An experimental investigation of Fischer–Tropsch synthesis over washcoated metallic structured supports

In principle, the application of monolithic catalysts to the Fischer–Tropsch synthesis can solve many of the problems related to the classical Fischer–Tropsch reactors, in particular concerning the necessity to operate with short diffusion distances and low pressure drops, preferably according to the ideal plug-flow behavior, while still maintaining a reasonable inventory of catalytic material in the reactor volume.The preparation of prototype cobalt-based catalysts, washcoated onto metallic structured supports with different geometries, is described herein, together with the evaluation of the catalytic properties of such systems in the Fischer–Tropsch synthesis at industrially relevant process conditions (220–235 °C, 20 bar, 2.1  mol_H2/mol_CO,  5000 cm³(STP)_CO+H2/h/g_cat). Comparative tests with the same catalyst in the powdered form were also carried out at the same process conditions.It was found that the structured catalysts maintained the activity and the selectivity of the original powdered catalyst, provided that the washcoat thickness is sufficiently thin.     

High temperature SrCe0.9Eu0.1O3−δ proton conducting membrane reactor for H2 production using the water–gas shift reaction

The water–gas shift (WGS) reaction is used to shift the CO/H₂ ratio prior to Fischer–Tropsch synthesis and/or to increase H₂ yield. A WGS membrane reactor was developed using a mixed protonic–electronic conducting SrCe_0.9Eu_0.1O_3−δ membrane coated on a Ni–SrCeO_3−δ support. The membrane reactor overcomes the thermodynamic equilibrium limitations. A 46% increase in CO conversion and total H₂ yield was achieved at 900 °C under 3% CO and 6% H₂O, resulting in a 92% single pass H₂ production yield and 32% single pass yield of pure permeated H₂.     

Effect of CO2 in the feed stream on the deactivation of Co/γ-Al2O3 Fischer–Tropsch catalyst

The influence of CO₂ on the deactivation of Co/γ-Al₂O₃ Fischer–Tropsch (FT) catalyst in CO hydrogenation has been investigated. The presence of CO₂ in the feed stream reveals a negative effect on catalyst stability and in the formation of heavy hydrocarbons. The CO₂ acts as a mild oxidizing agent on cobalt metal during Fischer–Tropsch synthesis. During FT synthesis on Co/γ-Al₂O₃ of 70 h, the CO conversion and C₅₊ selectivity in the presence of CO₂ decreased more significantly than in the absence of CO₂. CO₂ is found to be responsible for the partial oxidation of surface cobalt metal at FT synthesis environment with the co-existence of generated water.     

Intensified Fischer–Tropsch synthesis process with microchannel catalytic reactors

A microchannel catalytic reactor with improved heat and mass transport has been used for Fischer–Tropsch synthesis. It was demonstrated that this microchannel reactor based process can be carried out at gas hourly space velocity (GHSV) as high as 60,000 h⁻¹ to achieve greater than 60% of single-pass CO conversion while maintaining relatively low methane selectivity (<10%) and high chain growth probability (>0.9). In this study, performance data were obtained over a wide range of pressure (10–35 atm) and hydrogen-to-carbon monoxide ratio (1–2.5). The catalytic materials were characterized using BET, scanning electron microcopy (SEM), transmission electron microcopy (TEM), and H₂ chemisorption. A three-dimensional pseudo-homogeneous model was used to simulate temperature profiles in the exothermic reaction system in order to optimize the reactor design. Intraparticle non-isothermal characteristics are also analyzed for the FT synthesis catalyst.     

Catalytic NO–H2–CO–O2 reactions over Pt-supported mesoporous yttrium oxide

Catalytic light-off of a stream of NO, H₂, CO in an excess O₂ has been studied over various metal oxides loading 1 wt% Pt. Because a low-surface area Y₂O₃ (<5 m² g⁻¹) was found to exhibit the highest de-NO_x activity, a mesoporous Y₂O₃ was then synthesized from an yttrium-based surfactant mesophase templated by dodecyl sulfate , which was anion-exchanged by acetate (AcO = CH₃COO⁻). The product showed a 3-D mesoporosity with a large surface area (396 m² g⁻¹) and the Pt-supported catalyst achieved much improved light-off characteristics suitable for the low-temperature de-NO_x in the presence of CO and excess O₂.     

