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A stabilized catalyst support having improved hydrothermal stability, catalyst made therefrom, and method for producing hydrocarbons from synthesis gas using said catalyst. The stabilized support is made by a method comprising treating a crystalline hydrous alumina precursor in contact with at least

A stabilized catalyst support having improved hydrothermal stability, catalyst made therefrom, and method for producing hydrocarbons from synthesis gas using said catalyst. The stabilized support is made by a method comprising treating a crystalline hydrous alumina precursor in contact with at least one structural stabilizer or compound thereof. The crystalline hydrous alumina precursor preferably includes an average crystallite size selected from an optimum range delimited by desired hydrothermal resistance and desired porosity. The crystalline hydrous alumina precursor preferably includes an alumina hydroxide, such as crystalline boehmite, crystalline bayerite, or a plurality thereof differing in average crystallite sizes by at least about 1 nm. The crystalline hydrous alumina precursor may be shaped before or after contact with the structural stabilizer or compound thereof. The treating includes calcining at 450�� C. or more. Preferred structural stabilizers can include cobalt, magnesium, manganese, manganese, zirconium, boron, aluminum, barium, silicon, lanthanum, oxides thereof, or combinations thereof.

대표청구항 ▼

The invention claimed is: 1. A method for making a catalyst precursor with an enhanced hydrothermal stability comprising: preparing a stabilized catalyst support by a method comprising contacting a boehmite material with at least one structural stabilizer or a compound thereof, wherein the boehmite

The invention claimed is: 1. A method for making a catalyst precursor with an enhanced hydrothermal stability comprising: preparing a stabilized catalyst support by a method comprising contacting a boehmite material with at least one structural stabilizer or a compound thereof, wherein the boehmite material comprises two or more crystalline boehmites having different average crystallite sizes differing by at least about 1 nm; and subjecting the boehmite material to at least one heat treatment employing a temperature of about 450�� C. or higher, either before or after the contacting step; and applying a catalytic metal or a compound thereof to said stabilized catalyst support to form a catalyst precursor, wherein the catalytic metal comprises a Group 8 metal, Group 9 metal, Group 10 metal, or combinations thereof. 2. The method according to claim 1 wherein at least one of the two or more crystalline boehmites comprises an average crystallite size in a range of from about 4 nm to about 30 nm. 3. The method according to claim 2 wherein the at least one of the two or more crystalline boehmites comprises an average crystallite size in a range of from about 6 nm to about 30 nm. 4. The method according to claim 2 wherein the at least one of the two or more crystalline boehmites comprises an average crystallite size in a range of from about 8 nm to about 25 nm. 5. The method according to claim 2 wherein the at least one of the two or more crystalline boehmites comprises an average crystallite size in a range of from about 4 nm to about 20 nm. 6. The method according to claim 2 wherein the at least one of the two or more crystalline boehmites comprises an average crystallite size in a range of from about 15 nm to about 25 nm. 7. The method according to claim 1 wherein the boehmite material comprises a first crystalline boehmite having a first average crystallite size between about 4 nm and about 30 nm and a second crystalline boehmite having a second average crystallite size between about 20 nm and about 40 nm. 8. The method according to claim 7 wherein the second crystalline boehmite has a second average crystallite size from about 20 nm to about 35 nm. 9. The method according to claim 7 wherein the second crystalline boehmite has a second average crystallite size from about 25 nm to about 35 nm. 10. The method according to claim 1 wherein the structural stabilizer comprises at least one element selected from the group consisting of tungsten, tantalum, niobium, thorium, germanium, selenium, uranium, tin, antimony, vanadium, halfnium, sodium, potassium, boron, magnesium, aluminum, silicon, calcium, titanium, chromium, manganese, iron, cobalt, nickel, copper, zinc, gallium, strontium, zirconium, barium, thorium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, yterrbium, lutetium, oxides thereof, and combinations thereof. 11. The method according to claim 1 wherein the structural stabilizer comprises at least one element selected from the group consisting of cobalt, magnesium, manganese, zirconium, boron, aluminum, barium, silicon, lanthanum, zinc, oxides thereof, and any combination of two or more thereof. 