Patent ID: 7709541

Claim:
A Fischer-Tropsch catalyst having a skeletal iron structure and increased catalytic selectivity for C 5+ manufactured according to a method, comprising: forming a solid catalyst precursor composition by: melting together iron metal and a removable non-ferrous component comprising one or more of aluminum, antimony, silicon, tin, or zinc to form a molten iron alloy; and cooling the molten iron alloy to yield the solid catalyst precursor composition; removing at least a portion of the removable non-ferrous component from the solid catalyst precursor composition to form a skeletal iron structure composed of a porous metal framework having a specific surface area of at least about 20 m 2 /g, wherein the porous metal framework is comprised of fused iron metal and void spaces where the removable non-ferrous component was removed; depositing one or more first promoter metals on the skeletal iron structure or incorporating the one or more first promoter metals into the solid catalyst precursor composition during formation thereof or both, wherein the one or more first promoter metals comprise at least one metal selected from the group consisting of titanium, zirconium, vanadium, cobalt, molybdenum, tungsten, and platinum-group metals, wherein the one or more first promoter metals increase catalytic selectivity for C 5+ in a Fischer-Tropsch synthesis compared to a skeletal iron catalyst in the absence of the one or more first promoter metals; and optionally, depositing one or more second promoter metals on the skeletal iron structure or incorporating one or more second promoter metals into the catalyst precursor composition during the formation thereof or both, wherein the one or more second promoter metals comprise at least one metal selected from the group consisting of manganese, calcium, copper, chromium, potassium, and magnesium.