Disclosed herein, inter alia, are novel nickel-ruthenium-magnesium oxide catalyst compositions and methods of making and using the same. The catalysts provide for improved methanation activity of syngas (CO+H.sub.2) and producer gas in, for example, a fixed-bed reactor. In this manner, the CO conversion and CH.sub.4 yield can be maximized in methanation reactions.

Disclosed herein, inter alia, are novel nickel-ruthenium-magnesium oxide catalyst compositions and methods of making and using the same. The catalysts provide for improved methanation activity of syngas (CO+H.sub.2) and producer gas in, for example, a fixed-bed reactor. In this manner, the CO conversion and CH.sub.4 yield can be maximized in methanation reactions.

A composite catalyst containing heteroatom-doped zeolite for preparing light olefin using direct conversion of syngas formed by compounding component I and component II in a mechanical mixing mode. The active ingredient of component I is a metal oxide, and the component II is a heteroatom-doped zeolite. The zeolite topology is CHA or AEI, and the skeleton atoms include Al—P—O or Si—Al—P—O; the heteroatoms is at least one of divalent metal Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Sr, Zr, Mo, Cd, Ba and Ce, trivalent metal Ti and Ga, and tetravalent metal Ge. A weight ratio of the active ingredient in the component I to the component II is 0.1-20. The reaction process has high light olefin selectivity; the sum selectivity of the light olefin including ethylene, propylene and butylene can reach 50-90%, while the selectivity of a methane side product is less than 7%.

A composite catalyst containing heteroatom-doped zeolite for preparing light olefin using direct conversion of syngas formed by compounding component I and component II in a mechanical mixing mode. The active ingredient of component I is a metal oxide, and the component II is a heteroatom-doped zeolite. The zeolite topology is CHA or AEI, and the skeleton atoms include Al—P—O or Si—Al—P—O; the heteroatoms is at least one of divalent metal Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Sr, Zr, Mo, Cd, Ba and Ce, trivalent metal Ti and Ga, and tetravalent metal Ge. A weight ratio of the active ingredient in the component I to the component II is 0.1-20. The reaction process has high light olefin selectivity; the sum selectivity of the light olefin including ethylene, propylene and butylene can reach 50-90%, while the selectivity of a methane side product is less than 7%.

The present invention provides a Fischer-Tropsch catalyst comprising greater than about 40% by weight of cobalt, and having a packed apparent bulk density greater than about 1.30 g/mL.

Embodiments of the present invention relates to two improved catalysts and associated processes that directly converts carbon dioxide and hydrogen to liquid fuels. The catalytic converter is comprised of two catalysts in series that are operated at the same pressures to directly produce synthetic liquid fuels or synthetic natural gas. The carbon conversion efficiency for CO.sub.2 to liquid fuels is greater than 45%. The fuel is distilled into a premium diesel fuels (approximately 70 volume %) and naphtha (approximately 30 volume %) which are used directly as “drop-in” fuels without requiring any further processing. Any light hydrocarbons that are present with the carbon dioxide are also converted directly to fuels. This process is directly applicable to the conversion of CO.sub.2 collected from ethanol plants, cement plants, power plants, biogas, carbon dioxide/hydrocarbon mixtures from secondary oil recovery, and other carbon dioxide/hydrocarbon streams. The catalyst system is durable, efficient and maintains a relatively constant level of fuel productivity over long periods of time without requiring re-activation or replacement.

The present invention provides a Fischer-Tropsch catalyst comprising greater than about 40% by weight of cobalt, and having a packed apparent bulk density greater than about 1.30 g/mL.

Embodiments of the present invention relates to two improved catalysts and associated processes that directly converts carbon dioxide and hydrogen to liquid fuels. The catalytic converter is comprised of two catalysts in series that are operated at the same pressures to directly produce synthetic liquid fuels or synthetic natural gas. The carbon conversion efficiency for CO.sub.2 to liquid fuels is greater than 45%. The fuel is distilled into a premium diesel fuels (approximately 70 volume %) and naphtha (approximately 30 volume %) which are used directly as “drop-in” fuels without requiring any further processing. Any light hydrocarbons that are present with the carbon dioxide are also converted directly to fuels. This process is directly applicable to the conversion of CO.sub.2 collected from ethanol plants, cement plants, power plants, biogas, carbon dioxide/hydrocarbon mixtures from secondary oil recovery, and other carbon dioxide/hydrocarbon streams. The catalyst system is durable, efficient and maintains a relatively constant level of fuel productivity over long periods of time without requiring re-activation or replacement.

Pathways are disclosed for the production of liquid hydrocarbon products comprising gasoline and/or diesel boiling-range hydrocarbons, and in certain cases renewable products having non-petroleum derived carbon. In representative processes, a gaseous feed mixture comprising CO.sub.2 in combination H.sub.2 and/or CH.sub.4 (or other hydrocarbon source of H.sub.2) is converted by reforming and/or reverse water-gas shift (RWGS) reactions, optionally further in combination with Fischer-Tropsch (FT) synthesis and/or cracking. A preferred gaseous feed mixture comprises biogas or otherwise a mixture of CO.sub.2 and H.sub.2 that is not readily upgraded using conventional processes. Catalysts described herein have a high activity for catalyzing the reforming (including dry reforming) of CH.sub.4 and other light hydrocarbons (e.g., those having been produced via FT synthesis and recycled as light ends back to the process) as well as simultaneously catalyzing the RWGS reaction. These attributes allow for flexibility in terms of compositions that may be converted efficiently. Economics of small-scale operations may be improved, if necessary, using an electrically heated reforming reactor in the first or initial reforming stage or RWGS stage.

A hybrid catalyst including a metal oxide catalyst component comprising chromium, zinc, and at least one additional metal selected from the group consisting of iron and manganese, and a microporous catalyst component that is a molecular sieve having 8-MR pore openings. The at least one additional metal is present in an amount from 5.0 at % to 20.0 at %.