Recent Progresses in Understanding of Co-Based Fischer–Tropsch Catalysis by Means of Transient Kinetic Studies and Theoretical Analysis

Direct Visualization of CO Interaction on Oxygen Poisoned Co(0001)

The poisoning of catalysts has always been a vital issue in catalytic reactions. In this study, direct observation of the interaction of CO and oxygen-poisoned Co(0001) has been achieved with scanning tunneling microscopy (STM), temperature-programmed desorption (TPD), and density functional theory calculation. A two-stage adsorption process of CO on a well-prepared p(2×2)-O layer covered Co(0001) was directly visualized. With increasing annealing time at a certain temperature after the CO dosage, the ordered (2 × 2) pattern formed in the first stage can be recovered, suggesting the weak interaction of CO with the O-covered Co(0001) surface in the latter stage. Compared to the clean Co(0001) surface, on an oxygen-poisoned surface, no further reaction was observed, illustrating the poisoning of the catalyst. Moreover, TPD results are in good agreement with the STM observation; a desorption energy of 0.35 eV is evaluated with a simple but accurate scheme.

A Review of Theoretical Studies on Carbon Monoxide Hydrogenation via Fischer-Tropsch Synthesis over Transition Metals

The increasing demand for clean fuels and sustainable products has attracted much interest in the development of active and selective catalysts for CO conversion to desirable products. This review maps the theoretical progress of the different facets of most commercial catalysts, including Co, Fe, Ni, Rh, and Ru. All relevant elementary steps involving CO dissociation and hydrogenation and their dependence on surface structure, surface coverage, temperature, and pressure are considered. The dominant Fischer-Tropsch synthesis mechanism is also explored, including the sensitivity to the structure of H-assisted CO dissociation and direct CO dissociation. Low-coordinated step sites are shown to enhance catalytic activity and suppress methane formation. The hydrogen adsorption and CO dissociation mechanisms are highly dependent on the surface coverage, in which hydrogen adsorption increases, and the CO insertion mechanism becomes more favorable at high coverages. It is revealed that the chain-growth probability and product selectivity are affected by the type of catalyst and its structure as well as the applied temperature and pressure.

Identifying Performance Descriptors in CO2 Hydrogenation over Iron-Based Catalysts Promoted with Alkali Metals

Alkali metal promoters have been widely employed for preparation of heterogeneous catalysts used in many industrially important reactions. However, the fundamentals of their effects are usually difficult to access. Herein, we unravel mechanistic and kinetic aspects of the role of alkali metals in CO₂ hydrogenation over Fe-based catalysts through state-of-the-art characterization techniques, spatially resolved steady-state and transient kinetic analyses. The promoters affect electronic properties of iron in iron carbides. These carbide characteristics determine catalyst ability to activate H₂ , CO and CO₂ . The Allen scale electronegativity of alkali metal promoter was successfully correlated with the rates of CO₂ hydrogenation to higher hydrocarbons and CH₄ as well as with the rate constants of individual steps of CO or CO₂ activation. The derived knowledge can be valuable for designing and preparing catalysts applied in other reactions where such promoters are also used.

Mechanistic Insights into the Effect of Sulfur on the Selectivity of Cobalt-Catalyzed Fischer–Tropsch Synthesis: A DFT Study

Sulfur is a common poison for cobalt-catalyzed Fischer–Tropsch Synthesis (FTS). Although its effects on catalytic activity are well documented, its effects on selectivity are controversial. Here, we investigated the effects of sulfur-covered cobalt surfaces on the selectivity of FTS using density functional theory (DFT) calculations. Our results indicated that sulfur on the surface of Co(111) resulted in a significant decrease in the adsorption energies of CO, HCO and acetylene, while the binding of H and CH species were not significantly affected. These findings indicate that sulfur increased the surface H/CO coverage ratio while inhibiting the adsorption of carbon chains. The elementary reactions of H-assisted CO dissociation, carbon and oxygen hydrogenation and CH coupling were also investigated on both clean and sulfur-covered Co(111). The results indicated that sulfur decreased the activation barriers for carbon and oxygen hydrogenation, while increasing the barriers for CO dissociation and CH coupling. Combining the results on elementary reactions with the modification of adsorption energies, we concluded that the intrinsic effect of sulfur on the selectivity of cobalt-catalyzed FTS is to increase the selectivity to methane and saturated short-chain hydrocarbons, while decreasing the selectivity to olefins and long-chain hydrocarbons.

