On the selectivity to higher hydrocarbons in Co-based Fischer–Tropsch synthesis

Role of H2O in Catalytic Conversion of C1 Molecules

Due to their role in controlling global climate change, the selective conversion of C1 molecules such as CH4, CO, and CO2 has attracted widespread attention. Typically, H2O competes with the reactant molecules to adsorb on the active sites and therefore inhibits the reaction or causes catalyst deactivation. However, H2O can also participate in the catalytic conversion of C1 molecules as a reactant or a promoter. Herein, we provide a perspective on recent progress in the mechanistic studies of H2O-mediated conversion of C1 molecules. We aim to provide an in-depth and systematic understanding of H2O as a promoter, a proton-transfer agent, an oxidant, a direct source of hydrogen or oxygen, and its influence on the catalytic activity, selectivity, and stability. We also summarize strategies for modifying catalysts or catalytic microenvironments by chemical or physical means to optimize the positive effects and minimize the negative effects of H2O on the reactions of C1 molecules. Finally, we discuss challenges and opportunities in catalyst design, characterization techniques, and theoretical modeling of the H2O-mediated catalytic conversion of C1 molecules.

Towards understanding the lower CH4 selectivity of HCP-Co than FCC-Co in Fischer-Tropsch synthesis

In Fischer-Tropsch synthesis (FTS), the cobalt catalyst has higher C5+ and lower CH4 selectivity in the hcp phase than in the fcc phase. However, a detailed explanation of the intrinsic mechanism is still missing. The underlying reason was explored combining density functional theory, Wulff construction, and a particle-level descriptor based on the slab model of surfaces that are prevalent in the Wulff shape to provide single-particle level understanding. Using a particle-level indicator of the reaction rates, we have shown that it is more difficult to form CH4 on hcp-Co than on fcc-Co, due to the larger effective barrier difference of CH4 formation and C-C coupling on hcp-Co particles, which leads to the lower CH4 selectivity of hcp-Co in FTS. Among the exposed facets of fcc-Co, the (311) surface plays a pivotal role in promoting CH4 formation. The reduction of CH4 selectivity in cobalt-based FTS is achievable through phase engineering of Co from fcc to hcp or by tuning the temperature and size of the particles.

H2O Derivatives Mediate CO Activation in Fischer-Tropsch Synthesis: A Review

The process of Fischer-Tropsch synthesis is commonly described as a series of reactions in which CO and H₂ are dissociated and adsorbed on the metals and then rearranged to produce hydrocarbons and H₂O. However, CO dissociation adsorption is regarded as the initial stage of Fischer-Tropsch synthesis and an essential factor in the control of catalytic activity. Several pathways have been proposed to activate CO, namely direct CO dissociation, activation hydrogenation, and activation by insertion into growing chains. In addition, H₂O is considered an important by-product of Fischer-Tropsch synthesis reactions and has been shown to play a key role in regulating the distribution of Fischer-Tropsch synthesis products. The presence of H₂O may influence the reaction rate, the product distribution, and the deactivation rate. Focus on H₂O molecules and H₂O-derivatives (H*, OH* and O*) can assist CO activation hydrogenation on Fe- and Co-based catalysts. In this work, the intermediates (C*, O*, HCO*, COH*, COH*, CH*, etc.) and reaction pathways were analyzed, and the H₂O and H₂O derivatives (H*, OH* and O*) on Fe- and Co-based catalysts and their role in the Fischer-Tropsch synthesis reaction process were reviewed.

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.

Activation of Cobalt Foil Catalysts for CO Hydrogenation

CO hydrogenation has been studied on cobalt foils as model catalysts for Fischer–Tropsch (FT) synthesis. The effect of pretreatment (number of calcinations and different reduction times) for cobalt foil catalysts at 220 °C, 1 bar, and H2/CO = 3 has been studied in a microreactor. The foils were examined by scanning electron microscopy (SEM). It was found that the catalytic activity of the cobalt foil increases with the number of pretreatments. The mechanism is likely an increase in the available cobalt surface area from progressively deeper oxidation of the foil, supported by surface roughness detected by SEM. The highest FT activity was obtained using a reduction time of only 5 min (compared to 1 and 30 min). Prolonged reduction caused the sintering of cobalt crystallites, while too short of a reduction time led to incomplete reduction and small crystallites susceptible to low turn-over frequency from structure sensitivity. Larger crystals from longer reduction times gave increased selectivity to heavier components. The paraffin/olefin ratio increased with the increasing number of pretreatments due to olefin hydrogenation favored by enhanced cobalt site density. From the results, it is suggested that olefin hydrogenation is not structure sensitive, and that mass transfer limitations may occur depending on the pretreatment procedure. Produced water did not influence the results for the low conversions experienced in the present study (<6%).

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.

