Highly active and selective Co‐based Fischer–Tropsch catalysts derived from metal–organic frameworks

The design of supported Co‐based Fischer–Tropsch (F–T) catalysts with suitable reducibility, dispersion, loading, and nanoparticle structure is necessary so that high catalytic activity and selectivity for C₅₊ hydrocarbons can be achieved. Herein, we report that pyrolyzing a Co‐metal–organic framework‐71 precursor can provide porous carbon‐supported Co catalysts with completely reduced, well‐dispersed face‐centered cubic (FCC) Co nanoparticles (～10 nm in average size). The catalysts can be further tailored dimensionally by doping with Si species, and the FCC Co nanoparticles can be partially transformed into hexagonal close‐packed Co via a Co₂C intermediate. All the as‐prepared catalysts had extremely high Co site density (>3.5 × 10^?4 mol/g‐cat.) because they had a high number of Co active sites and low mass. Aside from having high F–T activity and C₅₊ selectivity, with diesel fuels being the main constituents, they showed unprecedentedly high C₅₊ space time yields (up to 1.45 g/(g‐cat. h)) as compared to conventional Co catalysts. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2935–2944, 2017     

Performance of mix‐impregnated CeO2‐Ni/YSZ Anodes for Direct Oxidation of Methane in Solid Oxide Fuel Cells

CeO₂‐Ni/YSZ anodes for methane direct oxidation were prepared by the vacuum mix‐impregnation method. By this method, NiO and CeO₂ are obtained from nitrate decomposition and high temperature sintering is avoided, which is different from the preparation of conventional Ni‐yttria‐stabilised zirconia(YSZ) anodes. Impregnating CeO₂ into the anode can improve the cell performance, especially, when CH₄ is used as fuel_. The investigation indicated that CeO₂‐Ni/YSZ anodes calcined at higher temperature exhibited better stability than those calcined at lower temperature. Under the testing temperature of 1,073 K, the anode calcined at 1,073 K exhibited the best performance. The maximum power density of a cell with a 10 wt.‐%CeO₂‐25 wt.‐%Ni anode calcined at 1,073 K reached 480 mW cm^–2 after running on CH₄ for 5 h. At the same time, high discharge current favoured cell operation on CH₄ when using these anodes. No obvious carbon was found on the CeO₂‐Ni anode after testing in CH₄ as revealed from SEM and corresponding linear EDS analysis. In addition, cell performance decreased at the beginning of discharge testing which was attributed to the anode microstructure change observed with SEM.     

Performance and Evaluation of Cu‐based Nano‐composite Anodes for Direct Utilisation of Hydrocarbon Fuels in SOFCs

The anodes for direct utilisation of hydrocarbon fuels have been developed by using Cu/Ceria‐based nano‐composite powders. The CuO/GDC/YSZ–YSZ or CuO/GDC‐GDC nano‐composite powders were synthesised by coating nano‐sized CuO and CeO₂ particles on the YSZ or GDC core particles selectively by the Pechini process. Their microstructures and electrical properties have been investigated with long‐term stability in reactive gases of dry methane and air. The anodes fabricated using Cu‐based nano‐composite anodes showed almost no carbon deposition until 500 h in dry CH₄ atmosphere. The type of an electrolyte‐supported single cell in conjunction with the Cu/Ceria‐based anode must be selected together for the low melting temperature of Cu/CuO. The GDC electrolyte supported unit cell with the Cu/GDC–GDC anode showed the maximum power density of 0.1 Wcm^–2 and long‐term stability for more than 500 h under electronic load of 0.05 Acm^–2 at 650 °C in dry methane atmosphere.     

Effect of adding urea on performance of Cu/CeO2/yttria-stabilized zirconia anodes for solid oxide fuel cells prepared by impregnation method

Anode microstructure has a great influence on the cell performance. The addition of urea into impregnated solution has been proposed to tailor the distribution and/or morphology of Cu when fabricating the Cu-based anodes by impregnation method. While the previous reports demonstrated the single cell performance has not been improved in this route, in this paper, fuel cells with Cu/yttria-stabilized zirconia (YSZ) and Cu–CeO₂/YSZ anodes were fabricated and evaluated with improved outputs. The microstructure of Cu in anodes appeared significantly different after the addition of urea. The electronic conductivity obtained from the anodes impregnated with adding urea was twice as high as the ones without. Performance of fuel cells increases by 12% while operating on H₂ at 700 °C upon adding urea. Furthermore, the performance improvement was more prominent when such method was adopted in the fabrication of Cu–CeO₂/YSZ composite anodes. Cells with Cu–CeO₂/YSZ composite anodes operating in H₂ at 700 °C exhibited an increase of cell performance by 37%, from 337 to 462 mW cm⁻², by simply adding urea to the impregnated solution. And the performance enhancement for such fuel cells is also as high as 28% when using CH₄ as fuel.     

