Production of alkanes from mixtures of CO and H2

Claim 2

A process for producing hydrocarbons, including alkane hydrocarbons, from gaseous mixtures of CO and H 2 comprising contacting said mixture, at a temperature ranging from about 200° to 350° C. and for a time sufficient to convert at least a portion of said feed to alkane hydrocarbons, with a catalyst comprising a mixture of iron carbide and ilmenite supported on titania wherein the amount of said supported iron present in said supported iron carbide and ilmenite, calculated as Fe 2 O 3 , is at least about 2×10 -3 grams per square meter of titania support surface.

Claim 3

The process of claim 1 wherein said alkane hydrocarbons comprise greater than 50% of the hydrocarbons, including methane, produced by said process.

Claim 4

The processs of claim 2 wherein said process occurs at a pressure of at least about 100 psig.

Claim 5

The process of claim 3 wherein the amount of supported iron present in said supported iron carbide and ilmenite, calculated as Fe 2 O 3 , ranges between about 2 to 25 milligrams of iron per square meter of titania support surface.

Claim 6

The process of claim 4 wherein said catalyst contains one or more alkali metal promoters present in said catalyst in an amount of from about 0.5 to 5 wt.% based on the amount of iron, calculated as Fe 2 O 3 , present on said catalyst.

Claim 7

The process of either of claims 3, 4 or 1 wherein the mole ratio of H 2 to CO in said gaseous mixture is between about 1/2 to 3/1.

Claim 8

A process for producing predominantly alkane hydrocarbons from gaseous feed mixtures of H 2 and CO comprising contacting said feed, at a temperature of from about 200° to 350° C. and for a time sufficient to convert with at least a portion of said feed to alkane hydrocarbons, with a catalyst comprising a mixture of iron carbide and ilmenite supported on titania, wherein the amount of iron present in said supported iron carbide and ilmenite, calculated as Fe 2 O 3 , is at least about 2×10 -3 grams of iron per square meter of titania support surface, said catalyst having been formed by depositing an iron precursor compound on said titania support to form an iron/titania composite, calcining said composite to decompose said precursor compound and convert at least a portion thereof to iron oxide, followed by reducing said iron oxide/titania composite by first contacting same with hydrogen at a temperature of at least about 300° C. for a time sufficient to form a reduced composite and then contacting said reduced composite with CO at a temperature of at least about 200° C. for a time sufficient to form said catalyst.

Claim 9

A process for producing predominantly alkane hydrocarbons from gaseous feed mixtures of H 2 and CO comprising contacting said feed, at a temperature of from about 200° to 350° C. and for a time sufficient to convert with at least a portion of said feed to alkane hydrocarbons, with a catalyst comprising a mixture of iron carbide and ilmenite supported on titania, wherein the amount of iron present in said supported iron carbide and ilmenite, calculated as Fe 2 O 3 , is at least about 2×10 -3 grams of iron per square meter of titania support surface, said catalyst having been formed by depositing an iron precursor compound on said titania support to form an iron/titania composite, calcining said composite to decompose said precursor compound and convert at least a portion thereof to iron oxide, followed by reducing said iron oxide/titania composite by first contacting same with hydrogen at a temperature of at least about 300° C. for a time sufficient to form a reduced composite and then contacting said reduced composite with CO at a temperature of at least about 200° C. for a time sufficient to form said catalyst.

Claim 10

The process of claim 7 wherein the amount of iron supported on said catalyst ranges between about 2 to 25 milligrams of iron per square meter of titania support surface.

Claim 11

The process of claim 8 wherein said catalyst has been contacted with CO at elevated temperature prior to use and after the composite has been reduced with hydrogen.

Claim 12

The process of claim 9 wherein said catalyst contains one or more alkali promoter metals wherein the amount of said promoter metal present on said catalyst ranges between about 0.5 to 5 wt.% based on the amount of iron in the ilmenite and iron carbide, calculated as Fe 2 O 3 , supported on said catalyst.

Claim 13

The process of either of claims 9 or 10 wherein the amount of iron present in the ilmenite and iron carbide supported on said catalyst, calculated as Fe 2 O 3 , is between about 2.8 to 8.3 milligrams per square meter of titania support surface.

Claim 14

The process of claim 11 wherein the mole ratio of H 2 to CO in said gaseous feed mixture is between 1/2 to 3/1.