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An attrition resistant precipitated bulk iron catalyst is prepared from iron oxide precursor and a binder by spray drying. The catalysts are preferably used in carbon monoxide hydrogenation processes such as Fischer-Tropsch synthesis. These catalysts are suitable for use in fluidized-bed reactors, t

An attrition resistant precipitated bulk iron catalyst is prepared from iron oxide precursor and a binder by spray drying. The catalysts are preferably used in carbon monoxide hydrogenation processes such as Fischer-Tropsch synthesis. These catalysts are suitable for use in fluidized-bed reactors, transport reactors and, especially, slurry bubble column reactors.

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The invention claimed is: 1. An attrition resistant bulk iron catalyst comprising: substantially spherical particles, said particles comprising a finely divided iron component and a substantially uniformly distributed binder, said iron component being selected from the group consisting of iron oxid

The invention claimed is: 1. An attrition resistant bulk iron catalyst comprising: substantially spherical particles, said particles comprising a finely divided iron component and a substantially uniformly distributed binder, said iron component being selected from the group consisting of iron oxide precursors, iron oxide derivatives of iron oxide precursors and catalytically activated iron derivatives of iron oxide precursors, said iron component being present in an amount, calculated as Fe2O3, of at least 70 wt. %, said catalyst having an attrition loss after one hour as determined by ASTM D-5757-95 of less than about 15 wt. % based on actual catalyst weight. 2. The attrition resistant bulk iron catalyst of claim 1 wherein said binder comprises silica. 3. The attrition resistant bulk iron catalyst of claim 1 wherein said binder is derived from a binder oxide precursor of subcolloidal particle size. 4. The attrition resistant bulk iron catalyst of claim 1 wherein said catalyst additionally comprises a copper and/or potassium FTS promoter or a precursor thereof. 5. The attrition resistant bulk iron catalyst of claim 1 wherein said binder comprises less than about 20 wt. % of said catalyst. 6. The attrition resistant bulk iron catalyst of claim 1 wherein said binder comprises between about 8 and about 16 wt. % of said catalyst. 7. The attrition resistant bulk iron catalyst of claim 1 wherein said catalyst has a bulk density exceeding about 0.8 g/cm3. 8. The attrition resistant bulk iron catalyst of claim 1 wherein said iron component is present in an amount, calculated as Fe2O3, of at least 80 wt. %. 9. A process for producing an attrition resistant bulk iron catalyst comprising the steps: forming a slurry having a solids content comprising a finely divided iron component and a binder, said iron component being selected from the group consisting of iron oxide precursors, iron oxide derivatives of iron oxide precursors and catalytically activated iron derivatives of iron oxide precursors, said iron component being present in an amount, calculated as Fe2O3, of at least 70 wt. % of said solids content of said slurry; and, spray drying the slurry to form spray dried particles. 10. A process for producing an attrition resistant bulk iron catalyst according to claim 9 wherein said binder comprises polysilicic acid. 11. A process for producing an attrition resistant bulk iron catalyst according to claim 10 wherein said iron component comprises said iron oxide precursor. 12. A process for producing an attrition resistant bulk iron catalyst according to claim 11 further comprising the step of calcining said spray dried particles for a time and at a temperature sufficient to convert the iron oxide precursor to iron oxide. 13. A process for producing an attrition resistant bulk iron catalyst according to claim 12 wherein said polysilicic acid is present in said slurry in an amount sufficient to provide a binder content of less than about 20 wt. % following said calcining step. 14. A process for producing an attrition resistant bulk iron catalyst according to claim 9 wherein the slurry is treated with sufficient strong acid to reduce the pH to less than 2.0 prior to the spray drying step. 15. A process for producing an attrition resistant bulk iron catalyst according to claim 14 wherein the slurry is treated with sufficient strong acid to reduce the pH to between about 1.0 and 1.5 prior to the spray drying step. 16. A process for producing an attrition resistant bulk iron catalyst according to claim 14 wherein said strong acid is nitric acid. 17. A process for producing an attrition resistant bulk iron catalyst according to claim 15 wherein said strong acid is nitric acid. 18. A process for producing an attrition resistant bulk iron catalyst according to claim 12 further comprising the step following said calcining step, of activating said catalyst by treating the calcined particles under conditions sufficient to convert the iron oxide to at least one iron carbide. 