Fischer‐Tropsch Synthesis Over Co‐Ru/γ‐Al2O3 Catalyst in Supercritical Media

The Fischer‐Tropsch synthesis (FTS) in gaseous and supercritical phases was examined in a continuous, high‐pressure fixed‐bed reactor by employing a cobalt catalyst (Co‐Ru/γ‐Al₂O₃). The kinetic modeling of the FTS was investigated in the reactor over a 60–80 mesh cobalt catalyst. The Langmuir‐Hinshelwood kinetic equation was used for both the Fisher‐Tropsch (FT) and water gas shift (WGS) reactions. The kinetic model was applied for simulation of the reactor with 16–20 mesh cobalt catalyst. The simulation results showed a good agreement with the experimental data. The experimental data showed that higher CO conversion and lower CH₄ and CO₂ selectivities were achieved in supercritical media compared to the gaseous phase. The BET surface area and pore volume enhancement results provided evidence of the higher in situ extraction and greater solubility of heavy hydrocarbons in supercritical media than in gaseous phases. Furthermore, the effects of supercritical solvent such as n‐pentane, n‐hexane, n‐heptane and their mixtures were studied. Moreover, the influence of reaction temperature, H₂/CO ratio, W/F_(CO+H2) and pressure tuning in the supercritical media FT synthesis were investigated, as well as the effect of the supercritical fluid on the heat transfer within the reactor. The product carbon distribution had a similar shape for all types of solvents and shifted to lighter molar mass compounds with increasing temperature, H₂/CO ratio, and W/F_(CO+H2). Finally, the product distribution shifted to higher molar mass hydrocarbons with increasing pressure. As a result, one may conclude that a mixture of hydrocarbon products of the FTS can be used as a solvent for supercritical media in Fischer‐Tropsch synthesis.     

Increasing carbon utilization in Fischer-Tropsch synthesis using H2-deficient or CO2-rich syngas feeds

Fischer-Tropsch technology has become a topical issue in the energy industry in recent times. The synthesis of linear hydrocarbon that has high cetane number diesel fuel through the Fischer-Tropsch reaction requires syngas with high H₂/CO ratio. Nevertheless, the production of syngas from biomass and coal, which have low H₂/CO ratios or are CO₂ rich may be desirable for environmental and socio-political reasons. Efficient carbon utilization in such H₂-deficient and CO₂-rich syngas feeds has not been given the required attention. It is desirable to improve carbon utilization using such syngas feeds in the Fischer-Tropsch synthesis not only for process economy but also for sustainable development. Previous catalyst and process development efforts were directed toward maximising C₅₊ selectivity; they are not for achieving high carbon utilization with H₂-deficient and CO₂-rich syngas feeds. However, current trends in FTS catalyst design hold the potential of achieving high carbon utilization with wide option of selectivities. Highlights of the current trends in FTS catalyst design are presented and their prospect for achieving high carbon utilization in FTS using H₂-deficient and CO₂-rich syngas feeds is discussed.     

Kinetics study on cnt‐supported RuKCo FTS catalyst in a fixed bed reactor

The rate of syngas (H₂/CO) consumption over a RuKCo/CNT Fischer–Tropsch synthesis (FTS) catalyst was measured in a fixed bed microreactor at 210–225°C, 2–3.5 MPa, H₂/CO feed molar ratios of 1–2.5, and gas hourly space velocity (GHSV) range of 2700–3600 h^?1. The data have been used to model the kinetics of the FTS reactions within the range of the studied conditions. One empirical power law model and four semi‐empirical kinetic models based on Langmuir–Hinshelwood‐type equation have been evaluated. The best fitting was obtained with the equation: similar to that proposed by Brötz et al. The estimated activation energy (E = 80–85 kJ/mol) is lower than that is reported in the literature. The validity of these results are restricted to fixed beds with the given catalyst in the tested conversion regime.     

