Reaction mechanism of CO activation and methane formation on Co Fischer–Tropsch catalyst: A combined DFT, transient, and steady-state kinetic modeling

A DFT study towards dynamic structures of iron and iron carbide and their effects on the activity of the Fischer-Tropsch process

The Fe-based Fischer-Tropsch synthesis (FTS) catalyst shows a rich phase chemistry under pre-treatment and FTS conditions. The exact structural composition of the active site, whether iron or iron carbide (FeCx), is still controversial. Aiming to obtain an insight into the active sites and their role in affecting FTS activity, the swarm intelligence algorithm is implemented to search for the most stable Fe(100), Fe(110), Fe(210) surfaces with different carbon ratios. Then, ab initio atomistic thermodynamics and Wulffman construction were employed to evaluate the stability of these surfaces at different chemical potentials of carbon. Their FTS reactivity and selectivity were later assessed by semi-quantitative micro-kinetic equations. The results show that stability, reactivity, and selectivity of the iron are all affected by the carbonization process when the carbon ratio increases. Formation of the carbide, a rather natural process under experimental conditions, would moderately increase the turnover frequency (TOF), but both iron and iron carbide are active to the reaction.

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.

A Review of Theoretical Studies on Carbon Monoxide Hydrogenation via Fischer-Tropsch Synthesis over Transition Metals

The increasing demand for clean fuels and sustainable products has attracted much interest in the development of active and selective catalysts for CO conversion to desirable products. This review maps the theoretical progress of the different facets of most commercial catalysts, including Co, Fe, Ni, Rh, and Ru. All relevant elementary steps involving CO dissociation and hydrogenation and their dependence on surface structure, surface coverage, temperature, and pressure are considered. The dominant Fischer-Tropsch synthesis mechanism is also explored, including the sensitivity to the structure of H-assisted CO dissociation and direct CO dissociation. Low-coordinated step sites are shown to enhance catalytic activity and suppress methane formation. The hydrogen adsorption and CO dissociation mechanisms are highly dependent on the surface coverage, in which hydrogen adsorption increases, and the CO insertion mechanism becomes more favorable at high coverages. It is revealed that the chain-growth probability and product selectivity are affected by the type of catalyst and its structure as well as the applied temperature and pressure.

Mechanistic Connections between CO2 and CO Hydrogenation on Dispersed Ruthenium Nanoparticles

Catalytic routes for upgrading CO₂ to CO and hydrocarbons have been studied for decades, and yet the mechanistic details and structure-function relationships that control catalytic performance have remained unresolved. This study elucidates the elementary steps that mediate these reactions and examines them within the context of the established mechanism for CO hydrogenation to resolve the persistent discrepancies and to demonstrate inextricable links between CO₂ and CO hydrogenation on dispersed Ru nanoparticles (6-12 nm mean diameter, 573 K). The formation of CH₄ from both CO₂-H₂ and CO-H₂ reactants requires the cleavage of strong C≡O bonds in chemisorbed CO, formed as an intermediate in both reactions, via hydrogen-assisted activation pathways. The C═O bonds in CO₂ are cleaved via direct interactions with exposed Ru atoms in elementary steps that are shown to be facile by fast isotopic scrambling of C¹⁶O₂-C¹⁸O₂-H₂ mixtures. Such CO₂ activation steps form bound CO molecules and O atoms; the latter are removed via H-addition steps to form H₂O. The kinetic hurdles in forming CH₄ from CO₂ do not reflect the inertness of C═O bonds in CO₂ but instead reflect the intermediate formation of CO molecules, which contain stronger C≡O bonds than CO₂ and are present at near-saturation coverages during CO₂ and CO hydrogenation catalysis. The conclusions presented herein are informed by a combination of spectroscopic, isotopic, and kinetic measurements coupled with the use of analysis methods that account for strong rate inhibition by chemisorbed CO. Such methods enable the assessment of intrinsic reaction rates and are essential to accurately determine the effects of nanoparticle structure and composition on reactivity and selectivity for CO₂-H₂ reactions.

