Effect of time on stream and temperature on upgraded products from Fischer–Tropsch synthesis when zeolite is added to iron-based activated-carbon-supported catalyst

Fischer-Tropsch synthesis to olefins boosted by MFI zeolite nanosheets

Catalytic reactions are severely restricted by the strong adsorption of product molecules on the catalyst surface, where promoting desorption of the product and hindering its re-adsorption benefit the formation of free sites on the catalyst surface for continuous substrate conversion^1,2. A solution to this issue is constructing a robust nanochannel for the rapid escape of products. We demonstrate here that MFI zeolite crystals with a short b-axis of 90-110 nm and a finely controllable microporous environment can effectively boost the Fischer-Tropsch synthesis to olefins by shipping the olefin molecules. The ferric carbide catalyst (Na-FeC_x) physically mixed with a zeolite promoter exhibited a CO conversion of 82.5% with an olefin selectivity of 72.0% at the low temperature of 260 °C. By contrast, Na-FeC_x alone without the zeolite promoter is poorly active under equivalent conditions, and shows the significantly improved olefin productivity achieved through the zeolite promoter. These results show that the well-designed zeolite, as a promising promoter, significantly boosts Fischer-Tropsch synthesis to olefins by accelerating escape of the product from the catalyst surface.

Insights into the mechanism of carbon chain growth on zeolite-based Fischer-Tropsch Co/Y catalysts

In a zeolite-based Fischer-Tropsch bifunctional catalyst, zeolites, as the support of the active metal, can interact with the metal cluster to affect the electronic properties and structural effect of the catalyst, thus affecting the Fischer-Tropsch synthesis reaction. In this work, the Fischer-Tropsch synthesis process using a Co catalyst supported by Y-zeolite was simulated by the DFT method from the microscopic point of view. The reaction network was designed to investigate the reaction mechanism in terms of four parts consisting of H-assisted CO dissociation, C₁ hydrogenation, CH_x-CH_x coupling, and C₂-C₄ growth. It was found that the introduction of Y-zeolite enhanced the adsorption capacity of the catalyst for most species. Moreover, the catalytic mechanism of the Co/Y catalyst was clarified, and we found that the introduction of the Y-zeolite mainly reduced the reaction energy barriers of the CH-CH coupling and C₂-C₄ carbon chain growth process, which also explained the high proportion of long carbon chain hydrocarbons in the Fischer-Tropsch synthesis products after Y-zeolite was introduced.

Production of Light Olefins via Fischer-Tropsch Process Using Iron-Based Catalysts: A Review

The production of light olefins, as the critical components in chemical industries, is possible via different technologies. The Fischer–Tropsch to olefin (FTO) process aims to convert syngas to light olefins with high selectivity over a proper catalyst, reduce methane formation, and avoid the production of excess CO2. This review describes the production of light olefins through the FTO process using both unsupported and supported iron-based catalysts. The catalytic properties and performances of both the promoted and bimetallic unsupported catalysts are reviewed. The effect of support and its physico-chemical properties on the catalyst activity are also described. The proper catalyst should have high stability to provide long-term performance without reducing the activity and selectivity towards the desired product. The good dispersion of active metals on the surface, proper porosity, optimized metal-support interaction, a high degree of reducibility, and providing a sufficient active phase for the reaction are important parameters affecting the reaction. The selection of the suitable catalyst with enhanced activity and the optimum process conditions can increase the possibility of the FTO reaction for light-olefins production. The production of light olefins via the FTO process over iron-based catalysts is a promising method, as iron is cheap, shows higher resistance to sulfur, and has a higher WGS activity which can be helpful for the feed gas with a low H2/CO ratio, and also has higher selectivity towards light olefins.