Theoretical investigation of a water‐gas‐shift catalytic membrane for diesel reformate purification

The novel application of a catalytic water‐gas‐shift membrane reactor for selective removal of CO from H₂‐rich reformate mixtures for achieving gas purification solely via manipulation of reaction and diffusion phenomena, assuming Knudsen diffusion regime and the absence of hydrogen permselective materials, is described. An isothermal, two‐dimensional model is developed to describe a tube‐and‐shell membrane reactor supplied with a typical reformate mixture (9% CO, 3% CO₂, 28% H₂, and 15% H₂O) to the retentate volume and steam supplied to the permeate volume such that the overall H₂O:CO ratio within the system is 9:1. Simulations indicate that apparent CO:H₂ selectivities of 90:1 to >200:1 at H₂ recoveries of 20% to upwards of 40% may be achieved through appropriate design of the catalytic membrane and selection of operating conditions. Under these conditions, simulations predict an apparent hydrogen permeability of 2.3 × 10^?10 mol m^?1 Pa, which compares favorably against that of competing hydrogen‐permselective membranes. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4334–4345, 2013     

Transient Effects during Dynamic Operation of a Wall‐Cooled Fixed‐Bed Reactor for CO2 Methanation

The power‐to‐gas process is an option to transform fluctuating renewable electric energy into methane via water electrolysis and subsequent conversion of H₂ by methanation with CO₂. The dynamic behavior of the methanation reactor may then be a critical aspect. The kinetics of CO₂ methanation on a Ni‐catalyst were determined under isothermal and stationary conditions. Transient isothermal kinetic experiments showed a fast response of the rate on step changes of the concentrations of H₂, CO₂; in case of H₂O, the response was delayed. Non‐isothermal experiments were conducted in a wall‐cooled fixed‐bed reactor. Temperature profiles were measured and the effect of a changing volumetric flow was studied. The experimental data were compared with simulations by a transient reactor model.     

Syngas production from H2O and CO2 over Zn particles in a packed‐bed reactor

The solar thermochemical production of H₂ and CO (syngas) from H₂O and CO₂ is examined via a two‐step cycle based on Zn/ZnO redox reactions. The first, endothermic step is the thermolysis of the ZnO driven by concentrated solar energy. The second, nonsolar step is the exothermic reaction of Zn with a mixture of H₂O and CO₂ yielding syngas and ZnO; the latter is recycled to the first step. A series of experimental runs of the second step was carried out in a packed‐bed reactor where ZnO particles provided an effective inert support for preventing sintering and enabling simple and complete recycling to the first, solar step. Experimentation was performed for Zn mass fractions in the range of 33–67 wt % Zn‐ZnO, and inlet gas concentrations in the range 0–75% H₂O–CO₂, yielding molar Zn‐to‐ZnO conversions up to 91%. A 25 wt % Zn‐ZnO sample mixture produced from the solar thermolysis of ZnO was tested in the same reactor setup and exhibited high reactivity and conversions up to 96%. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Syngas Production via Reverse Water‐Gas Shift Reaction over a Ni‐Al2O3 Catalyst: Catalyst Stability,Reaction Kinetics,and Modeling

The synthesis of liquid fuels from CO₂, e.g., separated from flue gases of power plants, and H₂ from renewables, i.e., water electrolysis, is a concept for substituting fossil fuels in the transport sector. It consists of two steps, syngas production via reverse water‐gas shift (RWGS) and synfuel production by Fischer‐Tropsch synthesis. Research is concentrated on the RWGS using a Ni‐catalyst. The catalyst shows an appropriate performance in catalyzing the RWGS. The catalyst is stable at technically relevant temperatures. The intrinsic and effective kinetics were determined and considerations on a technical application of the process are proposed.     