Kinetics and Selectivity Study of Fischer–Tropsch Synthesis to C5+ Hydrocarbons: A Review

Fischer–Tropsch synthesis (FTS) is considered as one of the non-oil-based alternatives for liquid fuel production. This gas-to-liquid (GTL) technology converts syngas to a wide range of hydrocarbons using metal (Fe and Co) unsupported and supported catalysts. Effective design of the catalyst plays a significant role in enhancing syngas conversion, selectivity towards C5+ hydrocarbons, and decreasing selectivity towards methane. This work presents a review on catalyst design and the most employed support materials in FTS to synthesize heavier hydrocarbons. Furthermore, in this report, the recent achievements on mechanisms of this reaction will be discussed. Catalyst deactivation is one of the most important challenges during FTS, which will be covered in this work. The selectivity of FTS can be tuned by operational conditions, nature of the catalyst, support, and reactor configuration. The effects of all these parameters will be analyzed within this report. Moreover, zeolites can be employed as a support material of an FTS-based catalyst to direct synthesis of liquid fuels, and the specific character of zeolites will be elaborated further. Furthermore, this paper also includes a review of some of the most employed characterization techniques for Fe- and Co-based FTS catalysts. Kinetic study plays an important role in optimization and simulation of this industrial process. In this review, the recent developed reaction rate models are critically discussed.

Tuning reactivity of Fischer-Tropsch synthesis by regulating TiOx overlayer over Ru/TiO2 nanocatalysts

The activity of Fischer-Tropsch synthesis (FTS) on metal-based nanocatalysts can be greatly promoted by the support of reducible oxides, while the role of support remains elusive. Herein, by varying the reduction condition to regulate the TiO_x overlayer on Ru nanocatalysts, the reactivity of Ru/TiO₂ nanocatalysts can be differentially modulated. The activity in FTS shows a volcano-like trend with increasing reduction temperature from 200 to 600 °C. Such a variation of activity is characterized to be related to the activation of CO on the TiO_x overlayer at Ru/TiO₂ interfaces. Further theoretical calculations suggest that the formation of reduced TiO_x occurs facilely on the Ru surface, and it involves in the catalytic mechanism of FTS to facilitate the CO bond cleavage kinetically. This study provides a deep insight on the mechanism of TiO_x overlayer in FTS, and offers an effective approach to tuning catalytic reactivity of metal nanocatalysts on reducible oxides.

The Effect of CO Partial Pressure on Important Kinetic Parameters of Methanation Reaction on Co-Based FTS Catalyst Studied by SSITKA-MS and Operando DRIFTS-MS Techniques

A 20 wt% Co-0.05 wt% Pt/γ-Al2O3 catalyst was investigated to obtain a fundamental understanding of the effect of CO partial pressure (constant H2 partial pressure) on important kinetic parameters of the methanation reaction (x vol% CO/25 vol% H2, x = 3, 5 and 7) by performing advanced transient isotopic and operando diffuse reflectance infrared Fourier transform spectroscopy–mass spectrometry (DRIFTS-MS) experiments. Steady State Isotopic Transient Kinetic Analysis (SSITKA) experiments conducted at 1.2 bar, 230 °C after 5 h in CO/H2 revealed that the surface coverages, θCO and θCHx and the mean residence times, τCO, and τCHx (s) of the reversibly adsorbed CO-s and active CHx-s (Cα) intermediates leading to CH4, respectively, increased with increasing CO partial pressure. On the contrary, the apparent activity (keff, s−1) of CHx-s intermediates, turnover frequency (TOF, s−1) of methanation reaction, and the CH4-selectivity (SCH4, %) were found to decrease. Transient isothermal hydrogenation (TIH) following the SSITKA step-gas switch provided important information regarding the reactivity and concentration of active (Cα) and inactive -CxHy (Cβ) carbonaceous species formed after 5 h in the CO/H2 reaction. The latter Cβ species were readily hydrogenated at 230 °C in 50%H2/Ar. The surface coverage of Cβ was found to vary only slightly with increasing CO partial pressure. Temperature-programmed hydrogenation (TPH) following SSITKA and TIH revealed that other types of inactive carbonaceous species (Cγ) were formed during Fischer-Tropsch Synthesis (FTS) and hydrogenated at elevated temperatures (250–550 °C). The amount of Cγ was found to significantly increase with increasing CO partial pressure. All carbonaceous species hydrogenated during TIH and TPH revealed large differences in their kinetics of hydrogenation with respect to the CO partial pressure in the CO/H2 reaction mixture. Operando DRIFTS-MS transient isothermal hydrogenation of adsorbed CO-s formed after 2 h in 5 vol% CO/25 vol% H2/Ar at 200 °C coupled with kinetic modeling (H-assisted CO hydrogenation) provided information regarding the relative reactivity (keff) for CH4 formation of the two kinds of linear-type adsorbed CO-s on the cobalt surface.

