Identification of the active species in the working alumina-supported cobalt catalyst under various conditions of Fischer–Tropsch synthesis

Effects of Structure and Particle Size of Iron, Cobalt and Ruthenium Catalysts on Fischer–Tropsch Synthesis

This review emphasizes the importance of the catalytic conversion techniques in the production of clean liquid and hydrogen fuels (XTF) and chemicals (XTC) from the carbonaceous materials including coal, natural gas, biomass, organic wastes, biogas and CO2. Dependence of the performance of Fischer–Tropsch Synthesis (FTS), a key reaction of the XTF/XTC process, on catalyst structure (crystal and size) is comparatively examined and reviewed. The contribution illustrates the very complicated crystal structure effect, which indicates that not only the particle type, but also the particle shape, facets and orientation that have been evidenced recently, strongly influence the catalyst performance. In addition, the particle size effects over iron, cobalt and ruthenium catalysts were carefully compared and analyzed. For all Fe, Co and Ru catalysts, the metal turnover frequency (TOF) for CO hydrogenation increased with increasing metal particle size in the small size region i.e., less than the size threshold 7–8 nm, but was found to be independent of particle size for the catalysts with large particle sizes greater than the size threshold. There are some inconsistencies in the small particle size region for Fe and Ru catalysts, i.e., an opposite activity trend and an abnormal peak TOF value were observed on a Fe catalyst and a Ru catalyst (2 nm), respectively. Further study from the literature provides deeper insights into the catalyst behaviors. The intrinsic activity of Fe catalysts (10 nm) at 260–300 °C is estimated in the range of 0.046–0.20 s−1, while that of the Co and Ru catalysts (7–70 nm) at 220 °C are 0.1 s−1 and 0.4 s−1, respectively.

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.

A high-pressure reactor coupled to synchrotron radiation photoionization mass spectrometry

A high-pressure reactor was designed and coupled to synchrotron radiation photoionization mass spectrometry (SR-PIMS), which realizes the molecular-beam sampling and detection of gaseous products of high-pressure reactions. The reaction pressure can be controlled by varying the size of the pinhole of the pressure-bearing pipe. As tested by the Fischer-Tropsch synthesis (FTS) catalyzed by Co/SiO₂ at 230 °C, the reaction pressure of our setup can reach 1.3 MPa with a pinhole size of 50 µm and 0.16 MPa with a pinhole size of 150 µm. The FTS products were successfully online detected by SR-PIMS, and the photoionization efficiency spectra of selected products were acquired for unambiguous identification of the detected signals. Meanwhile, time-resolved SR-PIMS spectra were acquired with a temporal resolution of 10 s. The characterization results demonstrate that the product distribution (C₂-C₄, C₅-C₁₁, and C₁₂₊) of FTS depends on the reaction pressure, where a high pressure facilitates the formation of long-chain hydrocarbons. With the advantages of detecting unstable intermediates and distinguishing isomers, this setup will be useful for fundamental studies of high-pressure heterogeneous catalytic reactions.

Disk-Shaped Cobalt Nanocrystals as Fischer–Tropsch Synthesis Catalysts Under Industrially Relevant Conditions

Colloidal synthesis of metal nanocrystals (NC) offers control over size, crystal structure and shape of nanoparticles, making it a promising method to synthesize model catalysts to investigate structure-performance relationships. Here, we investigated the synthesis of disk-shaped Co-NC, their deposition on a support and performance in the Fischer–Tropsch (FT) synthesis under industrially relevant conditions. From the NC synthesis, either spheres only or a mixture of disk-shaped and spherical Co-NC was obtained. The disks had an average diameter of 15 nm, a thickness of 4 nm and consisted of hcp Co exposing (0001) on the base planes. The spheres were 11 nm on average and consisted of ε-Co. After mild oxidation, the CoO-NC were deposited on SiO2 with numerically 66% of the NC being disk-shaped. After reduction, the catalyst with spherical plus disk-shaped Co-NC had 50% lower intrinsic activity for FT synthesis (20 bar, 220 °C, H2/CO = 2 v/v) than the catalyst with spherical NC only, while C5+-selectivity was similar. Surprisingly, the Co-NC morphology was unchanged after catalysis. Using XPS it was established that nitrogen-containing ligands were largely removed and in situ XRD revealed that both catalysts consisted of 65% hcp Co and 21 or 32% fcc Co during FT. Furthermore, 3–5 nm polycrystalline domains were observed. Through exclusion of several phenomena, we tentatively conclude that the high fraction of (0001) facets in disk-shaped Co-NC decrease FT activity and, although very challenging to pursue, that metal nanoparticle shape effects can be studied at industrially relevant conditions.

Bridging the gap between industry and synchrotron: an operando study at 30 bar over 300 h during Fischer–Tropsch synthesis

Long-term operando spectroscopic study of a Fischer–Tropsch catalyst at a synchrotron radiation facility under realistic conditions with full product analysis.

