Cobalt species in promoted cobalt alumina-supported Fischer–Tropsch catalysts

The structure of cobalt species at different stages of the genesis of monometallic and Pt-promoted cobalt alumina-supported Fischer–Tropsch catalysts was studied using X-ray diffraction, UV–visible spectroscopy, in situ X-ray absorption, in situ magnetic method, X-ray photoelectron spectroscopy, and DSC–TGA thermal analysis. The catalysts were prepared by incipient wetness impregnation using solutions of cobalt nitrate and dihydrogen hexachloroplatinate. Both variation of catalyst calcination temperature between 473 and 773 K and promotion with 0.1 wt% of Pt had no significant affect on the size of supported Co₃O₄ crystallites. The size of cobalt oxide particles in the calcined catalysts seems to be influenced primarily by the pore diameter of the support. Cobalt reducibility was relatively low in monometallic cobalt alumina-supported catalysts and decreased as a function of catalyst calcination temperature. The effect was probably due to the formation of mixed surface compounds between Co₃O₄ and Al₂O₃ at higher calcination temperatures, which hinder cobalt reduction. Promotion with platinum spectacularly increased the rate of cobalt reduction; the promotion seemed to reduce the activation energy of the formation of cobalt metallic phases. Analysis of the magnetization data suggests that the presence of Pt led to the reduction of smaller cobalt oxide particles, which could not be reduced at the same conditions in the cobalt monometallic catalysts. Promotion of cobalt alumina-supported catalysts with small amounts of Pt resulted in a significant increase in Fischer–Tropsch cobalt time yield. The efficient control of cobalt reducibility through catalyst calcination and promotion seems to be one of the key issues in the design of efficient cobalt alumina-supported Fischer–Tropsch catalysts.     

Promotion Effects of Platinum and Ruthenium on Carbon Nanotube Supported Cobalt Catalysts for Fischer–Tropsch Synthesis

Abstract  

Carbon nanotube supported nano-size monometallic and noble metal (Pt and Ru) promoted cobalt catalysts were prepared by incipient wetness impregnation (IWI) using solution of cobalt nitrate and characterized by nitrogen adsorption isotherm, X-ray diffraction (XRD), temperature programmed reduction, in situ magnetic method and TEM. Analysis of the magnetization and H₂-TPR data suggested promotion with platinum and ruthenium significantly decreased the cobalt species reduction temperature. TEM and XRD results showed that the presence of noble metal promoters had no significant effect on the size of cobalt for carbon naotube as catalytic support. Promotion of cobalt carbon nanotube-supported catalysts with small amounts of Pt and Ru resulted in slight increase in Fischer–Tropsch cobalt time yield. The Pt and Ru promoted cobalt catalyst exhibited carbon monoxide conversion of 37.1 and 31.4, respectively. C₅+ hydrocarbon selectivity was attained at 80.0%. The Pt promoted cobalt supported on carbon nanotube yielded better catalytic stability than that of the monometallic cobalt catalyst.     

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.     

Ruthenium promotion of Co/SBA-15 catalysts with high cobalt loading for Fischer–Tropsch synthesis

30 wt.%Co/SBA-15 catalysts with different ruthenium contents (0.05–0.5 wt.%) were prepared by incipient wetness impregnation and characterized by diffuse reflectance infrared fourier transform spectroscopy, N₂ adsorption-desorption, X-ray diffractometry, temperature-programmed reduction and H₂ desorption, oxygen titration as well as X-ray photoelectron spectroscopy. The addition of a small amount of Ru promoter to Co/SBA-15 shifted the reduction temperature of both steps (Co₃O₄ → CoO and CoO → Co⁰) to lower temperatures and suppressed the formation of Co²⁺ species. After reduction, ruthenium atoms were encapsulated partially with cobalt cluster. There was no strong electronic interaction between metal cobalt and ruthenium, however, hydrogen spillover from ruthenium to cobalt oxide clusters occurred. With increasing ruthenium content, catalyst reducibility increased and the surface was enriched in cobalt atoms. Moreover, the peak intensities of both the linear and bridge types CO adsorption increased with the increase of ruthenium content, enhancing the catalytic activity on Fischer–Tropsch synthesis.     