Effect of the third acrylated vinyl comonomer on absorption and desorption properties of styrene–divinylbenzene–alkyl acrylate terpolymers,imbibing solvent on a water surface

A series of imbiber terpolymer beads was prepared by radical suspension copolymerization of styrene–divinylbenzene with varied contents of acrylated vinyl monomers, n‐butyl acrylate and 2‐ethyl hexyl acrylate, as the third comonomer. A DVB content of 6 wt % and a mixture of 60/40 wt % toluene/n‐heptane as the diluent were used throughout this study. The influence of acrylated vinyl comonomers on bead properties and swelling properties was investigated. The imbiber beads are capable of absorption and desorption of organic solvents having solubility parameters in the range of 14.9–20.9 (MPa)^1/2. Styrenic imbiber beads were swelled in a toluene/n‐heptane mixture of 50% by volume and the kinetics of absorption was studied. The imbiber beads could absorb the toluene/n‐heptane mixture completely within 20 min and yielded a maximum swelling ratio of 6.8. The diffusion coefficient values of these beads were in the range of 6.40 × 10⁻⁶ to 1.52 × 10⁻⁵ cm² s⁻¹. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 79: 504–516, 2001     

Characterization of a Cu‐La0.75Sr0.25Cr0.5Mn0.5O3 ‐CeO2/La0.75Sr0.25Cr0.5Mn0.5O3‐YSZ/Ni‐ScSZ Three‐Layer Structure Anode in Thin Film Solid Oxide Fuel Cell Running on Methane Fuel

Anodes for Solid Oxide Fuel Cell that is capable of directly using hydrocarbon without external reforming have been of great interest recently. In this paper, a three‐layer structure anode running on methane is fabricated by tape casting and screen printing method. The slurry of catalyst layer Cu‐LSCM‐CeO₂ (with weight ratios of 1.5:7.0:1.5, 2.0:7.0:1.0, 2.15:7.0:0.85 and 2.25:7.0:0.75, weight ratios of Cu/CeO₂ is 1:1, 2:1, 2.5:1 and 3:1, respectively) is screen‐printed on LSCM‐YSZ support layer and Ni‐ScSZ active layer. Thus, LSCM‐YSZ/Ni‐ScSZ anodes with Cu‐LSCM‐CeO₂ catalyst layer (denoted as LSCM‐YSZ1010, LSCM‐YSZ2010, LSCM‐YSZ2510 and LSCM‐YSZ3010, respectively) are obtained. Single cells with three‐layer structure anode are also fabricated and measured, of which the maximum power density reaches 491 and 670 mW cm⁻² for the cell with LSCM‐YSZ2510 anode running on methane at 750 °C and 800 °C, respectively. No significant degradation in performance has been observed after 240h of cell testing when LSCM‐YSZ2510 anode is exposed to methane at 750 °C. Very little carbon deposition is detected on the anode, suggesting that carbon deposition is limited during cell operation. Consequently, Cu‐LSCM‐CeO₂ catalyst layer on the surface of LSCM‐YSZ support layer makes it possible to have good stability for long‐term operation in methane due to very little carbon deposition.     

Synthesis,Structure and Electrical Properties of Mo‐doped CeO2–Materials for SOFCs

In this paper, we report the synthesis, structure and electrical conductivity of Mo‐doped compounds with a nominal chemical formula of Ce_1–xMo_xO_2+δ (x = 0.05, 0.07, 0.1) (CMO). The formation of fluorite‐like structure with a small amount of Ce₈Mo₁₂O₄₉ impurity (JCPDS Card No. 31‐0330) was confirmed using a powder X‐ray diffraction (PXRD). The fluoride‐type structure was retained under wet H₂ and CH₄ atmospheres at 700 and 800 °C, while diffraction peaks due to metal Mo were observed in dry H₂ under the same condition. AC impedance measurements showed that the total conductivity increases with increasing Mo content in CMO, and among the investigated samples, Ce_0.9Mo_0.1O_2+δ exhibited the highest electrical conductivity with a value of 2.8 × 10^–4 and 5.08 × 10^–2 S cm^–1 at 550 °C in air and wet H₂, respectively. The electrical conductivity was found to be nearly the same, especially at high temperatures, in air, O₂ and N₂. Chemical compatibility of Ce_0.9Mo_0.1O_2+δ with 10 mol‐% Y₂O₃ stabilised ZrO₂ (YSZ) and Ce_0.9Gd_0.1O_1.95 (CGO) oxide ion electrolytes in wet H₂ was evaluated at 800–1,000 °C, using PXRD and EDX analyses. PXRD showed that CMO was found to react with YSZ electrolyte at 1,000 °C. The area specific polarisation resistance (ASPR) of Ce_0.9Mo_0.1O_2+δ on YSZ was found to be 8.58 ohm cm² at 800 °C in wet H₂.     