Phase Controlled Synthesis of Pt Doped Co Nanoparticle Composites Using a Metal-Organic Framework for Fischer–Tropsch Catalysis

Recently, metal nanoparticles embedded in porous carbon composite materials have been playing a significant role in a variety of fields as catalyst supports, sensors, absorbents, and in energy storage. Porous carbon composite materials can be prepared using various synthetic methods; recent efforts provide a facile way to prepare the composites from metal-organic frameworks (MOFs) by pyrolysis. However, it is usually difficult to control the phase of metal or metal oxides during the synthetic process. Among many types of MOF, recently, cobalt-based MOFs have attracted attention due to their unique catalytic and magnetic properties. Herein, we report the synthesis of a Pt doped cobalt based MOF, which is subsequently converted into cobalt nanoparticle-embedded porous carbon composites (Pt@Co/C) via pyrolysis. Interestingly, the phase of the cobalt metal nanoparticles (face centered cubic (FCC) or hexagonal closest packing (HCP)) can be controlled by tuning the synthetic conditions, including the temperature, duration time, and dosage of the reducing agent (NaBH4). The Pt doped Co/C was characterized using various techniques including PXRD (powder X-ray diffraction), XPS (X-ray photoelectron spectroscopy), gas sorption analysis, TEM (transmission electron microscopy), and SEM (scanning electron microscopy). The composite was applied as a phase transfer catalyst (PTC). The Fischer-Tropsch catalytic activity of the Pt@Co/C (10:1:2.4) composite shows 35% CO conversion under a very low pressure of syngas (1 MPa). This is one of the best reported conversion rates at low pressure. The 35% CO conversion leads to the generation of various hydrocarbons (C1, C2–C4, C5, and waxes). This catalyst may also prove useful for energy and environmental applications.

Surface and interface design for heterogeneous catalysis

Recent progresses in catalytic nanocrystals with uniform and well-defined structures, in situ characterization techniques, and theoretical calculations are facilitating the innovation of efficient catalysts via surface and interface designs, including crystal phase design, morphology/facet design, and size design, followed by controlled synthesis.

Operando X-ray absorption spectroscopy study of the Fischer-Tropsch reaction with a Co catalyst

This article describes the setting up of a facility on the energy-scanning EXAFS beamline (BL-09) at RRCAT, Indore, India, for operando studies of structure-activity correlation during a catalytic reaction. The setup was tested by operando X-ray absorption spectroscopy (XAS) studies performed on a Co-based catalyst during the Fischer-Tropsch reaction to obtain information regarding structural changes in the catalyst during the reaction. Simultaneous gas chromatography (GC) measurements during the reaction facilitate monitoring of the product gases, which in turn gives information regarding the activity of the catalyst. The combination of XAS and GC techniques was used to correlate the structural changes with the activity of the catalyst at different reaction temperatures. The oxide catalyst was reduced to the metallic phase by heating at 400°C for 5 h under H₂ at ambient pressure and subsequently the catalytic reaction was studied at four different temperatures of 240, 260, 280 and 320°C. The catalyst was studied for 10 h at 320°C and an attempt has been made to understand the process of its deactivation from the XANES and EXAFS results.

Preparation of Cobalt Nanocrystals Supported on Metal Oxides To Study Particle Growth in Fischer-Tropsch Catalysts

Colloidal synthesis of nanocrystals (NC) followed by their attachment to a support and activation is a promising route to prepare model catalysts for research on structure-performance relationships. Here, we investigated the suitability of this method to prepare well-defined Co/TiO2 and Co/SiO2 catalysts for the Fischer-Tropsch (FT) synthesis with high control over the cobalt particle size. To this end, Co-NC of 3, 6, 9, and 12 nm with narrow size distributions were synthesized and attached uniformly on either TiO2 or SiO2 supports with comparable morphology and Co loadings of 2-10 wt %. After activation in H2, the FT activity of the TiO2-supported 6 and 12 nm Co-NC was similar to that of a Co/TiO2 catalyst prepared by impregnation, showing that full activation was achieved and relevant catalysts had been obtained; however, 3 nm Co-NC on TiO2 were less active than anticipated. Analysis after FT revealed that all Co-NC on TiO2 as well as 3 nm Co-NC on SiO2 had grown to ∼13 nm, while the sizes of the 6 and 9 nm Co-NC on SiO2 had remained stable. It was found that the 3 nm Co-NC on TiO2 already grew to 10 nm during activation in H2. Furthermore, substantial amounts of Co (up to 60%) migrated from the Co-NC to the support during activation on TiO2 against only 15% on SiO2. We showed that the stronger interaction between cobalt and TiO2 leads to enhanced catalyst restructuring as compared to SiO2. These findings demonstrate the potential of the NC-based method to produce relevant model catalysts to investigate phenomena that could not be studied using conventionally synthesized catalysts.