12. The method according to claim 1 wherein the structural stabilizer comprises at least one element selected from the group consisting of cobalt, magnesium, manganese, zirconium, aluminum, silicon, oxides thereof, and any combination of two or more thereof. 13. The method according to claim 1 wherein the stabilized catalyst support has an average particle size greater than about 30 microns. 14. The method according to claim 13 wherein the average particle size of the stabilized catalyst support is between about 30 microns and about 150 microns. 15. The method according to claim 13 wherein the average particle size of the stabilized catalyst support is between about 50 microns and about 100 microns. 16. The method according to claim 1 wherein the stabilized catalyst support has a BET surface area between about 50 m2/g and about 250 m2/g based on the total weight of the stabilized catalyst support. 17. The method according to claim 1 wherein the stabilized catalyst support has an average pore size greater than about 6 nm. 18. The method according to claim 1 wherein the at least one heat treatment employed during the preparing step of the stabilized catalyst support is performed after the contacting step, and further comprises calcining the boehmite material contacted with the at least one structural stabilizer or compound thereof at a temperature of about 450�� C. or higher to effect the conversion of the two or more crystalline boehmites to a stabilized aluminum oxide structure. 19. The method according to claim 18 wherein the at least one heat treatment comprises calcining the boehmite material contacted with the at least one structural stabilizer or compound thereof at a temperature between about 450�� C. and about 900�� C. 20. The method according to claim 18 wherein the at least one heat treatment comprises calcining the boehmite material contacted with the at least one structural stabilizer or compound thereof at a temperature between about 500�� C. and about 850�� C. 21. The method according to claim 18 wherein the at least one heat treatment comprises calcining the boehmite material contacted with the at least one structural stabilizer or compound thereof at a temperature between about 900�� C. and about 1600�� C. 22. The method according to claim 1 wherein the at least one heat treatment employed during the preparing step of the stabilized catalyst support is performed before the contacting step, and the preparing step comprises calcining the boehmite material at a temperature of about 450�� C. or higher to effect the conversion of the two or more crystalline boehmites to an aluminum oxide structure and form a calcined boehmite material, and thereafter contacting said calcined boehmite material with the at least one structural stabilizer or compound thereof. 23. The method according to claim 1 wherein the contacting step comprises impregnating a soluble decomposable compound of the at least one structural stabilizer onto the boehmite material. 24. The method according to claim 1 wherein the contacting step comprises impregnating an oxide of the at least one structural stabilizer onto the boehmite material. 25. The method according to claim 24 wherein the contacting step comprises applying a colloidal suspension comprising the oxide of the at least one structural stabilizer. 26. The method according to claim 1 further comprising shaping the boehmite material in the form of particles of a desired average particle size before the at least one heat treatment which employs a temperature of about 450�� C. or higher. 27. The method according to claim 26 wherein the shaping step comprises spray-drying. 28. The method according to claim 26 wherein the shaping step comprises extrusion. 29. The method according to claim 26 wherein the shaping step is performed after the contacting step. 30. The method according to claim 29 wherein the stabilized support preparation comprises contacting the boehmite material with the at least one structural stabilizer or compound thereof; shaping the contacted boehmite material; and calcining the shaped contacted material at a temperature of about 450�� C. or higher. 31. The method according to claim 26 wherein the shaping step is performed before the contacting step. 32. The method according to claim 31 wherein the stabilized support preparation comprises shaping the boehmite material; optionally, heat-treating the shaped boehmite material at a temperature of about 350�� C. or less to retain at least a majority of the crystalline boehmites; contacting the shaped boehmite material with the at least one structural stabilizer or compound thereof; and calcining the contacted shaped boehmite material at a temperature of about 450�� C. or higher. 