Patent ID: 6642281
Filing Date: 2003-11-04
Classification: B01J,C07C,C10G,Y02P

Abstract:
A process for the catalytic hydrogenation of carbon monoxide to form a mixture of hydrocarbons in a plurality of reactors operably connected in series comprising introducing a feed gas comprising carbon monoxide and hydrogen into at least one initial stage reactor and introducing the effluent therefrom into a final stage reactor so that unconverted feed gas is reacted therein, wherein the catalyst in the at least one initial stage reactor is a Dispersed Metal Catalyst (DAM) and is not immobilized, said catalyst comprising one or one or more members selected from the group consisting of Group VIII metals and copper and the catalyst in the final stage reactor is the same as or different from that in the initial stage reactor, said process additionally including the steps of:a) withdrawing a mixture comprising hydrocarbons and a portion of said catalyst from the at least one initial stage reactor during operation thereof: b) treating said catalyst mixture to reduce the hydrocarbon content thereof; c) heating the resulting mixture in a non-oxidizing atmosphere to a temperature above the melting temperature of at least one of said metals thereby substantially removing non-metallic impurities therefrom and forming a slag of any refractory metal oxides therein on the resulting melt; d) removing the slag, if present; e) cooling the melt to solidify it; f) treating the solid to reduce the particle size thereof to a fine powder of renewed catalyst; and g) returning at least a portion of the catalyst to said at least one initial stage reactor.