The disclosed invention relates to a process for conducting a Fischer-Tropsch reaction, comprising flowing a reactant mixture comprising fresh synthesis gas and tail gas in a microchannel reactor in contact with a catalyst to form at least one hydrocarbon product, the catalyst being derived from a c
The disclosed invention relates to a process for conducting a Fischer-Tropsch reaction, comprising flowing a reactant mixture comprising fresh synthesis gas and tail gas in a microchannel reactor in contact with a catalyst to form at least one hydrocarbon product, the catalyst being derived from a catalyst precursor comprising cobalt and a surface modified catalyst support.
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1. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microcha
1. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 2. The process of claim 1 wherein the catalyst is derived from a catalyst precursor comprising cobalt, a cobalt oxide, or a mixture thereof. 3. The process of claim 2 wherein the catalyst precursor further comprises a support. 4. The process of claim 3 wherein the support comprises a surface modified support wherein the surface modified support comprises a support which is modified by being treated with titania, zirconia, magnesia, chromia, alumina, or a mixture of two or more thereof. 5. The process of claim 3 wherein the support comprises a refractory metal oxide, carbide, carbon, nitride, or a mixture of two or more thereof. 6. The process of claim 3 wherein the support comprises alumina, zirconia, silica, titania, or a mixture of two or more thereof. 7. The process of claim 3 wherein the support comprises silica and its surface is modified by being treated with titania. 8. The process of claim 3 wherein the surface of the support is amorphous. 9. The process of claim 2 wherein the cobalt oxide comprises Co3O4 and/or CoO. 10. The process of claim 4 wherein the surface of the surface modified support is such that neutralization requires at least about 0.2 μmol NH3 per square meter. 11. The process of claim 3 wherein the support for the catalyst precursor has a FT-IR band intensity at about 950:980 cm−1 of at least about 1.2. 12. The process of claim 9 wherein the Co3O4 is in the form of particulates, the numerical average particle diameter of the Co3O4 being less than about 12 nanometers as determined by XRD. 13. The process of claim 2 wherein the catalyst precursor further comprises a noble metal. 14. The process of claim 1 wherein the microchannel reactor comprises a plurality of the process microchannels and a plurality of the heat exchange channels. 15. The process of claim 1 wherein the microchannel reactor comprises a plurality of the process microchannels and a plurality of the heat exchange channels, each heat exchange channel being in thermal contact with at least one process microchannel, at least one manifold for flowing the reactant mixture into the process microchannels, at least one manifold for flowing product out of the process microchannels, at least one manifold for flowing a heat exchange fluid into the heat exchange channels, and at least one manifold for flowing the heat exchange fluid out of the heat exchange channels. 16. The process of claim 1 wherein a plurality of the microchannel reactors are positioned in a vessel, each microchannel reactor comprising a plurality of the process microchannels and a plurality of the heat exchange channels, each heat exchange channel being in thermal contact with at least one process microchannel, the vessel being equipped with a manifold for flowing the reactant mixture to the process microchannels, a manifold for flowing the product from the process microchannels, a manifold for flowing a heat exchange fluid to the heat exchange channels, and a manifold for flowing the heat exchange fluid from the heat exchange channels. 17. The process of claim 16 wherein the vessel contains from 1 to about 1000 microchannel reactors. 18. The process of claim 1 wherein the at least one process microchannel has an internal dimension of width or height of up to about 10 mm. 19. The process of claim 1 wherein the at least one process microchannel has a length of up to about 10 meters. 20. The process of claim 1 wherein the at least one process microchannel and the at least one heat exchange channel are made of a material comprising: aluminum; titanium; nickel; copper; an alloy of any of the foregoing metals; steel; monel; inconel; brass; quartz; silicon; or a combination of two or more thereof. 21. The process of claim 1 wherein the reactant mixture flows in the at least one process microchannel and contacts surface features in the process microchannel, the contacting of the surface features imparting a disruptive flow to the reactant mixture. 22. The process of claim 1 wherein the at least one heat exchange channel comprises a microchannel. 23. The process of claim 1 wherein the catalyst is in the form of particulate solids. 24. The process of claim 1 wherein the catalyst is coated on interior walls of the at least one process microchannels or grown on interior walls of the at least one process microchannels. 25. The process of claim 1 wherein the catalyst is supported on a support having a flow-by configuration, a flow-through configuration, or a serpentine configuration. 26. The process of claim 1 wherein the catalyst is supported on a support having the configuration of a foam, felt, wad, fin, or a combination of two or more thereof. 27. The process of claim 1 wherein the catalyst is supported on a support in the form of a fin assembly comprising a plurality of fins. 28. The process of claim 1 wherein the catalyst is supported on corrugated inserts, the corrugated inserts being positioned in slots within the microchannel reactor. 29. The process of claim 1 wherein the at least one process microchannel has at least one heat transfer wall and the heat flux for heat exchange within the microchannel reactor is in the range from about 0.01 to about 500 watts per square centimeter of surface area of the at least one heat transfer wall. 30. The process of claim 1 wherein the pressure within the at least one process microchannel is in the range up to about 50 atmospheres. 31. The process of claim 1 wherein the temperature in the at least one process microchannel is in the range from about 150 to about 300° C. 32. The process of claim 1 wherein the contact time of the reactant mixture with the catalyst within the at least one process microchannel is up to about 2000 milliseconds. 33. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product comprises one or more hydrocarbons boiling at a temperature of at least about 30° C. at atmospheric pressure. 34. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product comprises one or more hydrocarbons boiling above a temperature of about 175° C. at atmospheric pressure. 35. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product comprises one or more paraffins and/or one or more olefins of 2 to about 200 carbon atoms. 36. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product comprises one or more olefins, one or more normal paraffins, one or more isoparaffins, or a mixture of two or more thereof. 37. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product is further processed using separation, fractionation, hydrocracking, hydroisomerizing, dewaxing, or a combination of two or more thereof. 38. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product is further processed to form an oil of lubricating viscosity or a middle distillate fuel. 39. The process of claim 1 wherein the at least one higher molecular weight hydrocarbon product is further processed to form a fuel. 40. The process of claim 1 wherein the process microchannel has fluid flowing in it in one direction, the at least one heat exchange channel has fluid flow in a direction that is co-current or counter-current to the flow of fluid in the at least one process microchannel. 41. The process of claim 1 wherein the at least one process microchannel has fluid flowing in it in one direction, the at least one heat exchange channel has fluid flowing in it in a direction that is cross-current to the flow of fluid in the at least one process microchannel. 42. The process of claim 1 wherein a tailored heat exchange profile is provided along the length of the at least one process microchannel, the local release of heat given off by the reaction conducted in the at least one process microchannel being matched with cooling provided by the at least one heat exchange channel. 43. The process of claim 1 wherein the catalyst comprises a graded catalyst. 44. The process of claim 1 wherein the Quality Index Factor for the microchannel reactor is less than about 50%. 45. The process of claim 1 wherein the superficial velocity for fluid flowing in the at least one process microchannel is at least about 0.01 m/s. 46. The process of claim 1 wherein the space velocity for fluid flowing in the at least one process microchannel is at least about 1000 hr−1. 47. The process of claim 1 wherein the pressure drop for fluid flowing in the at least one process microchannel is up to about 10 atmospheres per meter. 48. The process of claim 1 wherein the Reynolds number for the flow of fluid in the at least one process microchannel is in the range from about 10 to about 4000. 49. The process of claim 1 wherein the microchannel reactor comprises a plurality of the process microchannels, the process microchannels being formed by positioning a waveform between planar sheets. 50. The process of claim 49 wherein the microchannel reactor further comprises a plurality of the heat exchange channels in thermal contact with the process microchannels, the heat exchange channels being formed by positioning a waveform between planar sheets. 51. The process of claim 1 wherein the microchannel reactor comprises a plurality of plates in a stack defining a plurality of Fischer-Tropsch process layers and a plurality of heat exchange layers, each plate having a peripheral edge, the peripheral edge of each plate being welded to the peripheral edge of the next adjacent plate to provide a perimeter seal for the stack. 52. The process of claim 1 wherein the deactivation rate of the catalyst is less than a loss of about 0.2% CO conversion per day. 53. The process of claim 1 wherein the product further comprises H2O and H2, the H2O partial pressure for the product being in the range from about 3 to about 10 bar, the H2O/H2 molar ratio for the product being in the range from about 1:1 to about 5:1. 54. The process of claim 2 wherein the catalyst precursor comprises from about 10% to about 60% by weight cobalt based on the weight of the metal as a percentage of the total weight of the catalyst precursor. 55. The process of claim 2 wherein the catalyst precursor comprises from about 35% to about 60% by weight cobalt based on the weight of the metal as a percentage of the total weight of the catalyst precursor. 56. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel, the temperature in the at least one process microchannel being in the range from about 175° C. to about 225° C.;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 57. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel, the heat flux for heat exchange in the microchannel reactor being in the range from about 0.2 to about 5 W/cm2;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 58. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the length of the at least one process microchannel being in the range from about 0.2 to about 3 meters, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 59. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the at least one heat exchange channel having a heat exchange fluid in it exchanging heat with the at least one process microchannel;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1, the contact time of the reactant mixture with the catalyst being in the range from 20 to about 500 milliseconds;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 60. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the length of the at least one process microchannel being in the range from about 0.2 to about 3 meters, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1, the contact time of the reactant mixture with the catalyst being in the range from about 20 to about 500 milliseconds;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 61. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the length of the at least one process microchannel being in the range from about 0.2 to about 3 meters, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel, the heat flux for heat exchange in the microchannel reactor being in the range from about 0.2 to about 5 W/cm2;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1, the contact time of the reactant mixture with the catalyst being in the range from about 20 to about 500 milliseconds;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the deactivation rate of the catalyst is less than about 1.4% per day; andthe selectivity to methane in the product is in the range from about 0.01 to 10%. 62. A process for conducting a Fischer-Tropsch reaction, comprising: flowing a reactant mixture in a microchannel reactor in contact with a catalyst to form a product comprising at least one higher molecular weight hydrocarbon product, the microchannel reactor comprising at least one process microchannel and at least one heat exchange channel in thermal contact with the at least one process microchannel, the catalyst being in the at least one process microchannel, the at least one heat exchange channel having a heat exchange fluid in it for exchanging heat with the at least one process microchannel;wherein the product further comprises tail gas, at least part of the tail gas being separated from the higher molecular weight hydrocarbon product and combined with fresh synthesis gas to form the reactant mixture, the volumetric ratio of the fresh synthesis gas to the tail gas in the reactant mixture being in the range from about 1:1 to about 10:1;the reactant mixture comprising H2 and CO, the mole ratio of H2 to CO in the reactant mixture based on the concentration of CO in the fresh synthesis gas being in the range from about 1.4:1 to about 2.1:1;wherein the conversion of CO from the fresh synthesis gas in the reactant mixture is in the range from about 88% to about 95%, and the gas hourly space velocity for the flow of fluid in the at least one process microchannel being in the range from about 1000 to about 20,000 hr−1; andthe selectivity to methane in the product is in the range from about 0.01 to 10%.
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