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Abstract

Promoted skeletal iron catalysts are provided which contain 70-90 wt % iron together with promoters 0-5.0 wt. % copper, 0.1-10.0 wt. % manganese, and 0.1-3.0 wt. % potassium, with the balance being aluminum. The catalysts are prepared by mixing the metal chips or powders uniformly together, then melting and rapidly quenching the molten metals to form a solid metal alloy precursor including the promotor metals except potassium, removing most of the aluminum by caustic extraction/leaching to provide a base skeletal iron form, then loading the potassium promoter from a suitable potassium alcohol solution promoter. After evaporation of the solvent, the promoted skeletal iron catalyst is activated by contact with hydrogen. The promoted skeletal iron catalysts are utilized for F-T synthesis processes at 10-30 wt % catalyst concentration, 200-350.degree. C. temperature, 1.0-3.0 Mpa pressure and gas hourly space velocity of 0.5-5.0 L/gcat-h to produce desired hydrocarbon liquid products. The promoted skeletal iron catalysts provide good catalytic activity and selectivity for hydrogen and CO conversions, for distillate fuel products are attrition resistant synthesis, and are readily separable from waxy liquid product by gravity sedimentation.

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