Towards a morphology of cobalt nanoparticles: size and strain effects

Cobalt nanoparticles with diameters of 8 nm have recently shown promising performance for biomedical applications. However, it is still unclear how the shape of cobalt clusters changes with size when reaching the nanoparticle range. In the present work, density functional theory calculations have been employed to compare the stabilities of two non-crystalline (icosahedron and decahedron) shapes, and three crystalline motifs (hcp, fcc, and bcc) for magic numbered cobalt clusters with up to 1500 atoms, based on the changes in the cohesive energies, coordination numbers, and nearest-neighbour distances arising from varying geometries. Obtained trends were extrapolated to a 10⁴ size range, and an icosahedral shape was predicted for clusters up to 5500 atoms. Larger sized clusters adopt hcp stacking, in correspondence with the bulk phase. To explain the crystalline/non-crystalline crossovers, the contributions of the elastic strain density and twin boundary from the specimen surfaces to the cohesive energy of different motifs were evaluated. These results are expected to aid the design and synthesis of cobalt nanoparticles for applications ranging from catalysis to biomedical treatments.

Investigation of the deactivation behavior of Co catalysts in Fischer–Tropsch synthesis using encapsulated Co nanoparticles with controlled SiO2 shell layer thickness

The deactivation behavior of Co catalysts was clearly elucidated using Co nanoparticles confined by a porous SiO₂ shell layer with varying thickness and different reaction temperatures.

CO activation and methanation mechanism on hexagonal close-packed Co catalysts: effect of functionals, carbon deposition and surface structure

Regardless of the functionals used and the presence of graphitic carbon, the CO methanation rate on Co(0001) is mainly controlled by CHO decomposition.

Fischer–Tropsch Synthesis: Computational Sensitivity Modeling for Series of Cobalt Catalysts

Nearly a century ago, Fischer and Tropsch discovered a means of synthesizing organic compounds ranging from C1 to C70 by reacting carbon monoxide and hydrogen on a catalyst. Fischer–Tropsch synthesis (FTS) is now known as a pseudo-polymerization process taking a mixture of CO as H2 (also known as syngas) to produce a vast array of hydrocarbons, along with various small amounts of oxygenated materials. Despite the decades spent studying this process, it is still considered a black-box reaction with a mechanism that is still under debate. This investigation sought to improve our understanding by taking data from a series of experimental Fischer–Tropsch synthesis runs to build a computational model. The experimental runs were completed in an isothermal continuous stirred-tank reactor, allowing for comparison across a series of completed catalyst tests. Similar catalytic recipes were chosen so that conditional comparisons of pressure, temperature, SV, and CO/H2 could be made. Further, results from the output of the reactor that included the deviations in product selectivity, especially that of methane and CO2, were considered. Cobalt was chosen for these exams for its industrial relevance and respectfully clean process as it does not intrinsically undergo the water–gas shift (WGS). The primary focus of this manuscript was to compare runs using cobalt-based catalysts that varied in two oxide catalyst supports. The results were obtained by creating two differential equations, one for H2 and one for CO, in terms of products or groups of products. These were analyzed using sensitivity analysis (SA) to determine the products or groups that impact the model the most. The results revealed a significant difference in sensitivity between the two catalyst–support combinations. When the model equations for H2 and CO were split, the results indicated that the CO equation was significantly more sensitive to CO2 production than the H2 equation.