Pathways for CO2 Formation and Conversion During Fischer–Tropsch Synthesis on Iron-Based Catalysts

CO₂ reaction and formation pathways during Fischer–Tropsch synthesis (FTS) on a co-precipitated Fe–Zn catalyst promoted with Cu and K were studied using a kinetic analysis of reversible reactions and with the addition of ¹³C-labeled and unlabeled CO₂ to synthesis gas. Primary pathways for the removal of adsorbed oxygen formed in CO dissociation steps include reactions with adsorbed hydrogen to form H₂O and with adsorbed CO to form CO₂. The H₂O selectivity for these pathways is much higher than that predicted from WGS reaction equilibrium; therefore readsorption of H₂O followed by its subsequent reaction with CO-derived intermediates leads to the net formation of CO₂ with increasing reactor residence time. The forward rate of CO₂ formation increases with increasing residence time as H₂O concentration increases, but the net CO₂ formation rate decreases because of the gradual approach to WGS reaction equilibrium. CO₂ addition to synthesis gas does not influence CO₂ forward rates, but increases the rate of their reverse steps in the manner predicted by kinetic analyses of reversible reactions using non-equilibrium thermodynamic treatments. Thus the addition of CO₂ could lead to the minimization of CO₂ formation during FTS and to the preferential removal of oxygen as H₂O. This, in turn, leads to lower average H_2/CO ratios throughout the catalyst bed and to higher olefin content and C₅₊ selectivity among reaction products. The addition of ¹³CO₂ to H₂/¹²CO reactants did not lead to significant isotopic enrichment in hydrocarbon products, indicating that CO₂ is much less reactive than CO in chain initiation and growth. We find no evidence of competitive reactions of CO₂ to form hydrocarbons during reactions of H₂/CO/CO₂ mixtures, except via gas phase and adsorbed CO intermediates, which become kinetically indistinguishable from CO₂ as the chemical interconversion of CO and CO₂ becomes rapid at WGS reaction equilibrium.     

Partial oxidation of methane in hollow‐fiber membrane reactors based on alkaline‐earth metal‐free CO2‐tolerant oxide

The U‐shaped alkaline‐earth metal‐free CO₂‐stable oxide hollow‐fiber membranes based on (Pr_0.9La_0.1)₂(Ni_0.74Cu_0.21Ga_0.05)O_4+δ (PLNCG) are prepared by a phase‐inversion spinning process and applied successfully in the partial oxidation of methane (POM) to syngas. The effects of temperature, CH₄ concentration and flow rate of the feed air on CH₄ conversion, CO selectivity, H₂/CO ratio, and oxygen permeation flux through the PLNCG hollow‐fiber membrane are investigated in detail. The oxygen permeation flux arrives at approximately 10.5 mL/min cm² and the CO selectivity is higher than 99.5% with a CH₄ conversion of 97.0% and a H₂/CO ratio of 1.8 during 140 h steady operation. The spent hollow‐fiber membrane still maintains a dense microstructure and the Ruddlesden‐Popper K₂NiF₄‐type structure, which indicates that the U‐shaped alkaline‐earth metal‐free CO₂‐tolerant PLNCG hollow‐fiber membrane reactor can be steadily operated for POM to syngas with good performance. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3587–3595, 2014     

Catalytic partial oxidation of CH4 over bimetallic Ni‐Re/Al2O3: Kinetic determination for application in microreactor

The activity of a novel Ni‐Re/Al₂O₃ catalyst toward partial oxidation of methane was investigated in comparison with that of a precious‐metal Rh/Al₂O₃ catalyst. Reactions involving CH₄/O₂/Ar, CH₄/H₂O/Ar, CH₄/CO₂/Ar, CO/O₂/Ar, and H₂/O₂/Ar were performed to determine the kinetic expressions based on indirect partial oxidation scheme. A mathematical model comprising of Ergun equation as well as mass and energy balances with lumped indirect partial oxidation network was applied to obtain the kinetic parameters and then used to predict the reactant and product concentrations as well as temperature profiles within a fixed‐bed microreactor. H₂ and CO production as well as H₂/CO₂ and CO/CO₂ ratios from the reaction over Ni‐Re/Al₂O₃ catalyst were higher than those over Rh/Al₂O₃ catalyst. Simulation revealed that much smoother temperature profiles along the microreactor length were obtained when using Ni‐Re/Al₂O₃ catalyst. Steep hot‐spot temperature gradients, particularly at the entrance of the reactor, were, conversely, noted when using Rh/Al₂O₃ catalyst. © 2017 American Institute of Chemical Engineers AIChE J, 64: 1691–1701, 2018     