Precisely Engineering Architectures of Co/C Sub-Microreactors for Selective Syngas Conversion

Fischer-Tropsch synthesis (FTS) is an effective route to produce olefins, gasoline, diesel, and oxygenates from syngas (CO + H₂ ). However, it still remains a challenge for regulating the product distribution of FTS. Here, a series of Co/C sub-microreactors with precise designed nanoarchitectures are synthesized for selective syngas conversion. Through a combination of surface protection-assisted etching and following carbonization process, Co/C sub-microreactors with solid cube, double-shelled hollow box, and hollow box architectures, namely, Co/C-Cube, Co/C-DBox, Co/C-Box can be obtained. In FTS, comparing with solid Co/C-Cube, double-shelled hollow structured Co/C-DBox is inclined to grow long-chain hydrocarbon products, whereas hollow structured Co/C-Box avails the formation of short-chain hydrocarbon chemicals. Therefore, shape selective catalysis and controlled product distribution of FTS are realized by tuning the architectures of Co/C sub-microreactors. It is expected to fundamentally unravel the heterogeneous catalytic process via upfront designing and precisely regulating the architectures of micro/nanoreactors.

Fischer–Tropsch Synthesis: Computational Sensitivity Modeling for Series of Cobalt Catalysts

Nearly a century ago, Fischer and Tropsch discovered a means of synthesizing organic compounds ranging from C1 to C70 by reacting carbon monoxide and hydrogen on a catalyst. Fischer–Tropsch synthesis (FTS) is now known as a pseudo-polymerization process taking a mixture of CO as H2 (also known as syngas) to produce a vast array of hydrocarbons, along with various small amounts of oxygenated materials. Despite the decades spent studying this process, it is still considered a black-box reaction with a mechanism that is still under debate. This investigation sought to improve our understanding by taking data from a series of experimental Fischer–Tropsch synthesis runs to build a computational model. The experimental runs were completed in an isothermal continuous stirred-tank reactor, allowing for comparison across a series of completed catalyst tests. Similar catalytic recipes were chosen so that conditional comparisons of pressure, temperature, SV, and CO/H2 could be made. Further, results from the output of the reactor that included the deviations in product selectivity, especially that of methane and CO2, were considered. Cobalt was chosen for these exams for its industrial relevance and respectfully clean process as it does not intrinsically undergo the water–gas shift (WGS). The primary focus of this manuscript was to compare runs using cobalt-based catalysts that varied in two oxide catalyst supports. The results were obtained by creating two differential equations, one for H2 and one for CO, in terms of products or groups of products. These were analyzed using sensitivity analysis (SA) to determine the products or groups that impact the model the most. The results revealed a significant difference in sensitivity between the two catalyst–support combinations. When the model equations for H2 and CO were split, the results indicated that the CO equation was significantly more sensitive to CO2 production than the H2 equation.

Fischer–Tropsch: Product Selectivity–The Fingerprint of Synthetic Fuels

The bulk of the products that were synthesized from Fischer–Tropsch synthesis (FTS) is a wide range (C1–C70+) of hydrocarbons, primarily straight-chained paraffins. Additional hydrocarbon products, which can also be a majority, are linear olefins, specifically: 1-olefin, trans-2-olefin, and cis-2-olefin. Minor hydrocarbon products can include isomerized hydrocarbons, predominantly methyl-branched paraffin, cyclic hydrocarbons mainly derived from high-temperature FTS and internal olefins. Combined, these products provide 80–95% of the total products (excluding CO2) generated from syngas. A vast number of different oxygenated species, such as aldehydes, ketones, acids, and alcohols, are also embedded in this product range. These materials can be used to probe the FTS mechanism or to produce alternative chemicals. The purpose of this article is to compare the product selectivity over several FTS catalysts. Discussions center on typical product selectivity of commonly used catalysts, as well as some uncommon formulations that display selectivity anomalies. Reaction tests were conducted while using an isothermal continuously stirred tank reactor. Carbon mole percentages of CO that are converted to specific materials for Co, Fe, and Ru catalysts vary, but they depend on support type (especially with cobalt and ruthenium) and promoters (especially with iron). All three active metals produced linear alcohols as the major oxygenated product. In addition, only iron produced significant selectivities to acids, aldehydes, and ketones. Iron catalysts consistently produced the most isomerized products of the catalysts that were tested. Not only does product selectivity provide a fingerprint of the catalyst formulation, but it also points to a viable proposed mechanistic route.

Mechanism of Cobalt-Catalyzed CO Hydrogenation: 1. Methanation

The mechanism of CO hydrogenation to CH₄ at 260 °C on a cobalt catalyst is investigated using steady-state isotopic transient kinetic analysis (SSITKA) and backward and forward chemical transient kinetic analysis (CTKA). The dependence of CH_x residence time is determined by ¹²CO/H₂ → ¹³CO/H₂ SSITKA as a function of the CO and H₂ partial pressure and shows that the CH₄ formation rate is mainly controlled by CH_x hydrogenation rather than CO dissociation. Backward CO/H₂ → H₂ CTKA emphasizes the importance of H coverage on the slow CH_x hydrogenation step. The H coverage strongly depends on the CO coverage, which is directly related to CO partial pressure. Combining SSITKA and backward CTKA allows determining that the amount of additional CH₄ obtained during CTKA is nearly equal to the amount of CO adsorbed to the cobalt surface. Thus, under the given conditions overall barrier for CO hydrogenation to CH₄ under methanation condition is lower than the CO adsorption energy. Forward CTKA measurements reveal that O hydrogenation to H₂O is also a relatively slow step compared to CO dissociation. The combined transient kinetic data are used to fit an explicit microkinetic model for the methanation reaction. The mechanism involving direct CO dissociation represents the data better than a mechanism in which H-assisted CO dissociation is assumed. Microkinetics simulations based on the fitted parameters confirms that under methanation conditions the overall CO consumption rate is mainly controlled by C hydrogenation and to a smaller degree by O hydrogenation and CO dissociation. These simulations are also used to explore the influence of CO and H₂ partial pressure on possible rate-controlling steps.

