Deactivation of cobalt based Fischer–Tropsch catalysts: A review

Construction of Nanoflower Cobalt-Based Catalyst for Methane-Free CO Hydrogenation to Hydrocarbon Reaction

Methane and its oxidation product (i. e., CO2) are both greenhouse gases. In the product chain of CO hydrogenation to hydrocarbon reaction, methane is also an unwanted product due to its poor added value. Herein we investigated the effect of structure-directing agent urotropine on cobalt-based catalyst supported on Al-O-Zn type carrier and achieved an initial and pioneering exploration of methane-free CO hydrogenation to hydrocarbon reaction at mild CO conversion range. The catalyst modified by urotropine has a nanoflower micromorphology and can significantly change the reaction performance, almost completely eliminating the ability of the catalyst to inhibit C-C coupling within a mild CO conversion range, that is, it can produce no or less C1-C4 gaseous hydrocarbons, while rich in condensed hydrocarbons (i. e., C5+ hydrocarbon selectivity can reach as high as 92.8 %-100.0 %).

Nickel as Electrocatalyst for CO(2) Reduction: Effect of Temperature, Potential, Partial Pressure, and Electrolyte Composition

Electrochemical CO2 reduction on Ni has recently been shown to have the unique ability to produce longer hydrocarbon chains in small but measurable amounts. However, the effects of the many parameters of this reaction remain to be studied in more detail. Here, we have investigated the effect of temperature, bulk CO2 concentration, potential, the reactant, cations, and anions on the formation of hydrocarbons via a chain growth mechanism on Ni. We show that temperature increases the activity but also the formation of coke, which deactivates the catalyst. The selectivity and thus the chain growth probability is mainly affected by the potential and the electrolyte composition. Remarkably, CO reduction shows lower activity but a higher chain growth probability than CO2 reduction. We conclude that hydrogenation is likely to be the rate-determining step and hypothesize that this could happen either by *CO hydrogenation or by termination of the hydrocarbon chain. These insights open the way to further development and optimization of Ni for electrochemical CO2 reduction.

Compositional Evolution of Individual CoNPs on Co/TiO2 during CO and Syngas Treatment Resolved through Soft XAS/X-PEEM

The nanoparticle (NP) redox state is an important parameter in the performance of cobalt-based Fischer-Tropsch synthesis (FTS) catalysts. Here, the compositional evolution of individual CoNPs (6-24 nm) in terms of the oxide vs metallic state was investigated in situ during CO/syngas treatment using spatially resolved X-ray absorption spectroscopy (XAS)/X-ray photoemission electron microscopy (X-PEEM). It was observed that in the presence of CO, smaller CoNPs (i.e., ≤12 nm in size) remained in the metallic state, whereas NPs ≥ 15 nm became partially oxidized, suggesting that the latter were more readily able to dissociate CO. In contrast, in the presence of syngas, the oxide content of NPs ≥ 15 nm reduced, while it increased in quantity in the smaller NPs; this reoxidation that occurs primarily at the surface proved to be temporary, reforming the reduced state during subsequent UHV annealing. O K-edge measurements revealed that a key parameter mitigating the redox behavior of the CoNPs were proximate oxygen vacancies (Ovac). These results demonstrate the differences in the reducibility and the reactivity of Co NP size on a Co/TiO2 catalyst and the effect Ovac have on these properties, therefore yielding a better understanding of the physicochemical properties of this popular choice of FTS catalysts.

A density functional theory study on how γ-Al2O3 - Boehmite transformation affects carbon evolution during aqueous-phase reaction

Gamma-alumina (γ-Al2O3), one of the most common materials, is commercially used in many catalytic applications, including the active catalyst and support. However, the problem of fast deactivation makes the utilization of the γ-Al2O3 challenging. This work elucidates the mechanism of coke formation consisting of coke deposition and evolution on γ-Al2O3(110) surfaces in differential conditions, including; clean and hydroxylation γ-Al2O3(110) in terms of partial and fully hydroxylation of OH/γ-Al2O3(110) and AlOOH(010), respectively. We demonstrated that the γ-Al2O3(110) surface is proper for atomic coke deposition and dimerization in the initial state, where the presence of OH species promotes the coke evolution to higher coke, Cn (where n ≥ 3). Also, the higher coke formation thermodynamically preferred the cyclic form to the aliphatic one. The electron transfer from substrates to adsorbed coke illustrates the role of the electron donor of catalyst surfaces corresponding to the electron acceptor of adsorbed cokes.

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.