Influence of CO2 co-feeding on Fischer–Tropsch fuels production over carbon nanofibers supported cobalt catalyst

Nowadays, the syngas which is obtained from the reforming of coal, biomass or natural gas contain significantly amounts of CO₂ that cannot be separated and consequently, it can take part into the Fischer–Tropsch (FTS) catalytic activity. Therefore, the presence of CO₂ in the syngas flow should be taken into account. In the present study, the FTS CO hydrogenation process was compared to that of CO₂ on a carbon nanofibers supported Co catalyst. The influence of CO₂ content in the feed stream (H₂/CO/CO₂ ratio) on the reaction performance in terms of conversion and selectivity to the different products was described. Both the support and the prepared catalyst were characterized by nitrogen adsorption–desorption, temperature-programmed reduction (TPR) and X-ray diffraction (XRD). Results showed that CO hydrogenation was controlled by a Fischer–Tropsch regime, whereas CO₂ hydrogenation was controlled by a methanation process. When feed was composed of CO and CO₂ mixtures, the catalytic activity decreased with respect to that obtained with a CO₂-free feed stream. Moreover, the presence of CO₂ in feed stream favored the formation of lighter hydrocarbons and could block the production of further CO₂ via Water-Gas-Shift (WGS) reaction.     

Enhancing co‐production of H2 and syngas via water splitting and POM on surface‐modified oxygen permeable membranes

In this article, we report a detailed study on co‐production of H₂ and syngas on La_0.9Ca_0.1FeO_3?δ (LCF‐91) membranes via water splitting and partial oxidation of methane, respectively. A permeation model shows that the surface reaction on the sweep side is the rate limiting step for this process on a 0.9 mm‐thick dense membrane at 990°C. Hence, sweep side surface modifications such as adding a porous layer and nickel catalysts were applied; the hydrogen production rate from water thermolysis is enhanced by two orders of magnitude to 0.37 μmol/cm²?s compared with the results on the unmodified membrane. At the sweep side exit, syngas (H₂/CO = 2) is produced and negligible solid carbon is found. Yet near the membrane surface on the sweep side, methane can decompose into solid carbon and hydrogen at the surface, or it may be oxidized into CO and CO₂, depending on the oxygen permeation flux. © 2016 American Institute of Chemical Engineers AIChE J, 62: 4427–4435, 2016     

Gasoline-range hydrocarbon synthesis over Co/SiO2/HZSM-5 catalyst with CO2-containing syngas

Selective synthesis of gasoline-range hydrocarbons (C₅-C₁₂) was investigated in a fixed-bed micro reactor using two series of CO₂-containing syngas with various mole CO₂/(CO + CO₂) and H₂/(CO + CO₂) ratios, where Fischer-Tropsch synthesis(FTS) and in situ hydrocracking/hydroisomerization were performed over bifunctional Co/SiO₂/HZSM-5 catalyst. CO₂ was converted at 0.15-0.55 of CO₂/(CO + CO₂) ratio under H₂-rich condition (H₂/(CO + CO₂) = 2.0), highest conversion of 20.3% at 0.42. Further increasing CO₂ content decreased CO₂ conversion and quite amount of CO₂ acted as diluting component. For the syngas with low H₂ content or H₂/(CO + CO₂) ratio(< 1.85, H₂/CO = 2.0), the competitive adsorption of CO, H₂ and CO₂ resulted in low CO, CO₂ and total carbon conversion, which was 57.9%, 12.7% and 31.4% respectively at 0.74 of H₂/(CO + CO₂) ratio(H₂/CO/CO₂/N₂ = 40.8/20.4/34.8/4). FTS results indicated that high H₂ content and proper H₂/(CO + CO₂) ratio were favorable for the conversion of CO₂-containing syngas. More than 45% selectivity to gasoline-range hydrocarbons including isoparaffins was obtained under the two series of syngas. It was also tested that the catalytic activity of Co/SiO₂/HZSM-5 kept stable under CO₂-containing syngas(< 7.5%). And the quick catalytic deactivation under high CO₂ containing syngas(H₂/CO/CO₂/N₂ = 45.3/23.2/27.1/3.06) was due to carbon deposition and pore blockage by heavy hydrocarbon, tested by thermal gravimetry, N₂ physisorption and scanning electron microscopy(SEM).     

