in this application,
shall refer to this application as a whole and not to any particular portions of the
application.
[0153] As will be understood by one of ordinary skill in the art, each embodiment disclosed
herein can comprise, consist essentially of or consist of its particular stated element,
step, ingredient or component. As used herein, the transition term "comprise" or "comprises"
means includes, but is not limited to, and allows for the inclusion of unspecified
elements, steps, ingredients, or components, even in major amounts. The transitional
phrase "consisting of" excludes any element, step, ingredient or component not specified.
The transition phrase "consisting essentially of" limits the scope of the embodiment
to the specified elements, steps, ingredients or components and to those that do not
materially affect the embodiment.
[0154] Unless indicated to the contrary, the numerical parameters set forth in the specification
and attached claims are approximations that may vary depending upon the desired properties
sought to be obtained by the present invention. At the very least, and not as an attempt
to limit the application of the doctrine of equivalents to the scope of the claims,
each numerical parameter should at least be construed in light of the number of reported
significant digits and by applying ordinary rounding techniques.
[0155] Notwithstanding that the numerical ranges and parameters setting forth the broad
scope of the invention are approximations, the numerical values set forth in the specific
examples are reported as precisely as possible. Any numerical value, however, inherently
contains certain errors necessarily resulting from the standard deviation found in
their respective testing measurements.
[0156] Groupings of alternative elements or embodiments of the invention disclosed herein
are not to be construed as limitations. Each group member may be referred to and claimed
individually or in any combination with other members of the group or other elements
found herein. It is anticipated that one or more members of a group may be included
in, or deleted from, a group for reasons of convenience and/or patentability. When
any such inclusion or deletion occurs, the specification is deemed to contain the
group as modified thus fulfilling the written description of all Markush groups used
in the appended claims.
[0157] Some embodiments of this invention are described herein, including the best mode
known to the inventors for carrying out the invention. Of course, variations on these
described embodiments will become apparent to those of ordinary skill in the art upon
reading the foregoing description. The inventor expects skilled artisans to employ
such variations as appropriate, and the inventors intend for the invention to be practiced
otherwise than specifically described herein. Accordingly, this invention includes
all modifications and equivalents of the subject matter recited in the claims appended
hereto as permitted by applicable law. Moreover, any combination of the above-described
elements in all possible variations thereof is encompassed by the invention unless
otherwise indicated herein or otherwise clearly contradicted by context.
[0158] Furthermore, it is to be understood that the embodiments of the invention disclosed
herein are illustrative of the principles of the present invention. Other modifications
that may be employed are within the scope of the invention. Thus, by way of example,
but not of limitation, alternative configurations of the present invention may be
utilized in accordance with the teachings herein. Accordingly, the present invention
is not limited to that precisely as shown and described.