The formation of Co2C species in activated carbon supported cobalt-based catalysts and its impact on Fischer–Tropsch reaction

The cobalt carbide (Co₂C) species was formed in some activated carbon supported cobalt-based (Co/AC) catalysts during the activation of catalysts. It was found that the activity of Fischer–Tropsch reaction over Co-based catalysts decreased due to the formation of cobalt carbide species. Some promoters and pretreatment of activated carbon with steam could restrain the formation of cobalt carbide.     

Optimization of the pretreatment procedure in the design of cobalt silica supported Fischer–Tropsch catalysts

The effect of cobalt precursor, catalyst pretreatment and promotion with ruthenium and rhenium on the formation of cobalt metal nanoparticles and catalytic performance of supported Fischer–Tropsch (FT) catalysts was studied using a combination of techniques (DSC–TGA, UV–vis spectroscopy, XPS, XRD, EXAFS–XANES, in situ magnetization measurements, propene chemisorption and catalytic measurements). The cobalt promoted and unpromoted catalysts were prepared by aqueous co-impregnation using cobalt nitrate or acetate, ruthenium nitrosyl nitrate or perrhenic acid. In both unpromoted and Ru and Re-promoted cobalt catalysts after impregnation and drying, cobalt is present mainly in octahedrally coordinated complexes. The repartition of cobalt species between Co₃O₄ and cobalt silicate depends essentially on the exothermicity of precursor decomposition. Cobalt nitrate precursor, with an endothermic decomposition, favors Co₃O₄ crystallites. Lower temperature of cobalt nitrate decomposition and catalyst calcination generally leads to higher dispersion of supported cobalt oxide. Cobalt acetate precursor, with an exothermic decomposition, favors cobalt silicate. By optimizing the conditions of cobalt acetate decomposition, the fraction of cobalt silicate can be decreased favoring a more reducible Co₃O₄ phase. For the catalysts prepared from cobalt nitrate, promotion with ruthenium increases the cobalt dispersion, while maintaining high reducibility. For the catalyst prepared via low temperature decomposition of cobalt acetate, addition of ruthenium increases the fraction of Co₃O₄ crystalline phase and decreases the concentration of barely reducible cobalt silicate. The Fischer–Tropsch reaction rates over unpromoted and promoted cobalt catalysts were found to be primarily a function of the number of cobalt metal sites, which are generated by the reduction of Co₃O₄ crystallites.     

Chemisorption of C3 hydrocarbons on cobalt silica supported Fischer–Tropsch catalysts

Chemisorption of propene and propane was studied in a pulse reactor over a series of cobalt silica-supported Fischer–Tropsch catalysts. It was shown that interaction of propene with cobalt metal particles resulted in its rapid autohydrogenation. The reaction consists in a part of the propene being dehydrogenated to surface carbon and CH_x chemisorbed species; hydrogen atoms released in the course of propene dehydrogenation are then involved in hydrogenation of remaining propene molecules to propane at 323–423 K or in propene hydrogenolysis to methane and ethane at temperatures higher than 423 K. The catalyst characterization suggests that propene chemisorption over cobalt catalysts is primarily a function of the density of cobalt surface metal sites. A correlation between propene chemisorption and Fischer–Tropsch reaction rate was observed over a series of cobalt silica-supported catalysts. No propane chemisorption was observed at 323–373 K over cobalt silica-supported catalysts. Propane autohydrogenolysis was found to proceed at higher temperatures, with methane being the major product of this reaction over cobalt catalysts. Hydrogen for propane autohydrogenolysis is probably provided by adsorbed CH_x species formed via propane dehydrogenation. Propene and propane chemisorption is dramatically reduced upon the catalyst exposure to synthesis gas (H₂/CO = 2) at 323–473 K. Our results suggest that cobalt metal particles are probably completely covered by carbon monoxide molecules under the conditions similar to Fischer–Tropsch synthesis and thus, most of cobalt surface sites are not available for propene and propane chemisorption.     

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.     

Characterization of Silica-Supported Cobalt Catalysts Prepared by Decomposition of Nitrates Using Dielectric-Barrier Discharge Plasma

Abstract  

Low temperature decomposition of precursors usually leads to higher cobalt dispersion. In this study, we present a method to decompose cobalt precursors by using dielectric-barrier discharge (DBD) plasma without requiring a thermal calcination process. Cobalt (Co) catalysts prepared by DBD plasma were characterized by a range of techniques. The results indicate that the DBD decomposition method can not only reduce the decomposition time but also achieve an increased Co dispersion, small Co₃O₄ cluster size and uniform distribution compared to traditional calcination method. It was observed that the DBD-treated catalysts performed well in Fischer–Tropsch synthesis and were favorable for heavy hydrocarbon formation.     