Fischer‐Tropsch Synthesis: Modeling and Performance Study for Fe‐HZSM5 Bifunctional Catalyst

A water‐cooled fixed bed Fischer‐Tropsch reactor packed with Fe‐HZSM5 catalyst has been modeled in two dimensions (radial and axial) using the intrinsic reaction rates previously developed at RIPI. The reactor is used for production of high‐octane gasoline from synthesis gas. The Fischer‐Tropsch synthesis reactor was a shell and tube type with high pressure boiling water circulating on the shell side. By the use of a two‐dimensional model, the effects of some important operating parameters such as cooling temperature, H₂/CO ratio in syngas and reactor tube diameter on the performance capability of the reactor were investigated. Based on these results, the optimum operating conditions and the tube specification were determined. The model has been used to estimate the optimum operating conditions for the pilot plant to be operated in RIPI.     

The pyrolysis behaviors of polyimide foam derived from 3,3′,4,4′‐benzophenone tetracarboxylic dianhydride/4,4′‐oxydianiline

The thermal stability and pyrolysis behaviors of polyimide (PI) foam derived from 3,3′,4,4′‐benzophenone tetracarboxylic dianhydride (BTDA)/4,4′‐oxydianiline (4,4′‐ODA) in air and in nitrogen were studied. The decomposition products of PI foam were analyzed by thermogravimetry‐Fourier transform infrared spectroscopy (TG‐FTIR). Several integral and differential methods reported in the literatures were used in decomposition kinetics analysis of PI foam. The results indicated that the PI foam was easier to decompose in air than in nitrogen, with ～ 55% residue remaining in nitrogen versus zero in air at 800^oC. The main pyrolysis products were CO₂, CO, and H₂O in air and CO₂, CO, H₂O, and small organic molecules in nitrogen. The different dynamic methods gave similar results that the apparent activation energies, pre‐exponential factors, and reaction orders were higher in nitrogen than those in air. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Simulation Analysis of a GTL Process Using Aspen Plus

Gas‐to‐liquid (GTL) processes are becoming attractive due to the increasing price of crude oil. Process simulation analysis on the integrated GTL process is essential as part of an extended process integration analysis of the research subjects. The two sub‐process models for the GTL process, i.e., the syngas generation process and the Fischer Tropsch synthesis (FTS) process, are analyzed in detail with ASPEN Plus. The autothermal reforming process (ATR) is analyzed using Aspen Plus based on the Gibbs reactor model, while FTS is simulated with ASPEN Plus based on detailed kinetic models for industrial iron and cobalt catalysts. Integrated GTL processes with iron and cobalt‐based catalysts were simulated using ASPEN Plus. The optimal flowsheet structures were selected for each catalyst based on the overall performance in terms of thermal and carbon efficiency and product distributions. For the cobalt‐based catalyst, the full conversion concept without CO₂ removal from the FT tail gas is optimal. On the other hand, the once‐through concept with two series reactors and CO₂ removal from raw syngas is considered optimal for the iron‐based catalyst. The thermal efficiency to crude products is likely to be ca. 60 % for the cobalt‐based catalyst, whereas it is in the range of 49–55 % for the iron‐based catalyst. The carbon efficiency using the water‐gas shift reaction is lower using the iron‐based catalyst (61–68 %) than the cobalt‐based catalyst (73–75 %). As expected, the cobalt‐based catalyst is more active and selective, which offers better selectivity towards C₅+ (75–79 %). The selectivity towards C₅+ for the iron‐based catalyst lies in the range 63–75 %.     