33. The method according to claim 1 further including contacting the boehmite material with a pore-regulating agent before the shaping step. 34. The method according to claim 33 wherein the contacting step with the pore-regulating agent and the contacting step with the structural stabilizer or compound thereof are performed simultaneously. 35. The method according to claim 33 wherein the contact with the pore-regulating agent is before or after the contacting step with the structural stabilizer or compound thereof, and a heat-treatment is further performed between the two contacting steps at a temperature of about 350�� C. or less. 36. The method according to claim 33 wherein the pore-regulating agent is selected from the group consisting of nitric acid; acetic acid; any polycarboxylic acid containing between 2 and 22 carbon atoms; ammonium hydroxide; ammonium carbonate; ammonium bicarbonate; ammonium fomate; ammonium acetate; ammonium propionate; tetra-alkyl ammonium with alkyl being methyl, ethyl, propyl, butyl, or any combination thereof; graphite; ethylene oxide; ethylene glycol; propylene oxide; propylene glycol; acrylamide; ethylene amine; any polyethylene oxide; any polyethylene glycol; any polypropylene glycol; any polyethylene amine; any polyacrylamide; any polyvinyl alcohol; cellulose; methyl cellulose; any methyl cellulose ether; and any combinations of two or more thereof. 37. The method according to claim 1 wherein the two or more crystalline boehmites in the boehmite material are in the form of powders. 38. The method according to claim 37 wherein the boehmite material comprises a slurry or a sol containing said boehmite powders, wherein the slurry or sol has a solid content between about 20 wt % and about 45 wt % solids. 39. The method according to claim 37 wherein the boehmite material comprises a paste containing said boehmite powders, wherein the paste comprises a solid content between about 80 wt % and about 95 wt %. 40. The method according to claim 1 wherein the stabilized catalyst support preparation comprises mixing the two or more crystalline boehmites in a solvent to form a boehmite mixture; shaping the boehmite mixture in the absence of the at least one structural stabilizer or compound thereof to generate a shaped boehmite material in the form of particles of a desired average particle size; optionally, heat-treating the shaped boehmite material at a temperature of not more than 350�� C., so as to retain substantially the two or more crystalline boehmites; contacting the shaped boehmite material with the at least one structural stabilizer or compound thereof and subjecting the contacted shaped boehmite material to at least one heat treatment employing a temperature of about 450�� C. or higher. 41. The method according to claim 1 wherein the stabilized catalyst support preparation comprises mixing the two or more crystalline boehmites and the at least one structural stabilizer or compound thereof in a solvent to form a contacted boehmite mixture; shaping the contacted boehmite mixture to generate a shaped contacted boehmite material in the form of particles of a desired average particle size greater than about 30 microns; optionally, heat-treating the shaped boehmite material at a temperature of not more than 350�� C., so as to retain substantially the two or more crystalline boehmites; and calcining the contacted shaped boehmite material at a temperature of about 450�� C. or higher. 42. The method according to claim 1 wherein the contacting step in the method of preparing said stabilizing catalyst support comprises: a) forming a mixture of said boehmite material and a first portion of said structural stabilizer; b) drying the mixture to form a dried mixture comprising said first portion of said structural stabilizer and said boehmite material; c) treating said dried mixture to form a partially-stabilized support; d) applying a second portion of said structural stabilizer to the partially-stabilized support to form a support precursor; and further wherein the step of subjecting to at least one heat treatment is carried out after said contacting step by treating said support precursor to form said stabilized catalyst support. 43. The method according to claim 1 wherein the method of preparing said stabilized catalyst support comprises contacting said boehmite material with more than one compound of the at least one structural stabilizer. 