Characterization of Fischer–Tropsch Cobalt-Based Catalytic Systems (Co/SiO<Subscript>2</Subscript> and Co/Al<Subscript>2</Subscript>O<Subscript>3</Subscript>) by X-ray Diffraction and Magnetic Measurements

Results of the characterization of six Co-based Fischer–Tropsch (FT) catalysts, with 15% Co loading and supported on SiO₂ and Al₂O₃, are presented. Room temperature X-ray diffraction (XRD), temperature and magnetic field (H) variation of the magnetization (M), and low-temperature (5 K) electron magnetic resonance (EMR) are used for determining the electronic states (Co⁰, CoO, Co₃O₄, Co²⁺) of cobalt. Performance of these catalysts for FT synthesis is tested at reaction temperature of 240 °C and pressure of 20 bars. Under these conditions, 15% Co/SiO₂ catalysts yield higher CO and syngas conversions with higher methane selectivity than 15% Co/Al₂O₃ catalysts. Conversely the Al₂O₃ supported catalysts gave much higher selectivity towards olefins than Co/SiO₂. These results yield the correlation that the presence of Co₃O₄ yield higher methane selectivity whereas the presence of Co²⁺ species yields lower methane selectivity but higher olefin selectivity. The activities and selectivities are found to be stable for 55 h on-stream.     

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.     

Partial oxidation of methane to synthesis gas over α-Al2O3-supported bimetallic Pt–Co catalysts

The partial oxidation of methane to synthesis gas was studied at atmospheric pressure and in the temperature range of 550–800°C over -Al₂O₃-supported bimetallic Pt–Co, and monometallic Pt and Co catalysts, respectively. Both methane conversion and CO selectivity over a bimetallic Pt_0.5Co₁ catalyst were higher than those over monometallic Pt_0.5 and Co₁ catalysts. Furthermore, the addition of platinum in Pt–Co bimetallic catalysts effectively improved their resistance to carbon deposition with no coking occurring on Pt_0.5Co₁ during 80 h reaction. The FTIR study of CO adsorption observed only linearly bonded CO on bimetallic Pt–Co catalysts. TPR and XPS showed enhanced formation of a cobalt surface phase (CSP) in bimetallic Pt–Co catalysts. The origins of the good coking resistivity of bimetallic Pt–Co catalysts were discussed.     

Cobalt oxide species supported on SBA-15, KIT-5 and KIT-6 mesoporous silicas for ethyl acetate total oxidation

Cobalt oxide modified SBA-15, KIT-5 and KIT-6 mesoporous silicas with different pore size/pore entrances have been synthesized by a conventional wet impregnation method using cobalt nitrate as the precursor. The modified materials were characterized by N₂-physisorption, XRD, TEM-EDX, XPS, FT-IR, UV–vis and TPR-TG with hydrogen. Their catalytic activities in total oxidation of ethyl acetate were evaluated. A good correlation was observed between the catalytic activity, and the presence of spinel-type Co₃O₄ in the materials. Supports with larger mesopores facilitated the formation of such easily reducible spinel particles. However, the interconnectivity of the mesopores and the uniformity of the channel dimensions also had an influence on the catalytic activity, implying that mass-transfer effects, especially in the case of supports with cage-like mesopores.     

CO Hydrogenation: Exploring Iridium as a Promoter for Supported Cobalt Catalysts by TPR-EXAFS/XANES and Reaction Testing

Abstract  

The price of iridium currently trends at about half the cost of platinum, the latter being a typical reduction promoter for Co/Al₂O₃ Fischer–Tropsch (FT) synthesis catalysts in gas-to-liquids (GTL) technology. In the current contribution, both fixed-bed catalytic FT and TPR-EXAFS/XANES experiments were carried out over 0.1% iridium-doped 25% Co/Al₂O₃ catalysts in order to (1) assess the effectiveness of Ir as a promoter of cobalt oxide reduction and (2) evaluate the effectiveness of the incipient wetness impregnation (IWI) technique for adding the Ir precursor by comparing a catalyst prepared by IWI to one prepared by atomic layer deposition (ALD). Ir was demonstrated to be an effective promoter for facilitating the second step of cobalt oxide reduction, CoO to Co⁰, and the IWI method was found to be superior to ALD.     