Hydrogen Production Via CH4 and CO Assisted Steam Electrolysis

Porous composite anodes consisting of a yttria-stabilized zirconia (YSZ) backbone that was impregnated with CeO₂ and various amounts of metallic components including Cu, Co and Pd were fabricated. The performance of these anodes was then tested in a solid oxide water electrolysis cell under conditions where the anode was exposed to the reducing gasses H₂, CH₄ and CO. The reducing gasses were used to decrease the electrochemical potential of the cell and increase overall efficiency. The results of this study show that Cu–CeO₂–YSZ anodes have low catalytic activity for the oxidation of CO and CH₄ and are not very effective in lowering the cell potential while operating in the reducing gas assisted mode. The addition of Co to the Cu–CeO₂–YSZ anode resulted in a modest increase in the catalytic activity and enhanced the thermal stability of the anode. A Pd–C–CeO₂–YSZ anode was found to have the highest catalytic activity of those tested and gave the largest reductions in the operating potential of the solid oxide electrolysis cell.     

Synthesis of Mo–W carbide via propane carburization of the precursor sulfide: Kinetic analysis

Thermogravimetric analysis (TGA) has been used to investigate the carburization kinetics of Mo–W sulfide using an H₂:C₃H₈ feed mixture. The effect of heating rate over the range 1–10 K min^?1 showed that up to four different carburized products may be formed but the critical (peak) temperature for formation of these species and the amount (peak height) of each species formed are highly dependent on the heating rate employed. The critical temperature increased linearly with heating rate for each of the four products. The four TGA peaks corresponding to the four phase transformation species are consistent with XRD identifiable species, namely; α‐Mo₂C, β‐Mo₂C, W and MoC_1?x. Isothermal conversion–time data at three different temperatures are described by a reaction‐controlled shrinking core model implicating a first‐order dependency on the H₂:C₃H₈ ratio. The reaction exhibited fractional order dependence on the metal sulfide concentration, the associated global activation energy estimated as 227 kJ mol^?1 is representative of a non‐catalytic gas–solid reaction. Copyright © 2004 Society of Chemical Industry     

Metallkomplexe mit biologisch wichtigen Liganden. CXXIII. Darstellung von Isophthaloyl‐ und Terephthaloyl‐di‐[(β,γ,δ)‐amino‐α‐aminocarboxylat]‐verbrückten zweikernigen Ruthenium‐, Rhodium‐ und Iridium‐Halbsandwich‐Komplexen

The reaction of the Cu(II) bis N,O‐chelate‐complexes of L‐2,4‐diaminobutyric acid, L‐ornithine and L‐lysine {Cu[H₂N–CH(COO)(CH₂)_nNH₃]₂}²⁺(Cl^–)₂ (n = 2–4) with terephthaloyl dichloride or isophthaloyl dichloride gives the polymeric complexes {‐OC–C₆H₄–CO–NH–(CH₂)_n–CH(nh₂)(COO)Cu(OOC)(NH₂)CH–CH₂)_n–NH‐}_x 1 – 5 . From these the metal can be removed by precipitation of Cu(II) with H₂S. The liberated ω,ω′‐N,N′‐diterephthaloyl (or iso‐phthaloyl)‐diaminoacids 6 – 10 react with [Ru(cymene)Cl₂]₂, [Ru(C₆Me₆)Cl₂]₂, [Cp*RhCl₂]₂ or [Cp*IrCl₂]₂ to the ligand bridged bis‐amino acidate complexes [L_n(Cl)M–(OOC)(NH₂)CH–(CH₂)_nNH–CO]₂–C₆H₄ 11 – 14 .     