Study of ruthenium supported on Ta2O5–ZrO2 and Nb2O5–ZrO2 as catalysts for the partial oxidation of methane

Ru-based catalysts supported on Ta₂O₅–ZrO₂ and Nb₂O₅–ZrO₂ are studied in the partial oxidation of methane at 673–873 K. Supports with different Ta₂O₅ or Nb₂O₅ content were prepared by a sol–gel method, and RuCl₃ and RuNO(NO₃)₃ were used as precursors to prepare the catalysts (ca. 2 wt.% Ru). At 673 K high selectivity to CO₂ was found. An increase of temperature up to 773 K produced an increase in the selectivity to syngas (H₂/CO = 2.2–3.1), and this is related with the transformation of RuO₂ to metallic Ru as was determined from XRD and XPS results. At 873 K and with co-fed CO₂ an increase of the catalytic activity and CO selectivity was found. A TOF value of 5.7 s⁻¹ and H₂/CO ratio ca. 1 was achieved over Ru(Cl)/6TaZr. Catalytic results are discussed as a function of the support composition and characteristics of Ru-based phases.     

Carbon nanotube-supported Pd–ZnO catalyst for hydrogenation of CO2 to methanol

A type of Pd–ZnO catalysts supported on multi-walled carbon nanotubes (MWCNTs) were developed, with excellent performance for CO₂ hydrogenation to methanol. Under reaction conditions of 3.0 MPa and 523 K, the observed turnover-frequency of CO₂ hydrogenation reached 1.15 × 10⁻² s⁻¹ over the 16%Pd_0.1Zn₁/CNTs(h-type). This value was 1.17 and 1.18 times that (0.98 × 10⁻² and 0.97 × 10⁻² s⁻¹) of the 35%Pd_0.1Zn₁/AC and 20%Pd_0.1Zn₁/γ-Al₂O₃ catalysts with the respective optimal Pd_0.1Zn₁-loading. Using the MWCNTs in place of AC or γ-Al₂O₃ as the catalyst support displayed little change in the apparent activation energy for the CO₂ hydrogenation, but led to an increase of surface concentration of the Pd⁰-species in the form of PdZn alloys, a kind of catalytically active Pd⁰-species closely associated with the methanol generation. On the other hand, the MWCNT-supported Pd–ZnO catalyst could reversibly adsorb a greater amount of hydrogen at temperatures ranging from room temperature to 623 K. This unique feature would help to generate a micro-environment with higher concentration of active H-adspecies at the surface of the functioning catalyst, thus increasing the rate of surface hydrogenation reactions. In comparison with the “Parallel-type (p-type)” MWCNTs, the “Herringbone-type (h-type)” MWCNTs possess more active surface (with more dangling bonds), and thus, higher capacity for adsorbing H₂, which make their promoting action more remarkable.     

Preferential oxidation of CO in excess hydrogen over a nanostructured CuO–CeO2 catalyst with high surface areas

CuO–CeO₂ is prepared by coprecipitation and ethanol washing and characterized using BET, HR-TEM, XRD and TPR techniques. The results show that CuO–CeO₂ is nanosized (r_TEM = 6.5 nm) and possesses high surface area (S_BET = 138 m² g⁻¹). Furthermore, some lattice defects in the surface of CuO–CeO₂ are found, which are beneficial to enhance catalytic performance of CuO–CeO₂ in preferential oxidation of CO in excess hydrogen (PROX). Consequently, the nanostructured CuO–CeO₂ exhibits perfect catalytic performance in PROX. Namely, CO content can be lowered to less than 100 ppm at 150 °C with 100% selectivity of O₂ in the presence of 8% CO₂ and 20% H₂O at .     

Influence of the type of sepiolite on the modification of the pore-size distribution in γ-Al2O3 supports

γ-Al₂O₃ modified supports with bimodal pore-size distributions were prepared by the addition of different types of natural sepiolites (α or β) into alumina. The supports were characterized by nitrogen physisorption, mercury porosimetry, X-ray diffraction, HRTEM and DTA techniques. A wide range of S_BET (94–238 m² g^− 1), pore volumes (0.3–0.82 cm³ g^− 1), and pore sizes were obtained in the supports depending on the type of sepiolite and its concentration added into alumina. The pore sizes were distributed as follows: mesopores around 1.8 nm in radius, mesopores in the radius range 3.0–25 nm and macropores between 25 and 300 nm in radius. The shape of the pore-size distributions depended on the type of sepiolite: the modal peak for pores larger than 3.0 nm was broad with β-type sepiolites and narrow with α-type sepiolites. The mesopore and macropore sizes can be controlled by the type of sepiolite as well as its concentration added to alumina.     

