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 relates to a method for the treatment of an exhaust gas comprising carbon monoxide (CO) and/or one or more volatile organic compounds (VOCs) using a PGM-free catalyst article comprising a mixed oxide of Mn, Cu, Mg, Al and La. The present invention also relates to an HVAC system comprising a PGM-free catalyst article.

The present invention relates to a method for the treatment of an exhaust gas comprising carbon monoxide (CO) and/or one or more volatile organic compounds (VOCs) using a PGM-free catalyst article comprising a mixed oxide of Mn, Cu, Mg, Al and La. The present invention also relates to an HVAC system comprising a PGM-free catalyst article.

Disclosed here is a supported catalyst comprising a thermally stable core, wherein the thermally stable core comprises a metal oxide support and nickel disposed in the metal oxide support, wherein the metal oxide support comprises at least one base metal oxide and at least one transition metal oxide or rare earth metal oxide mixed with or dispersed in the base metal oxide. Optionally the supported catalyst can further comprise an electrolyte removing layer coating the thermally stable core and/or an electrolyte repelling layer coating the electrolyte removing layer, wherein the electrolyte removing layer comprises at least one metal oxide, and wherein the electrolyte repelling layer comprises at least one of graphite, metal carbide and metal nitride. Also disclosed is a molten carbonate fuel cell comprising the supported catalyst as a direct internal reforming catalyst.

Disclosed here is a supported catalyst comprising a thermally stable core, wherein the thermally stable core comprises a metal oxide support and nickel disposed in the metal oxide support, wherein the metal oxide support comprises at least one base metal oxide and at least one transition metal oxide or rare earth metal oxide mixed with or dispersed in the base metal oxide. Optionally the supported catalyst can further comprise an electrolyte removing layer coating the thermally stable core and/or an electrolyte repelling layer coating the electrolyte removing layer, wherein the electrolyte removing layer comprises at least one metal oxide, and wherein the electrolyte repelling layer comprises at least one of graphite, metal carbide and metal nitride. Also disclosed is a molten carbonate fuel cell comprising the supported catalyst as a direct internal reforming catalyst.

A process for producing a hydrogen-rich gas stream from a liquid hydrocarbon stream, the process comprising the steps of introducing the liquid hydrocarbon stream to a dual catalytic zone, the liquid hydrocarbon stream comprises liquid hydrocarbons selected from the group consisting of liquid petroleum gas (LPG), light naphtha, heavy naphtha, gasoline, kerosene, diesel, and combinations of the same, the dual catalytic zone comprises: a combustion zone comprising a seven component catalyst, and a steam reforming zone, the steam reforming zone comprising a steam reforming catalyst; introducing steam to the dual catalytic zone, introducing an oxygen-rich gas to the dual catalytic zone; contacting the liquid hydrocarbon stream, steam, and oxygen-rich gas with the seven component catalyst to produce a combustion zone fluid; and contacting the combustion zone fluid with the steam reforming catalyst to produce the hydrogen-rich gas stream, wherein the hydrogen-rich gas stream comprises hydrogen.

A process for producing a hydrogen-rich gas stream from a liquid hydrocarbon stream, the process comprising the steps of introducing the liquid hydrocarbon stream to a dual catalytic zone, the liquid hydrocarbon stream comprises liquid hydrocarbons selected from the group consisting of liquid petroleum gas (LPG), light naphtha, heavy naphtha, gasoline, kerosene, diesel, and combinations of the same, the dual catalytic zone comprises: a combustion zone comprising a seven component catalyst, and a steam reforming zone, the steam reforming zone comprising a steam reforming catalyst; introducing steam to the dual catalytic zone, introducing an oxygen-rich gas to the dual catalytic zone; contacting the liquid hydrocarbon stream, steam, and oxygen-rich gas with the seven component catalyst to produce a combustion zone fluid; and contacting the combustion zone fluid with the steam reforming catalyst to produce the hydrogen-rich gas stream, wherein the hydrogen-rich gas stream comprises hydrogen.

A catalyst composition includes a metal catalyst dispersed in a molten eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides. A process for the catalytic cracking of hydrocarbons includes contacting in a reactor system a carbon-containing feedstock with at least one catalyst in the presence of oxygen to generate olefinic and/or aromatic compounds; and collecting the olefinic and/or aromatic compounds; wherein: the at least one catalyst includes a metal catalyst dispersed in a molten eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides. A process for preparing the catalyst includes mixing metal catalyst precursors selected from transition metal compounds and rare-earth metal compounds and a eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides and heating it. A use of the catalyst in the catalytic cracking process of hydrocarbons.

Provided herein are catalyst materials and processes for processing hydrocarbons. For example, doped ceria-supported metal catalysts are provided exhibiting good activity and stability for commercially relevant dry reforming of methane as well as mixed hydrocarbon feedstocks under process conditions including low temperature and long term operation. Useful doped ceria-supported metal catalysts include nickel dispersed over Ti-doped ceria.

Provided herein are catalyst materials and processes for processing hydrocarbons. For example, doped ceria-supported metal catalysts are provided exhibiting good activity and stability for commercially relevant dry reforming of methane as well as mixed hydrocarbon feedstocks under process conditions including low temperature and long term operation. Useful doped ceria-supported metal catalysts include nickel dispersed over Ti-doped ceria.