Cobalt-Containing Dispersion Catalysts for Three-Phase Fischer-Tropsch Synthesis

Nanosized catalyst dispersions have significant potential for improving hydrocarbon production from carbon monoxide and hydrogen via Fischer–Tropsch synthesis, an essential alternative to the use of petroleum as a raw material. New dispersed cobalt catalysts and dispersed-phase cobalt-based catalysts with Pd, Al₂O₃, or ZrO₂ additives for the Fischer–Tropsch synthesis were synthesized in the present work. A dispersed cobalt phase was prepared in a heavy paraffin medium using ex situ and in situ approaches through thermal decomposition of a nitrate precursor at various temperatures. Analyses showed that an increase in the temperature for catalytic suspension formation from 215 to 260°C enlarged the particles in the dispersed phase from 190 to 264 nm, which was probably due to increased agglomeration at elevated temperatures. The rheological properties of the obtained catalytic suspensions can be described by the Bingham equation. Furthermore, the concentration of the dispersed phase had a direct impact on the structure of the entire catalytic system. Ultrafine suspensions of palladium-promoted catalytic systems were tested for the Fischer–Tropsch synthesis. The overall yield of C₅₊ hydrocarbons was as high as 50 g/m³, and the productivity of the Pd-promoted catalytic systems reached 270–290 g/(kg_Co · h).

Preliminary evaluation of a commercially viable Co-based hybrid catalyst system in Fischer–Tropsch synthesis combined with hydroprocessing

A hybrid catalyst for one-step conversion of syngas into liquid hydrocarbons, mainly gasoline and diesel, is proposed.

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.

Promotional effect of in situ generated hydroxyl on olefin selectivity of Co-catalyzed Fischer-Tropsch synthesis

The understanding of the water effect on olefin selectivity in Fischer-Tropsch synthesis (FTS) is limited by the complexity of the reaction network. Herein, we employ propene hydrogenation as a model reaction to isolate the water effect on olefin adsorption and hydrogenation from the complex reaction of FTS. It is clearly observed that the added water inhibits the activity of propene hydrogenation on two cobalt catalysts supported on high-surface-area alumina (HAS Al₂O₃) and low-surface-area alumina (LSA Al₂O₃), respectively. The inhibiting effect is much stronger for Co/HSA Al₂O₃. DFT investigation demonstrates that the in situ generated OH, rather than H₂O and O, impedes the adsorption of propene and thus decreases the activity of propene hydrogenation. The suppressive effect of OH on propene adsorption is attributed to the downshift of the d-band center and the Bader charge of the catalyst surface. The DFT-based kinetic analysis finds that the higher site coverage of OH results in the more pronounced negative effect on propene hydrogenation. Furthermore, the theory of OH-induced weak olefin adsorption and low olefin hydrogenation activity could rationalize the enhancement effect of water on the olefin selectivity and the particle size dependence of the water effect in FTS. The insights obtained here may inspire researchers to optimize olefin selectivity by manipulating the electronic properties of catalysts with hydroxyl species.

Kinetic Study Based on the Carbide Mechanism of a Co-Pt/γ-Al2O3 Fischer–Tropsch Catalyst Tested in a Laboratory-Scale Tubular Reactor

A Co-Pt/γ-Al2O3 catalyst was manufactured and tested for Fischer–Tropsch applications. Catalyst kinetic experiments were performed using a tubular fixed-bed reactor system. The operative conditions were varied between 478 and 503 K, 15 and 30 bar, H2/CO molar ratio 1.06 and 2.11 at a carbon monoxide conversion level of about 10%. Several kinetic models were derived, and a carbide mechanism model was chosen, taking into account an increasing value of termination energy for α-olefins with increasing carbon numbers. In order to assess catalyst suitability for the determination of reaction kinetics and comparability to similar Fischer–Tropsch Synthesis (FTS) applications, the catalyst was characterized with gas sorption analysis, temperature-programmed reduction (TPR), and X-ray diffraction (XRD) techniques. The kinetic model developed is capable of describing the intrinsic behavior of the catalyst correctly. It accounts for the main deviations from the typical Anderson-Schulz-Flory distribution for Fischer–Tropsch products, with calculated activation energies and adsorption enthalpies in line with values available from the literature. The model suitably predicts the formation rates of methane and ethylene, as well as of the other α-olefins. Furthermore, it properly estimates high molecular weight n-paraffin formation up to carbon number C80.

Co-culture-based biological carbon monoxide conversion by Citrobacter amalonaticus Y19 and Sporomusa ovata via a reducing-equivalent transfer mediator

The biological conversion of carbon monoxide (CO) has been highlighted for the development of a C1 gas biorefinery process. Despite this, the toxicity and low reducing equivalent of CO uptake make biological conversion difficult. The use of synthetic co-cultures is an alternative way of enhancing the performance of CO bioconversion. This study evaluated a synthetic co-culture consisting of Citrobacter amalonaticus Y19 and Sporomusa ovata for acetate production from CO. In this consortium, the CO₂ and H₂ produced by the water-gas shift reaction of C. amalonaticus Y19, were utilized further by S. ovata. Higher acetate production was achieved in the co-culture system compared to the monoculture counterparts. Furthermore, syntrophic cooperation via various reducing equivalent carriers provided new insights into the synergistic metabolic benefits with a toxic and refractory substrate, such as CO. This study also suggests an appropriate model for examining the syntrophic interaction between microbial species in a mixed community.