CO adsorption energy on planar Au/TiO2 model catalysts under catalytically relevant conditions

The adsorption of CO on planar Au/TiO₂ model catalysts was studied by polarization-modulation infrared reflection–absorption spectroscopy (PM-IRAS) under catalytically relevant pressure (10–50 mbar) and temperature (30–120 °C) conditions, both in pure CO and in CO/O₂ reaction gas mixtures. The adsorption energy of CO on the Au particles was determined by a quantitative analysis of the temperature dependence of the CO absorption intensity in adsorption isobars. The data reveal considerable effects of the Au particle size when pure CO is used; the initial adsorption energy decreases from 74 kJ mol⁻¹ (2 nm mean Au particle diameter) to 62 kJ mol⁻¹ (4 nm). For CO/O₂ gas mixtures, the initial CO adsorption energy is, irrespective of the Au particle size, constant at 63 kJ mol⁻¹ (i.e., the CO adsorption energy is reduced for smaller Au particles), but this effect vanishes for larger Au particles.     

Electrodeposited Cu–ZnO and Mn–Cu–ZnO nanowire/tube catalysts for higher alcohols from syngas

Cu–ZnO and Mn–Cu–ZnO catalysts have been prepared by electrodeposition and tested for the synthesis of higher alcohols via CO hydrogenation. The catalysts were prepared in the form of nanowires and nanotubes using a nanoporous polycarbonate membrane, which served as a template for the electrodeposition of the precursor metals from an aqueous electrolyte solution. Electrodeposition was carried out using variable amounts of Zn(NO₃)₂, Cu(NO₃)₂, Mn(NO₃)₂ and NH₄NO₃ at different galvanostatic conditions. A fixed bed reactor was used to study the reaction of CO and H₂ to produce alcohols at 270 °C, 10–20 bar, H₂/CO = 2/1, and 10,000–33,000 scc/h g_cat. In addition to methane and CO₂, methanol was the main alcohol product. The addition of manganese to the Cu–ZnO catalyst increased the selectivity toward higher alcohols by reducing methane formation; however, CO₂ selectivity remained high. Maximum ethanol selectivity was 5.5%, measured as carbon efficiency.     

Evidence of strong metal–oxide interactions in promoted Rh/SiO2 on CO hydrogenation: Analysis at the site level using SSITKA

It has been suggested that the behavior of Group VIII metal catalysts supported on transition metal oxides can be significantly affected by pretreatment conditions due to strong metal–oxide interactions (SMOI). However, the origins for the SMOI effect are still in debate. In this research, SMOI of Rh and vanadium oxide (as a promoter) supported on SiO₂ were studied at the site level for the first time, which provides an insight into the modification of surface properties after high temperature reduction. H₂ chemisorption, Fischer–Tropsch synthesis (FTS), and SSITKA (steady-state isotopic transient kinetic analysis) were used to probe the SMOI effects. The catalytic properties of the catalysts for CO hydrogenation were investigated using a differential fixed bed reactor at 230 °C and 1.8 atm, while for SSITKA, a reaction temperature of 280 °C and an excess of H₂ was used to maximize methane production. The addition of V to Rh/SiO₂ suppresses H₂ chemisorption, and high reduction temperature further decreases H₂ chemisorption on Rh/V/SiO₂ but has little effect on Rh/SiO₂. As reduction temperature increases, the activity for CO hydrogenation on Rh/SiO₂ remains essentially unchanged, but the activity of Rh/V/SiO₂ decreases significantly. SSITKA shows that the concentration of surface reaction intermediates decreases on Rh/V/SiO₂ as the reduction temperature increases, but the activities of the reaction sites increase. The results suggest that Rh being covered by VO_x species is probably the main reason for the decreased overall activity induced by high reduction temperature, but more active sites appear to be formed probably at the Rh–VO_x interface.     