44. A method for making a catalyst precursor with an enhanced hydrothermal stability, comprising: a) shaping a material comprising a crystalline hydrous alumina precursor to form a shaped alumina precursor material in the form of particles with a desired average particle size, wherein the crystalline hydrous alumina precursor comprises at least one crystalline boehmite having an average crystallite size from about 4 nm to about 30 nm or comprises at least one crystalline bayerite; b) optionally, treating the shaped alumina precursor material to a temperature not exceeding about 350�� C. so as to retain a substantial portion of the crystalline hydrous alumina precursor; c) contacting the shaped alumina precursor material containing the crystalline hydrous alumina precursor with at least one structural stabilizer or a compound thereof; d) calcining the shaped alumina precursor material in the presence of the at least one structural stabilizer or compound thereof under suitable conditions to effect the conversion of the crystalline hydrous alumina precursor to a stabilized aluminum oxide structure and to generate a stabilized catalyst support; and e) applying a catalytic metal or a compound thereof to said stabilized catalyst support to form the catalyst precursor, wherein the catalytic metal comprises a Group 8 metal, Group 9 metal, Group 10 metal, or combinations thereof. 45. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size in a range of from about6 nm to about 30 nm. 46. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size in a range of from about8 nm to about 25 nm. 47. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size in a range of from about 4 nm to about 20 nm. 48. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size in a range of from about 15 nm to about 25 nm. 49. The method according to claim 44 wherein the stabilized aluminum oxide structure comprises a transition alumina matrix which includes at least a portion of the structural stabilizer or compound thereof, wherein the transition alumina matrix includes an alumina phase selected from the group consisting of gamma-alumina; eta-alumina; delta alumina; theta-alumina, and any combinations of two or more thereof. 50. The method according to claim 44 wherein the stabilized aluminum oxide structure comprises a gamma-alumina matrix which includes at least a portion of the structural stabilizer or compound thereof. 51. The method according to claim 44 wherein the stabilized aluminum oxide structure comprises a theta-alumina matrix which includes at least a portion of the structural stabilizer or oxide thereof. 52. The method according to claim 44 wherein the structural stabilizer comprises at least one element selected from the group consisting of tungsten, tantalum, niobium, thorium, germanium, selenium, uranium, tin, antimony, vanadium, halfnium, sodium, potassium, boron, magnesium, aluminum, silicon, calcium, titanium, chromium, manganese, iron, cobalt, nickel, copper, zinc, gallium, strontium, zirconium, barium, thorium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, yterrbium, lutetium, oxides thereof, and any combinations of two or more thereof. 53. The method according to claim 44 wherein the structural stabilizer comprises at least one element selected from the group consisting of cobalt, magnesium, manganese, zirconium, boron, aluminum, barium, silicon, lanthanum, zinc, oxides thereof, and any combinations of two or more thereof. 54. The method according to claim 44 wherein the structural stabilizer comprises at least one element selected from the group consisting of cobalt, magnesium, manganese, zirconium, aluminum, silicon, oxides thereof, and any combination of two or more thereof. 55. The method according to claim 44 wherein the calcining step is performed at a temperature between about 450�� C. and about 850�� C. 56. The method according to claim 44 wherein the calcining step is performed at a temperature between about 500�� C. and about 850�� C. 57. The method according to claim 44 wherein the calcining step is performed at a pressure of about 100 kPa or more. 58. The method according to claim 44 wherein the calcining step is performed at a temperature between about 900�� C. and about 1600�� C. 59. The method according to claim 44 wherein the shaping step comprises spray-drying. 60. The method according to claim 44 wherein the particles of the shaped boehmite material have a particle size between about 10 microns and about 250 microns. 61. The method according to claim 44 wherein the desired average particle size is between about 30 microns and about 150 microns. 62. The method according to claim 44 wherein the desired average particle size is between about 50 microns and about 100 microns. 63. The method according to claim 44 wherein the shaping step comprises extrusion. 64. The method according to claim 63 wherein the desired average particle size is greater than about 0.5 millimeters. 