Enhanced hydroformylation by carbon dioxide‐expanded media with soluble Rh complexes in nanofiltration membrane reactors

A novel process for continuous hydroformylation in CO₂‐expanded liquids (CXLs) is demonstrated using bulky phosphite ligands that are effectively retained in the stirred reactor by a nanofiltration membrane. The reactor is operated at 50°C with a syngas pressure of 0.6 MPa to avoid CO inhibition of reaction rate and selectivity. The nanofiltration pressure is provided by ～3.2 MPa CO₂ that expands the hydroformylation mixture and increases the H₂/CO ratio in the CXL phase resulting in enhanced turnover frequency (～340 h^?1), aldehydes selectivity (>90%) and high regioselectivity (n/i ～8) at nearly steady operation. The use of pressurized CO₂ also reduces the viscosity in the CXL phase, thereby improving the mass‐transfer properties. Constant permeate flux is maintained during the 50 h run with Rh leakage being less than 0.5 ppm. This technology concept has potential applications in homogeneous catalytic processes to improve resource utilization and catalyst containment for practical viability. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4287–4296, 2013     

Novel Co‐Mn‐O nanosheet catalyst for CO preferential oxidation toward hydrogen purification

Co‐Mn‐O composite oxide nanosheet catalyst was successfully prepared using a facile urea‐assisted one‐step hydrothermal method in the absence of organic or organic templating reagent. Co‐Mn‐O nanosheet catalyst was optimized by varying hydrothermal process parameters such as molar ratio of Co‐Mn to urea, hydrothermal temperature, and hydrothermal time. Various characterization techniques including scanning electron microscopy, X‐ray diffraction, nitrogen adsorption, X‐ray photoelectron spectroscopy, Raman spectroscopy, and H₂ temperature‐programmed reduction were used to reveal the relationship between catalyst nature and catalytic performance in CO preferential oxidation (CO PROX) in excess H₂. The developed Co‐Mn‐O nanosheet catalyst have demonstrated much superior catalytic performance to Co‐Mn‐O nanoparticle, particularly in the low temperature range, and 100% CO conversion over the developed Co‐Mn‐O nanosheet can be achieved in temperature range of 50 to 150°C at 10,000 mL g^?1 h^?1 of gas hourly space velocity in the standard feed. Furthermore, the almost complete CO removal over Co‐Mn‐O nanosheet at 125°C of low temperature with 94.9% selectivity can be achieved even in the simulated reformed gas. The excellent catalytic performance is ascribed to nanosheet morphology, more surface Co³⁺, smaller average crystallite size, higher reducibility, and strong Co‐Mn interaction. Catalytic stability investigation indicates the developed nanostructured catalyst exhibits high catalytic stability for CO PROX reaction in simulated gas. The developed Co‐Mn‐O nanosheet catalyst can be a potential candidate for catalytic elimination of trace CO from H₂‐rich gas for Proton exchange membrane fuel cell applications. © 2014 American Institute of Chemical Engineers AIChE J, 61: 239–252, 2015     

Study on Fe–Al2O3 interaction over precipitated iron catalyst for Fischer–Tropsch synthesis

Two model spherical iron catalysts (100Fe/0Al₂O₃ and 100Fe/15Al₂O₃) with free Cu and K promoters were prepared by the combination of co-precipitation and spray drying method for the application of slurry Fischer–Tropsch synthesis (FTS). The effect of Fe–Al₂O₃ interaction on the reduction/carburization behavior in H₂/CO/syngas, surface basicity and the change of phase structure were comparatively studied by means of H₂ or CO temperature-programmed reduction (TPR), CO₂ temperature-programmed desorption (TPD) and Mössbauer effect spectroscopy (MES). The results showed that the catalyst incorporated with Al₂O₃ exhibits a strong Fe–Al₂O₃ interaction, which obviously weakens the surface basicity, stabilizes the FeO phase and inhibits the reduction of iron catalyst in H₂ or syngas. Furthermore, Fe–Al₂O₃ interaction also restrains the carburization of iron catalyst in CO or syngas. In slurry FTS process, it was found that the strong Fe–Al₂O₃ interaction decreases the FTS activity and suppresses the water gas shift (WGS) reaction, but can stabilize the active sites of iron catalyst and improve its run stability. Due to the strong Fe–Al₂O₃ interaction, the weak surface basicity on the catalyst incorporated with Al₂O₃ greatly decreases the selectivity of heavy hydrocarbon products.