Phase relations and electrical properties in the pseudo-ternary La2O3–TiO2–Mn2O3 system in air

Scanning electron microscopy (SEM), electron-probe microanalysis, energy- and wavelength-dispersive X-ray analysis and X-ray powder diffraction were used to investigate the subsolidus phase relations in the pseudo-ternary La₂O₃–TiO₂–Mn₂O₃ system in air (oxygen partial pressure p_O2=0.21   atm) at 1275 °C. The addition of Mn₂O₃ to the starting La₂O₃:3TiO₂ mixture led to the formation of a La-deficient perovskite La_2/3TiO₃ compound. The oxides form two new compounds with the proposed compositions: (i) La_1.7Ti_13.0Mn_6.3O_38−x, with a davidite-like crystal structure, and (ii) La₄₉Ti₁₈Mn₁₃O₁₂₉. There were also several solid solutions existing over a wide range of concentrations.     

Effect of calcium promoter on a precipitated iron–manganese catalyst for Fischer–Tropsch synthesis

A series of precipitated Fe/Mn Fischer–Tropsch synthesis (FTS) catalysts incorporated with calcium promoter were prepared by the combination of co-precipitation and spray-drying technology. The catalysts were characterized by using N₂ physisorption, CO₂ temperature-programmed desorption and Mössbauer spectroscopy methods. FTS performances of the catalysts were tested in a 1 dm³ continuous stirred tank reactor. It is found that calcium promoter has negligible effect on the textural properties, and the addition of calcium promoter can enhance the surface basicity of the catalyst. An appropriate amount of calcium promoter can promote the reduction and carburization of the catalysts during the reduction and Fischer–Tropsch synthesis (FTS) reaction in syngas, but the excessive addition of calcium promoter will decrease the extent of reduction and carburization. The reaction results indicated that the activities of both FTS and water-gas shift (WGS) decrease with the incorporation of calcium promoter. Calcium promoter can inhibit the hydrogenation ability, suppress the formation of methane, and enhance the selectivities to olefin and higher molecular weight products.     

Effect of promotion with ruthenium on the structure and catalytic performance of mesoporous silica (smaller and larger pore) supported cobalt Fischer–Tropsch catalysts

The effects of promotion with ruthenium on the structure of cobalt catalysts and their performance in Fischer–Tropsch synthesis were studied using MCM-41 and SBA-15 as catalytic supports. The catalysts were characterized by N₂ physisorption, H₂-temperature programmed reduction, in situ magnetic measurements, X-ray diffraction and X-ray photoelectron spectroscopy. It was found that monometallic cobalt catalysts supported by smaller pore mesoporous silicas (d_p = 3–4 nm) had much lower activity in Fischer–Tropsch synthesis than their larger pore counterparts (d_p = 5–6 nm). Promotion with ruthenium of smaller pore cobalt catalysts led to a considerable increase in Fischer–Tropsch reaction rate, while the effect of the promotion with ruthenium was less significant with the catalysts supported by larger pore silicas.Characterizations of smaller pore cobalt catalysts revealed strong impact of ruthenium promotion on the repartition of cobalt between reducible Co₃O₄ phase and barely reducible amorphous cobalt silicate in the calcined catalyst precursors. Smaller pore monometallic cobalt catalysts showed high fraction of barely reducible cobalt silicate. Promotion with ruthenium led to a significant increase in the fraction of reducible Co₃O₄ and in decrease in the amount of cobalt silicate. In both calcined monometallic and Ru-promoted cobalt catalysts supported by larger pore silicas, easy reducible Co₃O₄ was the dominant phase. Promotion with ruthenium of larger pore catalysts had smaller influence on cobalt dispersion, fraction of reducible cobalt phases and thus on catalytic performance.     

Influence of Ru segregation on the activity of Ru–Co/γ-Al2O3 during FT synthesis: A comparison with that of Ru–Co/SiO2 catalysts

γ-Al₂O₃ and SiO₂ supported Co catalysts, with varying amounts of Ru, were prepared and evaluated for Fischer–Tropsch synthesis (FTS). The composition of Ru for optimum activity was found to be support-dependent. The reducible Co₃O₄ was high in the region of 0–1.64 wt.% of Ru in Co/SiO₂ catalysts. Co/γ-Al₂O₃ displayed a maximum for reducible Co species at 0.42 wt.% Ru. Segregation of Ru occurred beyond this composition decreasing the extent of reduction. Co/γ-Al₂O₃ catalysts showed lower activity and olefin selectivity, in spite of higher Co dispersion, than Co/SiO₂ catalysts. The catalytic performance depends on the amount of reducible Co species, which again depends upon the optimum content of Ru.     

