Stable carbonous catalyst particles composed of an inorganic catalytic metal/metal
oxide powder and a carbonaceous binder material are formed having a basic inner
substantially uniform-porous carbon coating of the catalytic powder, and may include
an outer porous carbon coating layer. Suitable inorganic catalytic powders include
zinc-chromite (ZnO/Cr2 03) and suitable carbonaceous liquid binders
having molecular weight of 200-700 include partially polymerized furfuryl alcohol,
which are mixed together, shaped and carbonized and partially oxidized at elevated
temperature. Such stable carbonous catalyst particles such as 0.020-0.100 inch
(0.51-2.54 mm) diameter extrudates, have total carbon content of 2-25 wt. % and
improved crush strength of 1.0-5 1b/mn, 50-300 m2/g surface
area, and can be advantageously utilized in fixed bed or ebullated/fluidized bed
reactor operations. This invention also includes method steps for making the stable
carbonous catalyst particles having improved particle strength and catalytic activity,
and processes for utilizing the active stable carbonous carbon-coated catalysts
such as for syn-gas reactions in ebullated/fluidized bed reactors for producing
alcohol products and Fischer-Tropsch synthesis liquid products.
