초록 ▼

A method for producing a cobalt on alumina catalyst is disclosed. The catalyst is prepared by thoroughly mixing cobalt nitrate into a peptized alumina slurry, and then spray-drying the slurry to form attrition resistant microspheres. The cobalt prepared by this invention is fully reducible. Option

A method for producing a cobalt on alumina catalyst is disclosed. The catalyst is prepared by thoroughly mixing cobalt nitrate into a peptized alumina slurry, and then spray-drying the slurry to form attrition resistant microspheres. The cobalt prepared by this invention is fully reducible. Optionally, metals such as ruthenium can be added to the cobalt/alumina catalyst by impregnation or methods known in the prior art.

대표청구항 ▼

What is claimed is: 1. A method for the preparation of an attrition-resistant, cobalt-alumina catalyst comprising the steps: a) preparing an alumina slurry by combining an alumina powder with a peptizing agent, wherein said peptizing agent is selected from the group consisting of an acidic aluminum

What is claimed is: 1. A method for the preparation of an attrition-resistant, cobalt-alumina catalyst comprising the steps: a) preparing an alumina slurry by combining an alumina powder with a peptizing agent, wherein said peptizing agent is selected from the group consisting of an acidic aluminum salt, an acidic cobalt salt, a mineral acid, a carboxy acid, and combinations thereof; b) combining a cobalt source with said alumina slurry; c) allowing said cobalt and alumina slurry to gel; d) homogenizing said cobalt and alumina gel with a sufficient amount of water to form a homogenized slurry; and e) spray-drying said homogenized slurry to form attrition resistant cobalt-alumina catalyst particles, wherein said catalyst comprises about 5 wt % to about 60 wt % cobalt and about 40 wt % to about 95 wt % alumina. 2. The method of claim 1 further including milling said alumina slurry before combining with said cobalt source. 3. The method of claim 1 further including milling said alumina sluny after combining with said cobalt source. 4. The method of claim 1 wherein said mineral acid and carboxy acid are not monobasic acids. 5. The method of claim 1 wherein said attrition resistance is less than about 2. 6. The method of claim 1 further including impregnating said catalyst particles with about 0.0001 wt % to about 5 wt % of at least one promoter. 7. The method of claim 6 wherein said at least one promoter is selected from the group consisting of Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Cu, Ag, Au, Sc, Y, La, Ti, Zr, Hf, V, Nb, Ta, Rh, Pd, Os, 1k, Pt, Mn, B, P, Re, Ru and combinations thereof. 8. The method of claim 1 further including calcining said catalyst particles after spray-drying. 9. The method of claim 1 wherein said peptizing agent is selected from the group consisting of an acidic aluminum salt, an acidic cobalt salt, and combinations thereof. 10. The method of claim 1 wherein said acidic aluminum salt is aluminum nitrate. 11. The method of claim 1 wherein said acidic cobalt salt is cobalt nitrate. 12. The method of claim 1 wherein said cobalt source is selected from the group consisting of metallic cobalt, cobalt oxide, a basic cobalt salt, cobalt ammine hydroxide, cobalt ammine carbonate, cobalt hydroxide, cobalt hydroxy carbonate, an acidic cobalt salt, cobalt nitrate, cobalt nitrate hydrate, cobalt acetate, cobalt acetate hydrate, cobalt forrnate, cobalt acetylacetonate, cobalt oxalate, cobalt phosphate hydrate, and combinations thereof. 13. The method of claim 1 wherein said cobalt source is selected from the group consisting of cobalt nitrate, cobalt nitrate hydrate, cobalt acetate, cobalt acetate hydrate, cobalt fonnate, cobalt acetylacetonate, cobalt oxalate, cobalt phosphate hydrate, and combinations thereof. 14. The method of claim 1 wherein said cobalt source is cobalt nitrate. 15. The method of claim 1 wherein said homogenized slurry has a percent solids content of from about 5% solids to about 50% solids. 16. The method of claim 1 wherein said cobalt-alumina catalyst particles are microspheres having a median particle size between about 10 microns and 200 microns. 17. A catalyst made by the method of claim 1. 