65. The method according to claim 44 wherein the contacting step employs a compound of the at least one structural stabilizer, and said compound of the at least one structural stabilizer comprises a salt, an acid, a hydroxide, an oxide, an organic compound of the at least one structural stabilizer or any combination of two or more thereof. 66. The method according to claim 44 wherein the contacting step employs a compound of the at least one structural stabilizer, and said compound of the at least one structural stabilizer includes an oxide of the at least one structural stabilizer. 67. The method according to claim 44 wherein said compound of the at least one structural stabilizer includes a colloidal suspension comprising an oxide of the at least one structural stabilizer. 68. The method according to claim 44 wherein the contacting step employs a compound of the at least one structural stabilizer, and said compound of the at least one structural stabilizer includes an alkoxide of the at least one structural stabilizer. 69. The method according to claim 44 wherein the contacting step employs a compound of the at least one structural stabilizer, and said compound of the at least one structural stabilizer excludes an alkoxide of the at least one structural stabilizer. 70. The method according to claim 44 wherein the contacting step employs a compound of the at least one structural stabilizer, said compound of the at least one structural stabilizer being decomposable to an oxide form during the calcining of step (d). 71. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a non-dispersible crystalline boehmite. 72. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a dispersible crystalline boehmite. 73. The method according to claim 44 wherein the contacting step comprises forming a mixture of a compound of at least one structural stabilizer and the shaped alumina precursor material in a solvent, wherein the compound of at least one structural stabilizer is insoluble in said solvent. 74. The method according to claim 44 wherein the contacting step comprises forming a mixture of a compound of at least one structural stabilizer and the shaped alumina precursor material in a solvent, wherein the compound of at least one structural stabilizer is dissolved in said solvent. 75. The method according to claim 74 wherein the contacting step comprises impregnating a compound of the at least one structural stabilizer onto the shaped alumina precursor material. 76. The method according to claim 44 wherein the material before the shaping step is in a form of a powder. 77. The method according to claim 44 wherein the material before the shaping step is in the form of a sol or a slurry. 78. The method according to claim 44 wherein the material before the shaping step is in the form of a paste. 79. The method according to claim 44 wherein the crystalline hydrous alumina precursor comprises a first crystalline boehmite having a first average crystallite size and a second crystalline boehmite having a second average crystallite size, wherein the first average crystallite size is at least about 1 nm smaller than the second average crystallite size. 80. The method according to claim 79 wherein the first crystalline boehmite has a first average crystallite size equal to or greater than about 4 nm, and the second crystalline boehmite has a second average crystallite size equal to or lower than about 40 nm. 81. A method for making a catalyst precursor with enhanced hydrothermal stability, comprising: providing a material comprising a crystalline hydrous alumina precursor, wherein the crystalline hydrous alumina precursor comprises at least one crystalline boehmite having an average crystallite size selected from an optimum range from about 4 nm to about 30 nm, or comprises at least one crystalline bayerite; contacting the material with at least one structural stabilizer or a compound thereof; shaping the contacted material in the presence of the compound of the at least one structural stabilizer so as to form a shaped alumina precursor material in the form of particles of a desired average particle size, wherein the shaped alumina precursor material comprises the crystalline hydrous alumina precursor and the at least one structural stabilizer or compound thereof; calcining the shaped alumina precursor material under suitable calcination conditions to effect the conversion of the crystalline hydrous alumina precursor to a stabilized aluminum oxide structure and to generate a stabilized catalyst support; and applying a catalytic metal or a compound thereof to said stabilized catalyst support to form a catalyst precursor, wherein the catalytic metal comprises a Group 8 metal, a Group 9 metal, a Group 10 metal, or combinations thereof. 