Spectroscopic investigation of a Co(0001) model catalyst during exposure to H2 and CO at near-ambient pressures

Cobalt catalysts, although already used industrially for Fischer-Tropsch synthesis, are prone to a number of deactivation mechanisms such as oxidation of the active phase, and the deposition of carbon and reaction products. We have performed near-ambient-pressure X-ray photoelectron spectroscopy on Co(0001) model catalysts during exposure to gases relevant to Fischer-Tropsch synthesis, i.e., CO and H2, at 0.25 mbar total pressure. At this pressure, CO seems to be more efficient at keeping the Co(0001) surface metallic than H2, which is the opposite behavior as reported in the literature for other pressure ranges. We offer an interpretation of these differences based on the preferred adsorption and dissociation sites of CO and H2 compared to the oxidizing agent water (present as impurity in the gas feed and one of the products of the reaction). Additionally, detailed carbon spectra measured at the HIPPIE beamline of MAX IV allow for the distinction of different adsorbed species: CO and COx species are present in correlation to the presence of oxygen on the surface. Carbidic carbon and graphitic carbon can both be removed by hydrogen, whereas adsorbed hydrocarbons possibly poison the surface.

Bifunctional Europium for Operando Catalyst Thermometry in an Exothermic Chemical Reaction

Often the reactor or the reaction medium temperature is reported in the field of heterogeneous catalysis, even though it could vary significantly from the reactive catalyst temperature. The influence of the catalyst temperature on the catalytic performance and vice versa is therefore not always accurately known. We here apply EuOCl as both solid catalyst and thermometer, allowing for operando temperature determination. The interplay between reaction conditions and the catalyst temperature dynamics is studied. A maximum temperature difference between the catalyst and oven of +16 °C was observed due to the exothermicity of the methane oxychlorination reaction. Heat dissipation by radiation appears dominating compared to convection in this set-up, explaining the observed uniform catalyst bed temperature. Application of operando catalyst thermometry could provide a deeper mechanistic understanding of catalyst performances and allow for safer process operation in chemical industries.

Recent advances in Co2C-based nanocatalysts for direct production of olefins from syngas conversion

Syngas conversion provides an important platform for efficient utilization of various carbon-containing resources such as coal, natural gas, biomass, solid waste and even CO₂. Various value-added fuels and chemicals including paraffins, olefins and alcohols can be directly obtained from syngas conversion via the Fischer-Tropsch Synthesis (FTS) route. However, the product selectivity control still remains a grand challenge for FTS due to the limitation of Anderson-Schulz-Flory (ASF) distribution. Our previous works showed that, under moderate reaction conditions, Co₂C nanoprisms with exposed (101) and (020) facets can directly convert syngas to olefins with low methane and high olefin selectivity, breaking the limitation of ASF. The application of Co₂C-based nanocatalysts unlocks the potential of the Fischer-Tropsch process for producing olefins. In this feature article, we summarized the recent advances in developing highly efficient Co₂C-based nanocatalysts and reaction pathways for direct syngas conversion to olefins via the Fischer-Tropsch to olefin (FTO) reaction. We mainly focused on the following aspects: the formation mechanism of Co₂C, nanoeffects of Co₂C-based FTO catalysts, morphology control of Co₂C nanostructures, and the effects of promoters, supports and reactors on the catalytic performance. From the viewpoint of carbon utilization efficiency, we presented the recent efforts in decreasing the CO₂ selectivity for FTO reactions. In addition, the attempt to expand the target products to aromatics by coupling Co₂C-based FTO catalysts and H-ZSM-5 zeolites was also made. In the end, future prospects for Co₂C-based nanocatalysts for selective syngas conversion were proposed.

Single-Atom Metal Anchored Zr6-Cluster-Porphyrin Framework Hollow Nanocapsules with Ultrahigh Active-Center Density for Electrocatalytic CO2 Reduction

Designing earth-abundant electrocatalysts toward highly efficient CO₂ reduction has significant importance to decrease the global emission of greenhouse gas. Herein, we propose an efficient strategy to anchor non-noble metal single atoms on Zr₆-cluster-porphyrin framework hollow nanocapsules with well-defined and abundant metal-N₄ porphyrin sites for efficient electrochemical CO₂ reduction. Among different transition metal single atoms (Mn, Fe, Co, Ni, and Cu), Co single-atom anchored Zr₆-cluster-porphyrin framework hollow nanocapsules demonstrated the highest activity and selectivity for CO production. The rich Co-N₄ active centers and hierarchical porous structure contribute to enhanced CO₂ adsorption capability and moderate binding strength of reaction intermediates, thus facilitating *CO desorption and CO₂-to-CO conversion. The Co-anchored nanocapsules maintain high efficiency and well-preserved stability during long-term electrocatalysis tests. Moreover, the Co-anchored nanocapsules exhibit a remarkable solar-to-CO energy conversion efficiency of 12.5% in an integrated solar-driven CO₂ reduction/O₂ evolution electrolysis system when powered by a custom large-area [Cs_0.05(FA_0.85MA_0.15)_0.95]Pb_0.9(I_0.85Br_0.15)₃-based perovskite solar cell.