Investigation of C1 + C1 Coupling Reactions in Cobalt-Catalyzed Fischer-Tropsch Synthesis by a Combined DFT and Kinetic Isotope Study

Understanding the chain growth mechanism is of vital importance for the development of catalysts with enhanced selectivity towards long-chain products in cobalt-catalyzed Fischer-Tropsch synthesis. Herein, we discriminate various C1 + C1 coupling reactions by theoretical calculations and kinetic isotope experiments. CHx(x=0−3), CO, HCO, COH, and HCOH are considered as the chain growth monomer respectively, and 24 possible coupling reactions are first investigated by theoretical calculations. Eight possible C1 + C1 coupling reactions are suggested to be energetically favorable because of the relative low reaction barriers. Moreover, five pathways are excluded where the C1 monomers show low thermodynamic stability. Effective chain propagation rates are calculated by deconvoluting from reaction rates of products, and an inverse kinetic isotope effect of the C1 + C1 coupling reaction is observed. The theoretical kinetic isotope effect of CO + CH2 is inverse, which is consistent with the experimental observation. Thus, the CO + CH2 pathway, owing to the relatively lower barrier, the high thermodynamic stability, and the inverse kinetic isotope effect, is suggested to be a favorable pathway.

A review of Fischer Tropsch synthesis process, mechanism, surface chemistry and catalyst formulation

For more than half a century, Fischer-Tropsch synthesis (FTS) of liquid hydrocarbons was a technology of great potential for the indirect liquefaction of solid or gaseous carbon-based energy sources (Coal-To-Liquid (CTL) and Gas-To-Liquid (GTL)) into liquid transportable fuels. In contrast with the past, nowadays transport fuels are mainly produced from crude oil and there is not considerable diversity in their variety. Due to some limitations in the first generation bio-fuels, the Second-Generation Biofuels (SGB)’ technology was developed to perform the Biomass-To-Liquid (BTL) process. The BTL is awell-known multi-step process to convert the carbonaceous feedstock (biomass) into liquid fuels via FTS technology. This paper presents a brief history of FTS technology used to convert coal into liquid hydrocarbons; the significance of bioenergy and SGB are discussed aswell. The paper covers the characteristics of biomass, which is used as feedstock in the BTL process. Different mechanisms in the FTS process to describe carbon monoxide hydrogenation aswell as surface polymerization reaction are discussed widely in this paper. The discussed mechanisms consist of carbide, CO-insertion and the hydroxycarbene mechanism. The surface chemistry of silica support is discussed. Silanol functional groups in silicon chemistry are explained extensively. The catalyst formulation in the Fischer Tropsch (F-T) process as well as F-T reaction engineering is discussed. In addition, the most common catalysts are introduced and the current reactor technologies in the F-T indirect liquefaction process are considered.

