Higher alcohols synthesis via CO hydrogenation on Fe-promoted Co/AC catalysts

A review of Co/Co2C-based catalysts in Fischer-Tropsch synthesis: from fundamental understanding to industrial applications

Fischer-Tropsch synthesis (FTS), which provides a green route to the production of clean fuels and fine chemicals, represents some significant applications of catalytic materials and processes in the chemical industry. FTS reactions show a diversity of mechanisms, involve various catalytic materials, and offer options for continuous investigation. Cobalt-based catalysts have been widely used for Fischer-Tropsch synthesis both in academia and in industry. This mini-review will focus on relevant research achievements in cobalt-based FTS catalysts by our group in the Dalian Institute of Chemical Physics (DICP). Specific contents will include the development of Co/Co₂C-based nano-catalysts (i) for the highly selective synthesis of clean fuels over Co-based catalysts supported by carbon materials and (ii) for the synthesis of linear α-alcohols and olefins over Co-Co₂C-based catalysts supported by carbon materials. The direct synthesis of linear α-alcohols from syngas using a Co-Co₂C/AC catalyst is highlighted. The innovative work of FTS using activated carbon (AC)-supported Co/Co₂C-based nano-catalysts could bring some insight into new FTS catalyst designs.

Ni-Co bimetallic catalysts on coconut shell activated carbon prepared using solid-phase method for highly efficient dry reforming of methane

Ni-Co bimetallic catalysts supported on coconut shell activated carbon are synthesized using solid-phase method and investigated for dry reforming of methane, to explore the impact of Ni:Co ratio on the catalyst activity and stability. The catalyst performances are evaluated under the temperature varying from 600 to 900 °C and gas hourly space velocity (GHSV) of 7200 mL/h·g-cat. The characterization results show that metal nanoparticles are produced on the support, and the bimetallic catalyst with an explicit Ni:Co ratio (2:1) is the most beneficial for metal particle dispersion and acquires the minimum particle size of 4.41 nm. The bimetallic catalysts with an explicit Ni:Co ratio of 1:2 and 1:1 exhibit a synergistic effect towards the conversions of CH₄ and CO₂, respectively. The experimental results reveal that the highest CH₄ and CO₂ conversions rise to 94.0% and 97.5% within 12 h at 900 °C on average, respectively, assisted with the two bimetallic catalysts. The intensity of disordered carbon and thermal stability are enhanced with the extension of reforming process, contributing to a long-term catalytic stability. Besides, no obvious carbon deposition is detected, leading to a highly catalytic stability for the bimetallic catalysts.

Carbon-based catalysts for Fischer-Tropsch synthesis

Fischer-Tropsch synthesis (FTS) is an essential approach to convert coal, biomass, and shale gas into fuels and chemicals, such as lower olefins, gasoline, diesel, and so on. In recent years, there has been increasing motivation to deploy FTS at commercial scales which has been boosting the discovery of high performance catalysts. In particular, the importance of support in modulating the activity of metals has been recognized and carbonaceous materials have attracted attention as supports for FTS. In this review, we summarised the substantial progress in the preparation of carbon-based catalysts for FTS by applying activated carbon (AC), carbon nanotubes (CNTs), carbon nanofibers (CNFs), carbon spheres (CSs), and metal-organic frameworks (MOFs) derived carbonaceous materials as supports. A general assessment of carbon-based catalysts for FTS, concerning the support and metal properties, activity and products selectivity, and their interactions is systematically discussed. Finally, current challenges and future trends in the development of carbon-based catalysts for commercial utilization in FTS are proposed.

Influence of Carbon Content in Ni-Doped Mo2C Catalysts on CO Hydrogenation to Mixed Alcohol

Herein, we synthesize the Ni-doped Mo2C catalysts by a one-pot preparation method to illuminate the effect of the number of carbon atoms in Mo2C lattice on CO hydrogenation to mixed alcohol. The Ni doping inhibits the agglomeration of Mo2C crystals into large particles and the surface carbon deposition, which increase the active surface area. In addition, the interaction between Ni and Mo increases the electron cloud density of Mo species and promotes the non-dissociative adsorption and insertion of CO. Especially, our results indicate that with the increase of the nickel content, the number of carbon atoms in Mo2C lattice on the surface of the catalyst shows a volcano type variation. The low carbon content induces the formation of coordination unsaturated molybdenum species which exhibit the higher catalytic activity and mixed alcohol selectivity than other molybdenum species. Among the catalysts, the MC-Ni-1.5 catalyst with Ni/Mo molar ratio of 1.5:8.5, which has the largest amount of coordination unsaturated molybdenum species, shows the highest space-time yield of mixed alcohols, which is three times higher than that of the Mo2C catalyst.