Mechanism of Cobalt-Catalyzed CO Hydrogenation: 2. Fischer-Tropsch Synthesis

Fischer–Tropsch (FT) synthesis is one of the most complex catalyzed chemical reactions in which the chain-growth mechanism that leads to formation of long-chain hydrocarbons is not well understood yet. The present work provides deeper insight into the relation between the kinetics of the FT reaction on a silica-supported cobalt catalyst and the composition of the surface adsorbed layer. Cofeeding experiments of ¹²C₃H₆ with ¹³CO/H₂ evidence that CH_x surface intermediates are involved in chain growth and that chain growth is highly reversible. We present a model-based approach of steady-state isotopic transient kinetic analysis measurements at FT conditions involving hydrocarbon products containing up to five carbon atoms. Our data show that the rates of chain growth and chain decoupling are much higher than the rates of monomer formation and chain termination. An important corollary of the microkinetic model is that the fraction of free sites, which is mainly determined by CO pressure, has opposing effects on CO consumption rate and chain-growth probability. Lower CO pressure and more free sites leads to increased CO consumption rate but decreased chain-growth probability because of an increasing ratio of chain decoupling over chain growth. The preferred FT condition involves high CO pressure in which chain-growth probability is increased at the expense of the CO consumption rate.

Potassium adsorption behavior on hcp cobalt as model systems for the Fischer-Tropsch synthesis: a density functional theory study

Potassium (K), an important impurity in syngas from biomass, can have a large influence on the activity and selectivity of cobalt-based Fischer-Tropsch synthesis (FTS) catalysts in Biomass to Liquids (BTL) processes. In this work, the potassium adsorption behavior on hcp cobalt was systematically studied using density functional theory. The surface energy calculations and Wulff construction of the equilibrium shape of hcp cobalt showed it is dominated by 10 facets. The interaction of K with these facets has been investigated. The results showed that the stepped facet (10-12) has the highest K adsorption energy of -2.40 eV. The facets (0001), (10-10), (10-11), (10-15), and (21-30) also showed relatively high K adsorption energies in the range of -2.28 to -2.34 eV. The corrugated facets exhibited comparatively lower K adsorption energies (-2.04 to -2.18 eV), and would be less favorable for K adsorption. It was also found that the adsorption properties depend on coverage, where the K adsorption energy decreased with increasing coverage. Diffusion energy barrier calculations indicated that K was mobile on typical facets (0001) and (10-11) with very low diffusion barriers (<0.15 eV). On stepped facets, although K could move freely along the same step (diffusion barrier <0.01 eV), diffusion from one step to another had a significantly higher barrier of 0.56 eV. This suggested that K atoms would be mobile to some extent during FTS reaction conditions, and tend to occupy the most favorable sites independent of their initial position. The results obtained in this work provide valuable information on the interaction of K with cobalt surfaces, relevant for practical cobalt catalysts and their application in BTL processes.

Computational investigation of the kinetics and mechanism of the initial steps of the Fischer-Tropsch synthesis on cobalt

A multi-site microkinetic model for the Fischer-Tropsch synthesis (FTS) reaction up to C₂ products on a FCC cobalt catalyst surface is presented. This model utilizes a multi-faceted cobalt nanoparticle model for the catalyst, consisting of the two dominant cobalt surface facets Co(111) and Co(100), and a step site represented by the Co(211) surface. The kinetic parameters for the intermediates and transition states on these sites were obtained using plane-wave, periodic boundary condition density functional theory. Using direct DFT data as is, the microkinetic results disagree with the expected experimental results. Employing an exploratory approach, a small number of microkinetic model modifications were tested, which significantly improved correspondence to the expected experimental results. Using network flux and sensitivity analysis, an in-depth discussion is given on the relative reactivity of the various sites, CO activation mechanisms, the nature of the reactive chain growth monomer, the probable C₂ formation mechanism, the active site ensemble interplay and the very important role of CO* surface coverage. The findings from the model scenarios are discussed with the aim of guiding future work in understanding the FTS mechanism and subsequent controlling kinetic parameters.

Apparatus for efficient utilization of isotopically-labeled gases in pulse transient studies of heterogeneously catalyzed gas phase reactions

Transient techniques, such as steady state isotopic transient kinetic analysis (SSITKA), are powerful methods for determining various mechanistic and kinetic insights into heterogeneously catalyzed gas-phase reactions.