Effect of Changing Amounts of Promoters and Base Fe Metal in a Multicomponent Catalyst Supported on Coal-Based Activated Carbon for Fischer–Tropsch Synthesis

The effect of varying the amounts of metals Fe, Cu, K, and Mo was studied on a catalyst supported on activated carbon (AC), which is an item of novelty of this paper. The base-case catalyst contains 16% Fe, 0.9% K, 6% Mo, and 0.8% Cu relative to the AC support. For all of the catalysts used, alcohol production is small. The production of hydrocarbons depends upon the amount of Fe and other promoters used. The amount of Fe was increased from 0% to 32% on the catalyst containing base-case amounts of the other materials. While 0% Fe shows no activity towards Fischer–Tropsch synthesis (FTS), 32% Fe shows a marginal increase in FTS activity when compared with 16% Fe. Furthermore, the amount of K was increased from 0% to 1.8%, with the other metals in their base-case amounts. The selectivity of C1–C4 decreases with the addition of K, while the selectivity of C5+ increases. Analogously, the amount of Mo was increased from 0% to 12%. A small amount of Mo results in an increase in FTS activity but decreases with the addition of more Mo. Cu on the catalyst was increased from 0% to 1.6%, with 0.8% Cu proving optimum for FTS.

Influence of Promotion on the Growth of Anchored Colloidal Iron Oxide Nanoparticles during Synthesis Gas Conversion

Using colloidal iron oxide nanoparticles with organic ligands, anchored in a separate step from the supports, has been shown to be beneficial to obtain homogeneously distributed metal particles with a narrow size distribution. Literature indicates that promoting these particles with sodium and sulfur creates an active Fischer–Tropsch catalyst to produce olefins, while further adding an H-ZSM-5 zeolite is an effective way to obtain aromatics. This research focused on the promotion of iron oxide colloids with sodium and sulfur using an inorganic ligand exchange followed by the attachment to H-ZSM-5 zeolite crystals. The catalyst referred to as FeP/Z, which consists of iron particles with inorganic ligands attached to a H-ZSM-5 catalyst, was compared to an unpromoted Fe/Z catalyst and an Fe/Z-P catalyst, containing the colloidal nanoparticles with organic ligands, promoted after attachment. A low CO conversion was observed on both FeP/Z and Fe/Z-P, originating from an overpromotion effect for both catalysts. However, when both promoted catalysts were washed (FeP/Z-W and Fe/Z–P-W) to remove the excess of promoters, the activity was much higher. Fe/Z-P-W simultaneously achieved low selectivity toward methane as part of the promoters were still present after washing, whereas for FeP/Z-W the majority of promoters was removed upon washing, which increased the methane selectivity. Moreover, due to the addition of Na+S promoters, the iron nanoparticles in the FeP/Z(-W) catalysts had grown considerably during catalysis, while those in Fe/Z-P(-W) and Fe/Z(-W) remained relatively stable. Lastly, as a large broadening of particle sizes for the used FeP/Z-W was found, where particle sizes had both increased and decreased, Ostwald ripening is suggested for particle growth accelerated by the presence of the promoters.

Recent Advances in Direct Synthesis of Value-Added Aromatic Chemicals from Syngas by Cascade Reactions over Bifunctional Catalysts

Value-added aromatic monomers such as benzene, toluene, and xylenes (BTX) are very important building-block chemicals for the production of plastics, polymers, solvents, pesticides, dyes, and adhesives. Syngas-to-aromatics (STA) is a very promising approach for the synthesis of aromatic monomers, and is catalyzed via bifunctional catalysts in a single reactor, wherein methanol/dimethyl ether and/or olefins intermediates formed from syngas on metal components are converted into aromatic monomers exclusively on the HZSM-5 by cascade reactions. Since an optimal Fischer-Tropsch synthesis (FTS) temperature of Fe-based catalysts is very close to an aromatization temperature of HZSM-5, Fe-based catalysts have been frequently used/modified for the synthesis of aromatic monomers from hydrogenation of carbon oxides (CO and CO₂ ). The nature of metal components and amounts of Brönsted acid sites on HZSM-5, and their mesoporosity and intimacy, significantly alter the selectivity for aromatics by tuning BTX distibution and catalyst stability. Although many developments have been achieved regarding the STA process in recent years, no reviews have been published in this flourishing research area over the last two decades. Here, the recent advances and forthcoming challenges in the progress of syngas (CO+H₂ ) chemistry and hydrogenation of CO₂ toward the value-added aromatic monomers through cascade reactions are highlighted.

Catalysis engineering of bifunctional solids for the one-step synthesis of liquid fuels from syngas: a review

The combination of acidic zeolites and Fischer–Tropsch synthesis (FTS) catalysts for one-step production of liquid fuels from syngas is critically reviewed.