19. A process for producing hydrocarbons comprising the steps: contacting syngas with an attrition resistant bulk iron catalyst comprising substantially spherical particles, said particles comprising a finely divided iron component and a substantially uniformly distributed binder, said iron component being selected from the group consisting of iron oxide precursors, iron oxide derivatives of said iron oxide precursors and catalytically activated iron derivatives of said iron oxide precursors, said iron component being present in an amount, calculated as Fe2O3, of at least 70 wt. %, said catalyst having an attrition loss after one hour as determined by ASTM D-5757-95 of less than about 15 wt. % based on actual catalyst weight, and recovering a product stream comprising at least one hydrocarbon. 20. The process of claim 19 wherein said contacting step is conducted in a slurry bubble column reactor. 21. The process of claim 20 wherein said syngas has a H2/CO ratio of less than 1.0. 22. The process of claim 21 wherein said hydrocarbon in said product stream comprises wax. 23. A process for producing hydrogen from carbon monoxide and steam comprising the steps: contacting a feed comprising carbon monoxide, steam, and optionally hydrogen, with an attrition resistant bulk iron catalyst comprising substantially spherical particles, said particles comprising a finely divided iron component and a substantially uniformly distributed binder, said iron component being selected from the group consisting of iron oxide precursors, iron oxide derivatives of said iron oxide precursors and catalytically activated iron derivatives of said iron oxide precursors, said iron component being present in an amount, calculated as Fe2O3, of at least 70 wt. %, said catalyst having an attrition loss after one hour as determined by ASTM D-5757-95 of less than about 15 wt. % based on actual catalyst weight, and recovering a product having an increased hydrogen content as compared to said feed stream. 24. The process of claim 23 wherein said contacting step is conducted in a slurry bubble column reactor. 25. The process of claim 24 wherein said feed has a H2/CO ratio of less than 1.0. 26. The attrition resistant bulk iron catalyst of claim 1, comprising an iron oxide precursor selected from the group consisting of iron nitrate, Fe(NO3)3, iron sulfate, iron chloride, iron acetate and an iron organometallic compound. 27. The attrition resistant bulk iron catalyst of claim 1, wherein the iron component comprises at least one selected from the group consisting of iron metal, an iron carbide and an iron oxide. 28. The attrition resistant bulk iron catalyst of claim 1, wherein the iron component comprises at least one selected from the group consisting of iron metal, iron oxide, iron nitrate, iron acetate, iron carbide, iron sulfate, and iron chloride. 29. The process of claim 9, wherein the iron component comprises at least one selected from the group consisting of iron nitrate, Fe(N)3)3, iron sulfate, iron chloride, iron acetate and an iron organometallic compound. 30. The process of claim 9, wherein the iron component comprises at least one selected from the group consisting of iron metal, an iron carbide and an iron oxide. 31. The process of claim 9, wherein the iron component comprises at least one selected from the group consisting of iron metal, iron oxide, iron nitrate, iron acetate, iron carbide, iron sulfate, and iron chloride. 32. The process of claim 19, wherein the iron component comprises at least one selected from the group consisting of iron nitrate, Fe(NO3)3, iron sulfate, iron chloride, iron acetate and an iron organometallic compound. 33. The process of claim 19, wherein the iron component comprises at least one selected from the group consisting of iron metal, an iron carbide and an iron oxide. 34. The process of claim 19, wherein the iron component comprises at least one selected from the group consisting of iron metal, iron oxide, iron nitrate, iron acetate, iron carbide, iron sulfate, and iron chloride. 35. The process of claim 23, wherein the iron component comprises at least one selected from the group consisting of iron nitrate, Fe(NO3)3, iron sulfate, iron chloride, iron acetate and an iron organometallic compound. 36. The process of claim 23, wherein the iron component comprises at least one selected from the group consisting of iron metal, an iron carbide and an iron oxide. 37. The process of claim 23, wherein the iron component comprises at least one selected from the group consisting of iron metal, iron oxide, iron nitrate, iron acetate, iron carbide, iron sulfate, and iron chloride. 38. The process of claim 19, wherein the hydrocarbon comprises a mixture of alkanes and alkenes. 39. The attrition resistant bulk iron catalyst of claim 1, wherein the binder is present in an amount of from 8 to 12 wt. %. 40. The process for producing an attrition resistant bulk iron catalyst according to claim 9, wherein the binder is present in the attrition resistant bulk iron catalyst of the spray dried particles in an amount of from 8 to 12 wt. %. 41. The process of claim 19, wherein the attrition resistant bulk iron catalyst comprises the binder in an amount of from 8 to 12 wt. %. 42. The process of claim 23, wherein the binder is present in the attrition resistant bulk iron catalyst in an amount of from 8 to 12 wt. %.