On the nature of active phases and sites in CO and CO2 hydrogenation catalysts

Advanced characterisation techniques are shedding new light on the identification of active CO_x hydrogenation phases and sites.

Chemical imaging of Fischer-Tropsch catalysts under operating conditions

Although we often understand empirically what constitutes an active catalyst, there is still much to be understood fundamentally about how catalytic performance is influenced by formulation. Catalysts are often designed to have a microstructure and nanostructure that can influence performance but that is rarely considered when correlating structure with function. Fischer-Tropsch synthesis (FTS) is a well-known and potentially sustainable technology for converting synthetic natural gas ("syngas": CO + H₂) into functional hydrocarbons, such as sulfur- and aromatic-free fuel and high-value wax products. FTS catalysts typically contain Co or Fe nanoparticles, which are often optimized in terms of size/composition for a particular catalytic performance. We use a novel, "multimodal" tomographic approach to studying active Co-based catalysts under operando conditions, revealing how a simple parameter, such as the order of addition of metal precursors and promoters, affects the spatial distribution of the elements as well as their physicochemical properties, that is, crystalline phase and crystallite size during catalyst activation and operation. We show in particular how the order of addition affects the crystallinity of the TiO₂ anatase phase, which in turn leads to the formation of highly intergrown cubic close-packed/hexagonal close-packed Co nanoparticles that are very reactive, exhibiting high CO conversion. This work highlights the importance of operando microtomography to understand the evolution of chemical species and their spatial distribution before any concrete understanding of impact on catalytic performance can be realized.

In situ investigation on Co-phase evolution and its performance for Fischer–Tropsch synthesis over Nb-promoted cobalt catalysts

The influences of Nb on the Co-phase evolution, reducibility, chemisorption, and Fischer–Tropsch synthesis performance of catalysts were in situ researched.

Stacking disorder in silicon carbide supported cobalt crystallites: an X-ray diffraction, electron diffraction and high resolution electron microscopy study

Supported cobalt Fischer-Tropsch catalysts are characteristically nanoparticulate and the reduced SiC supported catalyst was found to contain both HCP and FCC polymorphs. This is reflected in the powder XRD patterns and generally there is a poor fit between the experimental and calculated diffractograms. This was ascribed to small crystallite sizes and the occurrence of disorder, manifested as peak broadening and peak shifts. Selected area electron diffraction data of suitably oriented cobalt catalyst grains on silicon carbide supports show non-periodic disorder in the zone axis orientations that contain the common (001) (HCP) and (111) (FCC) reciprocal lattice planes. Both FCC and HCP polymorphs are present in the same grains and these show disorder mainly in the HCP component. The disorder is further examined using high angle annular dark field (HAADF) scanning transmission electron microscopy at atomic resolution and the stacking sequences elucidated. Random sequences of mainly FCC are interrupted by HCP sequences and twin surfaces with reverse stacking sequences are also present. This study highlights the presence of significant disorder in cobalt catalyst grains confirmed by HAADF microscopy.

Combined Operando X-ray Diffraction/Raman Spectroscopy of Catalytic Solids in the Laboratory: The Co/TiO2 Fischer-Tropsch Synthesis Catalyst Showcase

A novel laboratory setup for combined operando X-ray diffraction and Raman spectroscopy of catalytic solids with online product analysis by gas chromatography is presented. The setup can be used with a laboratory-based X-ray source, which results in important advantages in terms of time-on-stream that can be measured, compared to synchrotron-based experiments. The data quality was much improved by the use of a relatively high-energy MoKα radiation instead of the more conventional CuKα radiation. We have applied the instrument to study the long-term deactivation of Co/TiO2 Fischer-Tropsch synthesis (FTS) catalysts. No sign of Co sintering or bulk oxidation was found during the experiments. However, part of the metallic Co was converted into cobalt carbide (Co2C), at elevated pressure (10 bar). Furthermore, graphitic-like coke species are clearly formed during FTS at atmospheric pressure, whereas at elevated pressure fluorescence hampered the interpretation of the measured Raman spectra.

Effect of cobalt supported on meso–macro porous hydrotalcite in Fischer–Tropsch synthesis

Hydrotalcite based cobalt catalysts were prepared by a slurry precipitation method, followed by a slurry impregnation method.

Enhanced catalytic activity of cobalt catalysts for Fischer–Tropsch synthesis via carburization and hydrogenation and its application to regeneration

In Fischer–Tropsch synthesis (FTS), cobalt carbide (Co₂C) is not a catalytically active material, but rather an undesired cobalt phase associated with low catalytic performance.

X-ray spectroscopic and scattering methods applied to the characterisation of cobalt-based Fischer–Tropsch synthesis catalysts

This review aims to critically assess the use of X-ray techniques, both of a scattering (e.g. X-ray diffraction (XRD), pair distribution function (PDF)) and spectroscopic nature (X-ray absorption spectroscopy (XAFS)), in the study of cobalt-based Fisher–Tropsch synthesis (FTS) catalysts.