Optimisation and Evaluation of La0.6Sr0.4CoO3 – δ Cathode for Intermediate Temperature Solid Oxide Fuel Cells

In this work, La_0.6Sr_0.4CoO_{3 – δ}/Ce_{1 – x}Gd_xO_{2 – δ} (LSC/GDC) composite cathodes are investigated for SOFC application at intermediate temperatures, especially below 700 °C. The symmetrical cells are prepared by spraying LSC/GDC composite cathodes on a GDC tape, and the lowest polarisation resistance (R_p) of 0.11 Ω cm² at 700 °C is obtained for the cathode containing 30 wt.‐% GDC. For the application on YSZ electrolyte, symmetrical LSC cathodes are fabricated on a YSZ tape coated on a GDC interlayer. The impact of the sintering temperature on the microstructure and electrochemical properties is investigated. The optimum temperature is determined to be 950 °C; the corresponding R_p of 0.24 Ω cm² at 600 °C and 0.06 Ω cm² at 700 °C are achieved, respectively. An YSZ‐based anode‐supported solid oxide fuel cell is fabricated by employing LSC/GDC composite cathode sintered at 950 °C. The cell with an active electrode area of 4 × 4 cm² exhibits the maximum power density of 0.42 W cm^–2 at 650 °C and 0.54 W cm^–2 at 700 °C. More than 300 h operating at 650 °C is carried out for an estimate of performance and degradation of a single cell. Despite a decline at the beginning, the stable performance during the later term suggests a potential application.     

Evaluation of the Performance of Carbon Supported Pt–Ru–Ni–P as Anode Catalyst for Methanol Electrooxidation

This research is aimed to improve the activity and stability of ternary alloy Pt–Ru–Ni/C catalyst. A novel anodic catalyst for direct methanol fuel cell (DMFC), carbon supported Pt–Ru–Ni–P nanoparticles, has been prepared by chemical reduction method by using NaH₂PO₂ as a reducing agent. One glassy carbon disc working electrode is used to test the catalytic performances of the homemade catalysts by cyclic voltammetric (CV), chronoamperometric (CA) and amperometric i–t measurements in a solution of 0.5 mol L^–1 H₂SO₄ and 0.5 mol L^–1 CH₃OH. The compositions, particle sizes and morphology of home‐made catalysts are evaluated by means of energy dispersive analysis of X‐ray (EDAX), X‐ray diffraction (XRD) and transmission electron micrographs (TEM), respectively. TEM images show that Pt–Ru–Ni–P nanoparticles have an even size distribution with an average diameter of less than 2 nm. The results of CV, CA and i–t curves indicate that the Pt–Ru–Ni–P/C catalyst shows significantly higher activity and stability for methanol electrooxidation due to the presence of non‐metal phosphorus in comparison to Pt–Ru–Ni/C one. All experimental results indicate that the addition of non‐metallic phosphorus into the Pt–Ru–Ni/C catalyst has definite value of research and practical application for enhancing the performance of DMFC.     

Gas–liquid chromatographic study of polystyrene–n‐alkane interactions

Gas–liquid chromatography is used to study the thermodynamic interactions between polystyrene and n‐alkanes (C₆–C₁₀). Polystyrene is used as a stationary phase with n‐alkanes as the probe molecules. Retention times and specific retention volumes are measured over the temperature interval of 60 to 170°C. Partial molar free energy of mixing, polymer–solvent interaction parameter, glass‐transition temperature, and solubility parameter of polystyrene at infinite dilution are calculated. Experimental results are discussed in terms of the theoretical calculations and size of the probe molecules. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 80: 1291–1298, 2001     

Kinetics of CO hydrogenation over coprecipitated cobalt–alumina

The kinetics of CO hydrogenation over coprecipitated 36 wt% Co/Al₂O₃ was studied in a fixed-bed microreactor at atmospheric pressure. Intrinsic kinetic data were obtained in the initial rate region using four different CO concentrations and two different H₂/CO ratios over the 473–523 K temperature range. The surface carbide mechanism with dissociative adsorption of hydrogen as the rate controlling step gives the most plausible kinetic model among the eight different models tested. C₁–C₄ production rates are found to be strongly influenced by temperature, and optimum C₁–C₄ hydrocarbon selectivity is obtained at 508 K. The activation energy for CO consumption and CH₄ formation are calculated as 74±2 kJ mol⁻¹ and 84±2 kJ mol⁻¹ respectively. ©1997 SCI     

Enhanced fracture toughness of epoxy resins with novel amine‐terminated poly(arylene ether sulfone)–carboxylic‐terminated butadiene‐acrylonitrile–poly(arylene ether sulfone) triblock copolymers

