Integral synthesis gas conversion catalyst extrudates and methods for preparing and using same

摘要

Methods for preparing integral synthesis gas conversion catalyst extrudates including an oxide of a Fischer-Tropsch (FT) metal component and a zeolite component are disclosed. The oxide of the FT metal component is precipitated from a solution into crystallites having a particle size between about 2 nm and about 30 nm. The oxide of the FT metal component is combined with a zeolite powder and a binder material, and the combination is extruded to form integral catalyst extrudates. The oxide of the FT metal component in the resulting catalyst is in the form of reduced crystallites located outside the zeolite channels. No appreciable ion exchange of FT metal occurs within the zeolite channels. The acid site density of the integral catalyst extrudate is at least about 80% of the zeolite acid site density.