18. A method for the preparation of a cobalt-alumina catalyst comprising the steps: a) preparing an alumina slurry by combining alumina powder with a peptizing agent selected from the group consisting of aluminum nitrate, cobalt nitrate and combinations thereof; b) combining a cobalt source with said alumina slurry; c) allowing said cobalt and alumina slurry to gel; d) adding a sufficient amount of water to said cobalt and alumina gel so that said gel is pumpable; e) homogenizing said gel; and f) spray-drying said homogenized gel to form cobalt-alumina catalyst particles, wherein said cobalt source is selected from the group consisting of metallic cobalt, cobalt oxide, cobalt nitrate, cobalt nitrate hydrate, cobalt acetate, cobalt acetate hydrate, cobalt fonnate, cobalt acetylacetonate, cobalt oxalate, cobalt phosphate hydrate, and combinations thereon and said catalyst comprises about 5 wt % to about 60 wt % cobalt. 19. The method of claim 18 further including milling said alumina slurry before combining with said cobalt source. 20. The method of claim 19 further including milling said alumina slurry to produce a homogenized alumina slurry having a percent solids content of about 5% solids to about 50% solids. 21. The method of claim 18 further including milling said alumina slurry after combining with said cobalt source. 22. The method of claim 21 further including milling said alumina slurry to produce a homogenized alumina slurry having a percent solids content of about 5% solids to about 50% solids. 23. The method of claim 18 wherein said acidic aluminum salt is aluminum nitrate. 24. The method of claim 18 wherein said catalyst comprises about 40 wt % to about 95 wt % alumina. 25. The method of claim 18 further including impregnating said catalyst particles with about 0.0001 wt % to about 5 wt % of at least one promoter. 26. The method of claim 25 wherein said at least one promoter is selected from the group consisting of Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Cu, Ag, Au, Sc, Y, La, Ti, Zr, Hf, V, Nb, Ta, Rh, Pd, Os, Ir, Pt, Mn, B, P, Re, Ru and combinations thereof. 27. The method of claim 18 further including calcining said catalyst particles. 28. The method of claim 18 wherein said cobalt source is cobalt nitrate. 29. The method of claim 18 wherein said cobalt-alumina catalyst particles are microspheres having a median particle size between about 10 microns and 200 microns. 30. A catalyst made by the method of claim 18. 31. A method for the preparation of a cobalt-alumina catalyst comprising the steps: a) preparing an alumina slurry by adding alumina powder to an aqueous solution of a peptizing agent, wherein said peptizing agent is selected from the group consisting of aluminum nitrate, cobalt nitrate and combinations thereof; b) adding a cobalt source to said alumina slurry; c) milling said cobalt and alumina slurry; d) allowing said cobalt and alumina slurry to gel; e) adding a sufficient amount of water to said cobalt and alumina gel so that said gel has a percent solids content of about 5% solids to about 60% solids; f) homogenizing said gel; and g) spray-drying said homogenized gel to form cobalt-alumina catalyst particles, wherein said catalyst comprises about 5 wt % to about 60 wt % cobalt. 32. The method of claim 31 wherein said spray drying is performed using a wheel atomizer spray dryer with an inlet temperature set from about 350° F. to about 1000° F., an outlet temperature set from about 220° F. to about 500° F., and a wheel speed of from about 1000 rpm to about 30000 rpm. 33. The method of claim 31 further including impregnating said catalyst particles with about 0.0001 wt % to about 5 wt % of at least one promoter, wherein said at least one promoter is selected from the group consisting of Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Cu, Ag, Au, Sc, Y, La, Ti, Zr, Hf, V. Nb, Ta, Rh, Pd, Os, Ir, Pt, Mn, B, P, Re, Ru and combinations thereof. 34. The method of claim 31 wherein said cobalt source is selected from the group consisting of metallic cobalt cobalt oxide, cobalt nitrate, cobalt nitrate hydrate, cobalt acetate, cobalt acetate hydrate, cobalt formate, cobalt acetylacetonate, cobalt oxalate, cobalt phosphate hydrate, and combinations thereof. 35. The method of claim 31 wherein said peptizing agent is cobalt nitrate and said cobalt source is cobalt nitrate. 36. A catalyst made by the method of claim 31.