Amine‐terminated poly(arylene ether sulfone)–carboxylic‐terminated butadiene‐acrylonitrile–poly(arylene ether sulfone) (PES‐CTBN‐PES) triblock copolymers with controlled molecular weights of 15,000 (15K) or 20,000 (20K) g/mol were synthesized from amine‐terminated PES oligomer and commercial CTBN rubber (CTBN 1300x13). The copolymers were utilized to modify a diglycidyl ether of bisphenol A epoxy resin by varying the loading from 5 to 40 wt %. The epoxy resins were cured with 4,4′‐diaminodiphenylsulfone and subjected to tests for thermal properties, plane strain fracture toughness (K_IC), flexural properties, and solvent resistance measurements. The fracture surfaces were analyzed with SEM to elucidate the toughening mechanism. The properties of copolymer‐toughened epoxy resins were compared to those of samples modified by PES/CTBN blends, PES oligomer, or CTBN. The PES‐CTBN‐PES copolymer (20K) showed a K_IC of 2.33 MPa m^0.5 at 40 wt % loading while maintaining good flexural properties and chemical resistance. However, the epoxy resin modified with a CTBN/8K PES blend (2:1) exhibited lower K_IC (1.82 MPa m^0.5), lower flexural properties, and poorer thermal properties and solvent resistance compared to the 20K PES‐CTBN‐PES copolymer‐toughened samples. The high fracture toughness with the PES‐CTBN‐PES copolymer is believed to be due to the ductile fracture of the continuous PES‐rich phases, as well as the cavitation of the rubber‐rich phases. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1556–1565, 2002; DOI 10.1002/app.10390     

Synthesis of Small‐Scale Boron‐Rich Nano‐Size Particles

The synthesis times required to produce high energy density compounds (C₂B₄H₂)_n and (C₂B₁₀H₄)_n by gas phase pyrolysis of the carboranes C₂B₄H₆ and C₂B₁₀H₁₂, respectively, have been measured at 1150–2000 K and carborane pressures of (0.3–3.0)⋅10⁻³ MPa. Kinetic model simulations of the synthesis have been performed. The temperatures, carborane pressures, and synthesis times required to produce small‐scale (C₂B₄H₂)_n and (C₂B₁₀H₄)_n particles of 10 to 30 nm diameter are determined.     

Ultrafine Amorphous Co–Fe–B Catalysts for the Hydrolysis of NaBH4 Solution to Generate Hydrogen for PEMFC

For hydrogen generation from alkaline sodium borohydride (NaBH₄) solution, Co–Fe–B catalysts with different Co/(Co + Fe) molar ratios (χ_Co) were prepared by the chemical reduction of CoCl₂ and FeCl₃ ethanol solution with KBH₄ solution. The X‐ray diffraction (XRD) and scanning electron microscopy (SEM) analyses revealed that the as‐prepared Co–Fe–B catalysts were in amorphous form and ultrafine. The hydrogen generation measurements showed that as‐prepared Co–B and Co–Fe–B catalysts exhibited excellent catalytic activity. Co–Fe–B with the Co/(Co + Fe) molar ratio (χ_Co) of 0.85 was the best. Its maximum hydrogen generation rate at 298 K was 4,310 mL min^–1 g^–1, while the Co–B was 2,773 mL min^–1 g^–1. The enhanced activity could be attributed to large active surface area, electron transfer from B and Fe to active Co sites, and improvement in the dispersion of Co–B with Fe₂O₃. The activation energy of Co–Fe–B catalyst with the molar ratio χ_Co = 0.85 was decreased to 29.09 kJ mol^–1 as compared to 30.85 kJ mol^–1 obtained with Co–B.     

Investigation of Dynamic Intra‐ and Intermolecular Processes within a Tether‐Length Dependent Series of Group 4 Bimetallic Initiators for Stereomodulated Degenerative Transfer Living Ziegler–Natta Propene Polymerization

