Stable carbonous catalyst particles and method for making and utilizing same

1. Stable carbonous catalyst particles having improved crush strength and attrition resistance, said catalyst particles comprising an active inorganic catalytic powder and a carbonaceous liquid binder material which after being mixed together then carbonized and partially oxidized at elevated temperature form a basic inner porous carbon coating bonding together the inorganic catalytic powder and providing a substantially uniform composition and structure having increased particle strength and surface area, said catalyst particles having total carbon content of 2-25 wt %, 1.0-5.0 1b/mm crush strength, 50-300 m 2 /g surface area, and 0.02-0.100 inch (0.51-2.54 mm) diameter particle size.

2. The carbonous catalyst particles of claim 1 , wherein said inorganic catalytic powder has size smaller than 200 mesh and includes zinc chromite, cesium-promoted zinc chromite, copper-promoted zinc chromite, and K- and Mn-promoted zirconia powder.

3. The carbonous catalyst particles of claim 1 , wherein said carbonaceous liquid binder materials have molecular weight of 200-700 and include partially polymerized furfuryl alcohol, furfuryl alcohol resins, polyvinyl acetate, polyvinyl butates, polyvinyl chlorides, coal-derived hydrocarbon liquid, or waxes from Fischer-Tropsch synthesis process.

4. The carbonous catalyst particles of claim 1 , wherein said basic inner carbon coating includes micropores which are created in said basic carbon coating by carbonization in an inert atmosphere at 800-1400° F. temperature for 24 hours, and then partial oxidization at 700-1000° F. temperature for 24 hours for creating said micropores in the basic carbon coating.

5. The carbonous catalyst particles of claim 1 , wherein the catalyst particle crush strength is 1.44.5 lb/mm.

6. The carbonous catalyst particles of claim 1 , wherein said particles have an extrudate shape and 0.025-0.075 inch (0.63-2:0 mm) diameter.

7. The carbonous catalyst particles of claim 1 , wherein said basic inner carbon-coated catalyst particles have a porous outer secondary carbon-coating layer which is carbonized and partially oxidized after a second application of said carbonaceous liquid binder material.

8. Stable carbonous catalyst particles having improved high crush strength and attrition resistance suitable for successful use in ebullated/fluidized bed reactor operations, said catalyst particles comprising cesium-promoted zinc powder having size smaller than 200 mesh and a carbonaceous partially polymerized furfuryl alcohol liquid binder material which after being mixed together and carbonized and oxidized at 700-1400° F. temperature form a basic inner porous carbon coating bonding the catalytic powder together, and including an outer porous carbon-coating layer, said catalyst particles having a total carbon content of 3-20 wt %, 1.4-4.5 lb/mm crush strength, 80-200 m 2 /g surface area, and an extrudate shape having 0.025-0.080 inch (0.64-2.0 mm) diameter.

9. A method for making stable carbonous catalyst particles containing an inorganic catalytic powder and a porous carbonized binder material, comprising the steps of:

(a) providing an inorganic catalytic powder and mixing said powder with a suitable carbonaceous liquid binder material having molecular weight of 200-700, and forming a substantially uniform powder-liquid binder mixture having a paste consistency;

(b) forming said powder-liquid binder mixture into shaped soft stable catalyst particles having 0.02-0.100 inch diameter;

(c) heating and first carbonizing said carbonaceous liquid binder material by heating said shaped soft catalyst particles to 800-1400° F. temperature in an inert atmosphere for 1-4 hours and converting the carbonaceous liquid binder to a porous graphite form and thereby basic inner carbon coating said catalytic powder in the shaped carbon-coated particles; and

(d) partially oxidizing said carbon-coated particles at 700-1000° F. temperature in a flow of inert gas containing 0.1-5 vol. % concentration oxygen atmosphere for 1-4 hours and forming micropores on the graphitie surface of the stable carbonous carbon-coated catalyst particles.

10. The method for making carbonous catalyst particles according to claim 9 , wherein said catalytic powder is zinc chromite, cesium-promoted zinc chromite, copper-promoted zinc chromite, or K- and Mn-promoted zirconia.

11. The method for making carbonous catalyst particles according to claim 9 , wherein said carbonaceous liquid binder includes partially polymerized furfuryl alcohol, furfuryl alcohol resins, polyvinyl acetate, or polyvinyl butates.

12. The method for making carbonous catalyst particles according to claim 9 , including providing at least one outer carbon coating by applying an outer coating of said carbonaceous liquid binder to said basic shaped inner carbon-coated particles, then carbonizing the outer coating of said carbonaceous liquid binder at 800-1400° F. temperature for 1-4 hours, followed by partially oxidizing the carbon-coated particles to provide the outer porous carbon coating layer.

13. The method for making a carbonous catalyst according to claim 12 , wherein said outer coating of said carbonaceous liquid binder is applied to said shaped soft catalyst particles before said first carbonizing step, and including partially oxiding the basic inner and outer carbon coating layer at 700-1000° F. temperature for 2-4 hours and forming micropores in the basic and outer carbon coatings.

14. A method for making stable carbonous catalyst particles containing an inorganic catalytic powder and a porous carbonized binder material, comprising the steps of:

(a) providing an inorganic catalytic powder of cesium-promoted zinc chromite, mixing said catalytic powder with a carbonaceous liquid binder material of partially polymerized furfural alcohol and forming a substantially uniform catalyst powder-binder mixture having a paste consistency;

(b) forming said catalyst powder-binder mixture into shaped soft extrudate particles having 0.025-0.075 inch (0.63-1.90 mm) diameter;

(c) heating said shaped soft extrudate particles and first carbonizing the carbonaceous liquid binder by heating to 800-1350° F. temperature in an inert atmosphere for 2-4 hours and converting the carbonacous liquid binder to a porous graphite form and thereby providing a basic inner carbon coating for said catalytic powder and providing basic inner carbon-coated particles;

(d) partially oxidizing said carbon-coated particles at 700-1000° F. temperature for 2-4 hours duration and forming micropores in the basic inner carbon coating; and

(e) providing a subsequent outer carbon coating on said basic inner carbon-coated particles by further contacting said particles with a carbonaceous liquid binder, then carbonizing the outer liquid binder at 800-1400° F. temperature, and followed by heating and partially oxidizing the carbonous particles and providing an outer porous carbon coating layer on the shaped basic inner carbon-coated particles.