Synthesis and properties of a zeolite LEV analogue from the system—Na2O–Al2O3–SiO2–N,N-dimethylpiperidine chloride–H2O

A new structure-directing agent (SDA) was firstly reported for the synthesis of a zeolite LEV analogue. N,N-dimethyl piperidine performed the SDA function, and induced the synthesis of products from a zeolite MOR with 12-ring channels to a zeolite LEV analogue with only 8-ring channels. The zeolite LEV analogue was synthesized from gels with initial compositions (5.0–6.0)Na₂O–Al₂O₃–(10–200)SiO₂–(4.0–8.0)N,N-dimethyl piperidine–400H₂O at 150 °C. The ²⁹Si NMR spectra showed that the relative intensities of the first line at −115 ppm for low Si/Al ratios were lower than that at high Si/Al ratios. Varying ion exchanges led to different acidities in the zeolite LEV analogue, with the acidity of H-LEV-HCl higher than that of H-LEV-NH₃·H₂O. Zeolite H-LEV in hydration of propene showed a higher selectivity of 1-propanol.     

Effect of Ru addition to Co/SiO2/HZSM-5 catalysts on Fischer–Tropsch synthesis of gasoline-range hydrocarbons

Microporous HZSM-5 zeolite and mesoporous SiO₂ supported Ru–Co catalysts of various Ru adding amounts were prepared and evaluated for Fischer–Tropsch synthesis (FTS) of gasoline-range hydrocarbons (C₅–C₁₂). The tailor-made Ru–Co/SiO₂/HZSM-5 catalysts possessed both micro- and mesopores, which accelerated hydrocracking/hydroisomerization of long-chain products and provided quick mass transfer channels respectively during FTS. In the same time, Ru increased Co reduction degree by hydrogen spillover, thus CO conversion of 62.8% and gasoline-range hydrocarbon selectivity of 47%, including more than 14% isoparaffins, were achieved simultaneously when Ru content was optimized at 1 wt% in Ru–Co/SiO₂/HZSM-5 catalyst.     

The first P–N containing RuCl3NO complex: fac-[RuCl3(NO)(P–N)] (P–N = [o-(N,N-dimethylamino)phenyl]diphenylphosphine)

Complex fac-[RuCl₃(NO)(P–N)] was synthesized from [RuCl₃(H₂O)₂(NO)] in methanol solution under reflux. The orange solid obtained was characterized by NMR (³¹P{¹H}, ¹H, ¹³C) and, cyclic voltammetry, ESI-MS, IR, elemental analysis and X-ray diffraction structure determination. The ³¹P{¹H} reveals the presence of singlet at 36 ppm. IR N–O stretching as KBr pellets or CH₂Cl₂ solution presented 1866 cm⁻¹ and 1872 cm⁻¹, respectively.     

Study on an iron–manganese Fischer–Tropsch synthesis catalyst prepared from ferrous sulfate

A systematic study was undertaken to investigate the effects of the initial oxidation degree of iron on the bulk phase composition and reduction/carburization behaviors of a Fe–Mn–K/SiO₂ catalyst prepared from ferrous sulfate. The catalyst samples were characterized by powder X-ray diffraction (XRD), Mössbauer spectroscopy, X-ray photoelectron spectroscopy (XPS) and H₂ (or CO) temperature-programmed reduction (TPR). The Fischer–Tropsch synthesis (FTS) performance of the catalysts was studied in a slurry-phase continuously stirred tank reactor (CSTR). The characterization results indicated that the fresh catalysts are mainly composed of α-Fe₂O₃ and Fe₃O₄, and the crystallite size of iron oxides is decreased with the increase of the initial oxidation degree of iron. The catalyst with high content of α-Fe₂O₃ in its as-prepared state has high content of iron carbides after being reduced in syngas. However, the catalyst with high content of Fe₃O₄ in its as-prepared state cannot be easily carburized in CO and syngas. FTS reaction study indicates that Fe-05 (Fe³⁺/Fe_total = 1.0) has the highest CO conversion, whereas Fe-03 (Fe³⁺/Fe_total = 0.55) has the lowest activity. The catalyst with high CO conversion has a high selectivity to gaseous hydrocarbons (C₁–C₄) and low selectivity to heavy hydrocarbons (C₅₊).