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.

Effect of Co-fed Water on a Co-Pt-Si/γ-Al2O3 Fischer-Tropsch Catalyst Modified with an Atomic Layer Deposited or Molecular Layer Deposition Overcoating

Atomic layer deposition (ALD) and molecular layer deposition (MLD) methods were used to prepare overcoatings on a cobalt-based Fischer-Tropsch catalyst. A Co-Pt-Si/γ-Al₂O₃ catalyst (21.4 wt % Co, 0.2 wt % Pt, and 1.6 wt % Si) prepared by incipient wetness impregnation was ALD overcoated with 30-40 cycles of trimethylaluminum (TMA) and water, followed by temperature treatment (420 °C) in an inert nitrogen atmosphere. MLD-overcoated samples with corresponding film thicknesses were prepared by using TMA and ethylene glycol, followed by temperature treatment (400 °C) in an oxidative synthetic air atmosphere. The ALD catalyst (40 deposition cycles) had a positive activity effect upon moderate water addition (P _H2O/P _H2 = 0.42), and compared with a non-overcoated catalyst, it showed resistance to irreversible deactivation after co-fed water conditions. In addition, MLD overcoatings had a positive effect on the catalyst activity upon moderate water addition. However, compared with a non-overcoated catalyst, only the 10-cycle MLD-overcoated catalyst retained increased activity throughout high added water conditions (P _H2O/P _H2 = 0.71). All catalyst variations exhibited irreversible deactivation under high added water conditions.

Undercooling, Thermal Stability, and Application in Exothermic Catalytic Reaction of SiO2 Encapsulated SnZnCu Microspheres

SiO2 encapsulated SnZnCu microspheres (several micrometers to about 30 μm in diameter) with very low undercooling, narrow freezing/melting range, and high thermal cycling stability have been produced and used as the temperature stabilizer of the packed bed in highly exothermic Fischer–Tropsch reaction. The core–shell structured SnZnCu@SiO2 microspheres are prepared in a two-step way, namely SnZnCu microspheres are firstly produced via a molten LiCl–KCl–CsCl eutectic-based metal emulsion method, and then a sol–gel approach is employed to coat them with a uniform, anti-leakage SiO2 layer. It is found that raising the amount of Zn to 4.0 at.% is critical for achieving a very low undercooling (<5 °C for SnZn0.04Cux@SiO2 vs. about 84 °C for Sn@SiO2) and a narrow freezing/melting peak width, and both undercooling and peak width are almost unchanged as the Cu content (x) increases from 1.5 to 3.0 at.%. However, their thermal cycling stability depends positively on the amount of Cu and can be remarkably improved when 3.0 at.% Cu is added. The results also show that low undercooling and narrow freezing/melting peak width are associated with the formation of Sn–Zn–Cu ternary eutectic and metastable phase Cu5Zn8, and poor thermal cycling stability of SnZn0.04Cux@SiO2 microspheres with low Cu content is related to the decomposition of Cu5Zn8 during thermal cycling. By embedding thermally stable SnZn0.04Cu0.03@SiO2 microspheres into the Co/SiO2 catalyst for Fischer–Tropsch synthesis, the temperature gradient in the catalyst bed can be significantly reduced by suppressing the formation of hot spots or thermal runaway and thus rapid deactivation of Co catalyst that occurs in the SnZn0.04Cux@SiO2-absent Co/SiO2 catalyst can be avoided.