Reaction performance and characterization of Co/Al2O3 Fischer–Tropsch catalysts promoted with Pt, Pd and Ru

A series of noble metal (Pt, Ru or Pd) promoted Co/Al₂O₃ catalysts were prepared by sequential impregnation method. The catalysts were characterized by XRD, TPR, H₂-TPD and TPSR techniques, and their catalytic performance in Fischer–Tropsch synthesis was investigated in a fixed-bed reactor. The results of activity measurements show that the addition of small amounts of noble metal greatly improved the activity of the Co/Al₂O₃ catalyst. TPR experimental results demonstrate that hydrogen spillover from the noble metal to cobalt oxide clusters facilitated the reduction of cobalt oxide and, thus significantly increased the reducibility of Co/Al₂O₃ catalyst. The presence of noble metal increased the amount of chemisorbed hydrogen and weakened the bond strength of Co–H. TPSR results indicate that CO was adsorbed in a more reactive state on the promoted catalysts.     

Silica-supported rhodium-cobalt catalysts for Fischer–Tropsch synthesis

The effects of the addition of Ag, Au, or Rh to a 15 wt% Co/SiO₂ catalyst on the Fischer–Tropsch (FT) synthesis were studied. Both Au and Rh showed a promoting effect on the FT activity, whereas the addition of Ag decreased the activity. The addition of a small amount of Rh (0.1–0.5 wt%) increased the CO conversion by 50% without affecting the selectivity. It was found that Rh catalyzed the reduction of cobalt oxides, but it did not change the number of surface cobalt atoms. It is proposed that the higher activity of Rh-promoted catalysts is due to the hydrogen spillover from Rh to Co during FT synthesis.     

Structure and catalytic performance of Pt-promoted alumina-supported cobalt catalysts under realistic conditions of Fischer–Tropsch synthesis

The structure of alumina-supported cobalt catalysts promoted with platinum and their catalytic performance in Fischer–Tropsch synthesis were investigated under realistic reaction conditions (P = 20 bar, T = 493 K) using in situ time-resolved X-ray diffraction with simultaneous analysis of reaction products. The catalysts were prepared via incipient wetness impregnation and characterized by a wide range of ex situ techniques. Direct in situ measurements were indicative of considerable versatility of alumina-supported cobalt catalysts during Fischer–Tropsch synthesis. Cobalt sintering occurred at the first hours of the reaction and resulted in a significant drop of the catalytic activity. In addition to sintering, partially oxidized catalysts containing smaller cobalt particles (mean particle size <5 nm) were slowly reducing during Fischer–Tropsch reaction. Treatment of cobalt catalysts in pure carbon monoxide led to selective transformation of cobalt metallic phases to Co₂C cobalt carbide. Cobalt carbidization followed by hydrogenation selectively led to cobalt hcp metallic phase, which seems to be more active in Fischer–Tropsch synthesis than cobalt fcc phase. Cobalt oxidation by water was not significant in the catalysts with metal particles larger than 5 nm even at high water concentrations.     

Hollow mesoporous silica sphere supported cobalt catalysts for F–T synthesis

High dispersion Co₃O₄ nano-particles supported on hollow mesoporous silica spheres (HMSS) with bimodal pore distribution were prepared by “two-solvent” technique. As-synthesized catalysts were characterized by XRD, N₂ adsorption–desorption, XPS, SEM, TEM, and H₂-TPR. The results showed that Co₃O₄ nano-particles were present inside the pore system of HMSS and the particles sizes increased with the increasing loaded cobalt content. The catalysts show good performance and high selectivity of C₅–C₁₈ hydrocarbon in F–T synthesis, which should attribute to the unique bimodal pore distribution facilitating reactants to access the active sites and to transport higher hydrocarbon products.     

Carbon Nanofiber Supported Cobalt Catalysts for Fischer–Tropsch Synthesis with High Activity and Selectivity

Platelet and fishbone carbon nanofibers (CNFs) have been used as supports for cobalt Fischer–Tropsch catalysts. The activity and selectivity of the CNF supported catalysts have been studied at 483 K, 20 bar, and H₂/CO = 2.1, and compared with corresponding activity and selectivity for α-Al₂O₃ and γ-Al₂O₃ supported cobalt catalysts. The platelet CNF supported catalyst has demonstrated high activity and high selectivity to C₅₊ hydrocarbons, with activity comparable with Co/γ-Al₂O₃ and selectivity comparable with Co/α-Al₂O₃.     

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.