The effect of oxidant species on direct, non-syngas conversion of methane to methanol over an FePO4 catalyst material

The effect of the phase transformation of a FePO₄ catalyst material from the tridymite-like (tdm) FePO₄ to the α-domain (α-Fe₃(P₂O₇)₂) during the direct selective oxidation of methane to methanol was studied using oxidant species O₂, H₂O and N₂O. The main reaction products were CH₃OH, carbon dioxide and carbon monoxide, whereas formaldehyde was produced in rather minute amounts. Results showed that the single-step non-syngas activation of CH₄ to oxygenate(s) on a solid FePO₄ phase-specific catalyst was influenced by the nature of the oxidizer used for the CH₄ turnover. Fresh and activated FePO₄ powder samples and their modified physicochemical surface and bulk properties, which affected the conversion and selectivity in the partial oxidation (POX) mechanism of CH₄, were investigated. Temperature-programmed re-oxidation (TPRO) profiles indicated that the type of moieties utilised in the procedures, determined the re-oxidizing pathway of the reduced multiphase FePO₄ system. Mössbauer spectroscopy measurements along with X-ray diffraction (XRD) examination of neat, hydrogenated and spent catalytic compounds, demonstrated a variation of the phosphate into a mixture of crystallites, which depended on operating process conditions (for example time-on-stream). The Mössbauer spectra revealed the change of the initial ferric orthophosphate, FePO₄ (tdm), to the divalent metal form, iron(ii) pyrophosphate (Fe₂P₂O₇); thereafter, reactivity was governed by the interaction (strength) with individual oxidizing agents. The Fe³⁺ ↔ Fe²⁺ chemical redox cycle can play a key mechanistic role in tailored multistep design, while the advantage of iron-based heterogeneous catalysis primarily lies in being inexpensive and comprising non-critical raw resources. When compared to the other catalysts reported in the literature, the FePO₄-tdm phase catalysts showed in this work exhibited a high activity towards methanol i.e., 12.3 × 10⁻³ μmol_MeOH g_cat h⁻¹ using N₂O as an oxidant. This catalyst also showed a high activity with O₂ as an oxidant (5.3 × 10⁻³ μmol_MeOH g_cat h⁻¹). Further investigations will include continuous reactor unit engineering optimisation.

The effect of the phase transformation of a FePO₄ catalyst material from the tridymite-like (tdm) FePO₄ to the α-domain (α-Fe₃(P₂O₇)₂) during the direct selective oxidation of methane to methanol was studied using oxidant species O₂, H₂O and N₂O.

Conversion of Carbon Monoxide into Methanol on Alumina-Supported Cobalt Catalyst: Role of the Support and Reaction Mechanism—A Theoretical Study

Density functional theory (DFT) was used to calculate the step-by-step hydrogenation of carbon monoxide (CO) to form methanol over a Co4 cluster/Al2O3 surface. A three-dimensional Co4 tetrahedral structure was selected to explore its interaction with the supporting Al2O3 (104) surface. Co4 chemically reacted with Al2O3 to form a new chemical system. The calculated results show that Al2O3 support has strengthened the Co4 catalyst during the reaction since the formation of the Co–O bond. Loading Co4 on the Al2O3 surface increases CO adsorption ability but decreases the dissociation ability of C–O to produce hydrocarbons. As such, CH3OH formation becomes more favorable both kinetically and thermodynamically on Co4/Al2O3. In CO hydrogenation, methanol was synthesized through a CO reaction with hydrogen via either an Eley–Rideal or Langmuir–Hinshelwood pathway to form the intermediates C*-O-H, H-C*-OH, H2-C*-OH, and finally the hydrogenation of H2-C*-OH to methanol with both hydrogenation steps forming C*-OH and final product as rate-limiting. These results showed that the interaction between Co, Al2O3 and H2 pressure can change the pathway of CO hydrogenation on Co/Al2O3 and it may, therefore, influence distribution of the final products.

Bimetallic Ni–Co catalysts supported on Mn–Al oxide for selective catalytic CO hydrogenation to higher alcohols

A sol–gel synthesis provides a facile method for preparing Ni–Co catalysts which contributed to the high selectivity for higher alcohols.