Fischer–Tropsch Synthesis for Light Olefins from Syngas: A Review of Catalyst Development

Light olefins as one the most important building blocks in chemical industry can be produced via Fischer–Tropsch synthesis (FTS) from syngas. FT synthesis conducted at high temperature would lead to light paraffins, carbon dioxide, methane, and C5+ longer chain hydrocarbons. The present work focuses on providing a critical review on the light olefin production using Fischer–Tropsch synthesis. The effects of metals, promoters and supports as the most influential parameters on the catalytic performance of catalysts are discussed meticulously. Fe and Co as the main active metals in FT catalysts are investigated in terms of pore size, crystal size, and crystal phase for obtaining desirable light olefin selectivity. Larger pore size of Fe-based catalysts is suggested to increase olefin selectivity via suppressing 1-olefin readsorption and secondary reactions. Iron carbide as the most probable phase of Fe-based catalysts is proposed for light olefin generation via FTS. Smaller crystal size of Co active metal leads to higher olefin selectivity. Hexagonal close-packed (HCP) structure of Co has higher FTS activity than face-centered cubic (FCC) structure. Transition from Co to Co3C is mainly proposed for formation of light olefins over Co-based catalysts. Moreover, various catalysts’ deactivation routes are reviewed. Additionally, techno-economic assessment of FTS plants in terms of different costs including capital expenditure and minimum fuel selling price are presented based on the most recent literature. Finally, the potential for global environmental impacts associated with FTS plants including atmospheric and toxicological impacts is considered via lifecycle assessment (LCA).

Passivation of Co/Al2O3 Catalyst by Atomic Layer Deposition to Reduce Deactivation in the Fischer–Tropsch Synthesis

The present work explores the technical feasibility of passivating a Co/γ-Al2O3 catalyst by atomic layer deposition (ALD) to reduce deactivation rate during Fischer–Tropsch synthesis (FTS). Three samples of the reference catalyst were passivated using different numbers of ALD cycles (3, 6 and 10). Characterization results revealed that a shell of the passivating agent (Al2O3) grew around catalyst particles. This shell did not affect the properties of passivated samples below 10 cycles, in which catalyst reduction was hindered. Catalytic tests at 50% CO conversion evidenced that 3 and 6 ALD cycles increased catalyst stability without significantly affecting the catalytic performance, whereas 10 cycles caused blockage of the active phase that led to a strong decrease of catalytic activity. Catalyst deactivation modelling and tests at 60% CO conversion served to conclude that 3 to 6 ALD cycles reduced Co/γ-Al2O3 deactivation, so that the technical feasibility of this technique was proven in FTS.

Cobalt Carbide Nanocatalysts for Efficient Syngas Conversion to Value-Added Chemicals with High Selectivity

Syngas conversion is a key platform for efficient utilization of various carbon-containing resources including coal, natural gas, biomass, organic wastes, and even CO₂. One of the most classic routes for syngas conversion is Fischer-Tropsch synthesis (FTS), which is already available for commercial application. However, it still remains a grand challenge to tune the product distribution from paraffins to value-added chemicals such as olefins and higher alcohols. Breaking the selectivity limitation of the Anderson-Schulz-Flory (ASF) distribution has been one of the hottest topics in syngas chemistry.Metallic Co⁰ is a well-known active phase for Co-catalyzed FTS, and the products are dominated by paraffins with a small amount of chemicals (i.e., olefins or alcohols). Specifically, a cobalt carbide (Co₂C) phase is typically viewed as an undesirable compound that could lead to deactivation with low activity and high methane selectivity. Although iron carbide (Fe_xC) can produce olefins with selectivity up to ∼60%, the fraction of methane is still rather high, and the required high reaction temperature (300-350 °C) typically causes coke deposition and fast deactivation. Recently, we discovered that Co₂C nanoprisms with preferentially exposed facets of (020) and (101) can effectively produce olefins from syngas conversion under mild reaction conditions with high selectivity. The methane fraction was limited within 5%, and the product distribution deviated greatly from ASF statistic law. The catalytic performances of Co₂C nanoprisms are completely different from that reported for the traditional FT process, exhibiting promising potential industrial application.This Account summarizes our progress in the development of Co₂C nanoprisms for Fischer-Tropsch synthesis to olefins (FTO) with remarkable efficiencies and stability. The underlying mechanism for the observed unique catalytic behaviors was extensively explored by combining DFT calculation, kinetic measurements, and various spectroscopic and microscopic investigation. We also emphasize the following issues: particle size effect of Co₂C, the promotional effect of alkali and Mn promoters, and the role of metal-support interaction (SMI) in fabricating supported Co₂C nanoprisms. Specially, we briefly review the synthetic methods for different Co₂C nanostructures. In addition, Co₂C can also be applied as a nondissociative adsorption center for higher alcohol synthesis (HAS) via syngas conversion. We also discuss the construction of a Co⁰/Co₂C interfacial catalyst for HAS and demonstrate how to tune the reaction network and strengthen CO nondissociative adsorption ability for efficient production of higher alcohols. We believe that the advances in the development of Co₂C nanocatalysts described here present a critic step to produce chemicals through the FTS process.

