Fischer–Tropsch synthesis in slurry-phase reactors over Mn- and Zr-modified Co/SiO2 catalysts

Fischer–Tropsch (F–T) synthesis was carried out in a gas-flowed slurry-phase reaction system over Mn- and Zr-modified Co/SiO₂ catalysts. A 0.5 L stirred tank slurry reactor (STSR) was used for catalyst screening and a 12.5 L slurry bubble column reactor (SBCR) was used for trial pilot operation. While using the 0.5 L reactor for catalyst screening, Co supported on the SiO₂ with an average pore size of 10 nm showed a high catalytic performance for the F–T synthesis due to the suitable Co particle size in the catalyst. Zr promoter improved the activity and Mn promoter improved the stability of Co/SiO₂ catalyst for the F–T synthesis. H₂-TPR profiles indicated that Zr and Mn promoters improved the reduction degree of Co₃O₄ particles (on SiO₂ surface) to Co⁰ active species in H₂ flow at low temperature. While using the 12.5 L reactor for trial pilot operation over Mn–Zr–Co/SiO₂ catalyst, the space-time yield (STY) of C₅₊ hydrocarbons (liquid fuel) showed almost the same values when various solvents (n-C₁₆H₃₄, n-C₁₄H₃₀, diesel from petrol station, F–T crude oil) were used. Diesel and F–T crude oil are suitable for using in a large-scaled F–T synthesis plant owing to the low prices. Mn–Zr–Co/SiO₂ catalyst achieved a STY of C₅₊ hydrocarbons larger than 1000 g-C₅₊ kg-cat^? 1 h^? 1 in the 12.5 L reactor. The production capacity of liquid fuel from the 12.5 L reactor reached to 15.6 L per day (assumed for 24 h continuous operation). The stirring was very important for the F–T synthesis both reaction in the 0.5 L reactor and reaction in the 12.5 L reactor. The shape of slurry reactor also influenced the CO conversion for the F–T synthesis: reaction in the 12.5 L SBCR gave a higher CO conversion than that of reaction in the 0.5 L STSR (at the same W/F value under the same stirring speed) because the slender column reactor (SBCR) extended the residue time of reaction gas in the slurry-phase containing catalyst.