The series of bimetallic complexes, [(η⁵‐C₅Me₅)Zr(Me)₂]₂ [N(t‐Bu)C(Me)N (CH₂)_n NC(Me)N(t‐Bu)] 3 (n=8), 4 (n=6), and 5 (n=4) were prepared in high yield through a simple, one‐pot synthesis involving 2 equiv. of in situ generated (η⁵‐C₅Me₅)Zr(Me)₃ and the corresponding bis‐carbodiimide, (t‐Bu)NCN (CH₂)_n NCN(t‐Bu). Compounds 3 – 5 were found to be highly isoselective for the living Ziegler–Natta polymerization of propene upon 100% activation using 2 equiv. of the borate co‐initiator, [PhNHMe₂] [B(C₆F₅)₄] ( 2 ), with the degree of stereoselectivity decreasing slightly as the two metal centers are brought closer together [cf., 3 (σ=0.92)> 4 (σ=0.91)> 5 (σ=0.89)]. Under conditions of sub‐stoichiometric activation by 2 , all three bimetallic initiators, 3 – 5 , were found to engage in degenerative transfer living Ziegler–Natta polymerization involving rapid and reversible methyl group transfer between active, (cationic) and dormant, (neutral) methyl, polymeryl zirconium centers. Under these conditions, the frequency of mr triad stereoerror incorporation into the polypropene (PP) microstructure decreases as the two metal centers are brought closer together as a result of increasing barriers for metal‐centered epimerization within the neutral metal site due to correspondingly greater non‐bonded steric interactions vis‐à‐vis mononuclear 1 .     

Sr2Fe1.5Mo0.5O6–δ – Zr0.84Y0.16O2–δ Materials as Oxygen Electrodes for Solid Oxide Electrolysis Cells

The high‐temperature solid oxide electrolysis cell (SOEC) is one of the most promising devices for hydrogen mass production. To make SOEC suitable from an economical point of view, each component of the SOEC has to be optimized. At this level, the optimization of the oxygen electrode is of particular interest since it contributes to a large extent to the cell polarization resistance. The present paper is focused on an alternative oxygen electrode of Zr_0.84Y_0.16O_2–δ‐Sr₂Fe_1.5Mo_0.5O_6–δ (YSZ‐SFM). YSZ‐SFM composite oxygen electrodes were fabricated by impregnating the YSZ matrix with SFM, and the ion‐impregnated YSZ‐SFM composite oxygen electrodes showed excellent performance. For a voltage of 1.2 V, the electrolysis current was 223 mA cm⁻², 327 mA cm⁻² and 310 mA cm⁻² at 750 °C for the YSZ‐SFM10, YSZ‐SFM20, and YSZ‐SFM30 oxygen electrode, respectively. A hydrogen production rate as high as 11.46 NL h⁻¹ has been achieved for the SOEC with the YSZ‐SFM20 electrode at 750 °C. The results demonstrate that YSZ‐SFM fabricated by impregnating the YSZ matrix with SFM is a promising composite electrode for the SOEC.     

Assessing the performance of an industrial SBCR for Fischer–Tropsch synthesis: Experimental and modeling

The main objective of this study is to predict the performance of an industrial‐scale (ID = 5.8 m) slurry bubble column reactor (SBCR) operating with iron‐based catalyst for Fischer–Tropsch (FT) synthesis, with emphasis on catalyst deactivation. To achieve this objective, a comprehensive reactor model, incorporating the hydrodynamic and mass‐transfer parameters (gas holdup, ε_G, Sauter‐mean diameter of gas bubbles, d₃₂, and volumetric liquid‐side mass‐transfer coefficients, k_La), and FT as well as water gas shift reaction kinetics, was developed. The hydrodynamic and mass‐transfer parameters for He/N₂ gaseous mixtures, as surrogates for H₂/CO, were obtained in an actual molten FT reactor wax produced from the same reactor. The data were measured in a pilot‐scale (0.29 m) SBCR under different pressures (4–31 bar), temperatures (380–500 K), superficial gas velocities (0.1–0.3 m/s), and iron‐based catalyst concentrations (0–45 wt %). The data were modeled and predictive correlations were incorporated into the reactor model. The reactor model was then used to study the effects of catalyst concentration and reactor length‐to‐diameter ratio (L/D) on the water partial pressure, which is mainly responsible for iron catalyst deactivation, the H₂ and CO conversions and the C₅₊ product yields. The modeling results of the industrial SBCR investigated in this study showed that (1) the water partial pressure should be maintained under 3 bars to minimize deactivation of the iron‐based catalyst used; (2) the catalyst concentration has much more impact on the gas holdup and reactor performance than the reactor height; and (3) the reactor should be operated in the kinetically controlled regime with an L/D of 4.48 and a catalyst concentration of 22 wt % to maximize C₅₊ products yield, while minimizing the iron catalyst deactivation. Under such conditions, the H₂ and CO conversions were 49.4% and 69.3%, respectively, and the C₅₊ products yield was 435.6 ton/day. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3838–3857, 2015