Preparation and High-Throughput Testing of TiO2-Supported Co Catalysts for Fischer‒Tropsch Synthesis

A series of Co/TiO2 catalysts was tested in a parameters field study for Fischer‒Tropsch synthesis (FTS). All catalysts were prepared by the conventional impregnation technique to obtain an industrially relevant Co content of 10 wt % or 20 wt %, respectively. In summary, 10 different TiO2 of pure anatase phase, pure rutile phase, as well as mixed rutile and anatase phase were used as supports. Performance tests were conducted with a 32-fold high-throughput setup for accelerated catalyst benchmarking; thus, 48 experiments were completed within five weeks in a relevant operation parameters field (170 °C to 233.5 °C, H2/CO ratio 1 to 2.5, and 20 bar(g)). The most promising catalyst showed a CH4 selectivity of 5.3% at a relevant CO conversion of 60% and a C5+ productivity of 2.1 gC5+/(gCo h) at 207.5 °C. These TiO2-based materials were clearly differentiated with respect to the application as supports in Co-catalyzed FTS catalysis. The most prospective candidates are available for further FTS optimization at a commercial scale.

On the Cobalt Carbide Formation in a Co/TiO2 Fischer-Tropsch Synthesis Catalyst as Studied by High-Pressure, Long-Term Operando X-ray Absorption and Diffraction

Operando X-ray absorption spectroscopy (XAS) and X-ray diffraction (XRD) were performed on a Co/TiO2 Fischer-Tropsch synthesis (FTS) catalyst at 16 bar for (at least) 48 h time-on-stream in both a synchrotron facility and a laboratory-based X-ray diffractometer. Cobalt carbide formation was observed earlier during FTS with operando XAS than with XRD. This apparent discrepancy is due to the higher sensitivity of XAS to a short-range order. Interestingly, in both cases, the product formation does not noticeably change when cobalt carbide formation is detected. This suggests that cobalt carbide formation is not a major deactivation mechanism, as is often suggested for FTS. Moreover, no cobalt oxide formation was detected by XAS or XRD. In other words, one of the classical proposals invoked to explain Co/TiO2 catalyst deactivation could not be supported by our operando X-ray characterization data obtained at close to industrially relevant reaction conditions. Furthermore, a bimodal cobalt particle distribution was observed by high-angle annular dark-field scanning transmission electron microscopy and energy-dispersive X-ray analysis, while product formation remained relatively stable. The bimodal distribution is most probably due to the mobility and migration of the cobalt nanoparticles during FTS conditions.

Structural transformations of solid electrocatalysts and photocatalysts

Heterogeneous catalysts often undergo structural transformations when they operate under thermal reaction conditions. These transformations are reflected in their evolving catalytic activity, and a fundamental understanding of the changing nature of active sites is vital for the rational design of solid materials for applications. Beyond thermal catalysis, both photocatalysis and electrocatalysis are topical because they can harness renewable energy to drive uphill reactions that afford commodity chemicals and fuels. Although structural transformations of photocatalysts and electrocatalysts have been observed in operando, the resulting implications for catalytic behaviour are not fully understood. In this Review, we summarize and compare the structural evolution of solid thermal catalysts, electrocatalysts and photocatalysts. We suggest that well-established knowledge of thermal catalysis offers a good basis to understand emerging photocatalysis and electrocatalysis research.

Recent developments in catalyst pretreatment technologies for cobalt based Fisher–Tropsch synthesis

Stringent environmental regulations and energy insecurity necessitate the development of an integrated process to produce high-quality fuels from renewable resources and to reduce dependency on fossil fuels, in this case Fischer–Tropsch synthesis (FTS). The FT activity and selectivity are significantly influenced by the pretreatment of the catalyst. This article reviews traditional and developing processes for pretreatment of cobalt catalysts with reference to their application in FTS. The activation atmosphere, drying, calcination, reduction conditions and type of support are critical factors that govern the reducibility, dispersion and crystallite size of the active phase. Compared to traditional high temperature H2 activation, both hydrogenation–carbidisation–hydrogenation and reduction–oxidation–reduction pretreatment cycles result in improved metal dispersion and exhibit much higher FTS activity. Cobalt carbide (Co2C) formed by CO treatment has the potential to provide a simpler and more effective way of producing lower olefins, and higher alcohols directly from syngas. Syngas activation or direct synthesis of the metallic cobalt catalyst has the potential to remove the expensive H2 pretreatment procedure, and consequently simplify the pretreatment process, which would make it more economical and thus more attractive to industry.