82. The method according to claim 81 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size between about 6 nm and about 30 nm. 83. The method according to claim 81 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size between about 8 nm and about 25 nm. 84. The method according to claim 81 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size between about 4 nm and about 20 nm. 85. The method according to claim 81 wherein the crystalline hydrous alumina precursor comprises a crystalline boehmite having an average crystallite size between about 15 nm and about 25 nm. 86. The method according to claim 81 wherein the crystalline hydrous alumina precursor comprises a crystalline bayerite or a plurality of crystalline bayerites. 87. The method according to claim 81 wherein the crystalline hydrous alumina precursor comprises a first crystalline boehmite having a first average crystallite size and a second crystalline boehmite having a second average crystallite size, wherein the first average crystallite size is at least about 1 nm smaller than the second average crystallite size. 88. The method according to claim 87 wherein the first crystalline boehmite has a first average crystallite size equal to or greater than about 4 nm, and the second crystalline boehmite has a second average crystallite size equal to or lower than about 40 nm. 89. The method according to claim 81 wherein the crystalline hydrous alumina precursor before the shaping step is in the form of a powder comprising primarily micron-sized particles. 90. The method according to claim 81 wherein the desired average particle size is between about 30 microns and about 150 microns. 91. The method according to claim 81 wherein the desired average particle size is between about 50 microns and about 100 microns. 92. The method according to claim 81 wherein the desired average particle size is between about 60 microns and about 90 microns. 93. The method according to claim 81 wherein the calcining step is performed at a pressure of about 100 kPa or more. 94. The method according to claim 81 wherein the calcining step is performed at a temperature between about 450�� C. and about 900�� C. 95. The method according to claim 81 wherein the calcining step is performed at a temperature between about 500�� C. and about 850�� C. 96. The method according to claim 81 wherein the calcining step is performed at a temperature between about 600�� C. and about 850�� C. 97. The method according to claim 81 wherein the calcining step is performed at a temperature between about 900�� C. and about 1600�� C. 98. The method according to claim 81 wherein the calcining step is performed at a temperature between about 1000�� C. and about 1500�� C. 99. The method according to claim 81 wherein the stabilized catalyst support has a BET surface area between about 50 m2/g and about 250 m2/g based on the total weight of the stabilized catalyst support. 100. The method according to claim 81 wherein the stabilized catalyst support has a BET surface area between about 70 m2/g and about 200 m2/g based on the total weight of the stabilized catalyst support. 101. The method according to claim 81 wherein the stabilized catalyst support has an average pose size greater than about 6 nm. 102. The method according to claim 81 wherein the stabilized catalyst support has an average pose size from about 6 nm to about 20 nm. 103. The method according to claim 81 further including contacting the crystalline hydrous alumina precursor with a pore-regulating agent before the shaping step. 104. The method according to claim 103 wherein the contacting step with the pore-regulating agent and the contacting step with the structural stabilizer or compound thereof are performed simultaneously. 105. The method according to claim 103 wherein the contacting with the pore-regulating agent is before or after the contacting step with the structural stabilizer or compound thereof, and a heat-treatment is further performed between the two contacting steps at a temperature of about 350�� C. or less. 106. The method according to claim 103 wherein the pore-regulating agent is selected from the group consisting of nitric acid; acetic acid; any polycarboxylic acid containing between 2 and 22 carbon atoms; ammonium hydroxide; ammonium carbonate; ammonium bicarbonate; ammonium formate; ammonium acetate; ammonium propionate; tetra-alkyl ammonium with alkyl being methyl, ethyl, propyl, butyl, or any combinations thereof graphite; ethylene oxide; ethylene glycol; propylene oxide; propylene glycol; acrylamide; ethylene amine; any polyethylene oxide; any polyethylene glycol; any polypropylene glycol; any polyethylene amine; any polyacrylamide; any polyvinyl alcohol; cellulose; methyl cellulose; any methyl cellulose ether; and any combinations of two or more thereof. 107. The method according to claim 81, wherein the contacting step comprises contacting said material with more than one compound of the at least one structural stabilizer.