Mechanism of Cobalt-Catalyzed CO Hydrogenation: 1. Methanation

The mechanism of CO hydrogenation to CH₄ at 260 °C on a cobalt catalyst is investigated using steady-state isotopic transient kinetic analysis (SSITKA) and backward and forward chemical transient kinetic analysis (CTKA). The dependence of CH_x residence time is determined by ¹²CO/H₂ → ¹³CO/H₂ SSITKA as a function of the CO and H₂ partial pressure and shows that the CH₄ formation rate is mainly controlled by CH_x hydrogenation rather than CO dissociation. Backward CO/H₂ → H₂ CTKA emphasizes the importance of H coverage on the slow CH_x hydrogenation step. The H coverage strongly depends on the CO coverage, which is directly related to CO partial pressure. Combining SSITKA and backward CTKA allows determining that the amount of additional CH₄ obtained during CTKA is nearly equal to the amount of CO adsorbed to the cobalt surface. Thus, under the given conditions overall barrier for CO hydrogenation to CH₄ under methanation condition is lower than the CO adsorption energy. Forward CTKA measurements reveal that O hydrogenation to H₂O is also a relatively slow step compared to CO dissociation. The combined transient kinetic data are used to fit an explicit microkinetic model for the methanation reaction. The mechanism involving direct CO dissociation represents the data better than a mechanism in which H-assisted CO dissociation is assumed. Microkinetics simulations based on the fitted parameters confirms that under methanation conditions the overall CO consumption rate is mainly controlled by C hydrogenation and to a smaller degree by O hydrogenation and CO dissociation. These simulations are also used to explore the influence of CO and H₂ partial pressure on possible rate-controlling steps.

Mechanism of Cobalt-Catalyzed CO Hydrogenation: 2. Fischer-Tropsch Synthesis

Fischer–Tropsch (FT) synthesis is one of the most complex catalyzed chemical reactions in which the chain-growth mechanism that leads to formation of long-chain hydrocarbons is not well understood yet. The present work provides deeper insight into the relation between the kinetics of the FT reaction on a silica-supported cobalt catalyst and the composition of the surface adsorbed layer. Cofeeding experiments of ¹²C₃H₆ with ¹³CO/H₂ evidence that CH_x surface intermediates are involved in chain growth and that chain growth is highly reversible. We present a model-based approach of steady-state isotopic transient kinetic analysis measurements at FT conditions involving hydrocarbon products containing up to five carbon atoms. Our data show that the rates of chain growth and chain decoupling are much higher than the rates of monomer formation and chain termination. An important corollary of the microkinetic model is that the fraction of free sites, which is mainly determined by CO pressure, has opposing effects on CO consumption rate and chain-growth probability. Lower CO pressure and more free sites leads to increased CO consumption rate but decreased chain-growth probability because of an increasing ratio of chain decoupling over chain growth. The preferred FT condition involves high CO pressure in which chain-growth probability is increased at the expense of the CO consumption rate.

Mechanism of Carbon Monoxide Dissociation on a Cobalt Fischer-Tropsch Catalyst

The way in which the triple bond in CO dissociates, a key reaction step in the Fischer–Tropsch (FT) reaction, is a subject of intense debate. Direct CO dissociation on a Co catalyst was probed by ¹²C¹⁶O/¹³C¹⁸O scrambling in the absence and presence of H₂. The initial scrambling rate without H₂ was significantly higher than the rate of CO consumption under CO hydrogenation conditions, which indicated that the surface contained sites sufficiently reactive to dissociate CO without the assistance of H atoms. Only a small fraction of the surface was involved in CO scrambling. The minor influence of CO scrambling and CO residence time on the partial pressure of H₂ showed that CO dissociation was not affected by the presence of H₂. The positive H₂ reaction order was correlated to the fact that the hydrogenation of adsorbed C and O atoms was slower than CO dissociation. Temperature‐programmed in situ IR spectroscopy underpinned the conclusion that CO dissociation does not require H atoms.

Dense CO Adlayers as Enablers of CO Hydrogenation Turnovers on Ru Surfaces

High CO* coverages lead to rates much higher than Langmuirian treatments predict because co-adsorbate interactions destabilize relevant transition states less than their bound precursors. This is shown here by kinetic and spectroscopic data-interpreted by rate equations modified for thermodynamically nonideal surfaces-and by DFT treatments of CO-covered Ru clusters and lattice models that mimic adlayer densification. At conditions (0.01-1 kPa CO; 500-600 K) which create low CO* coverages (0.3-0.8 ML from in situ infrared spectra), turnover rates are accurately described by Langmuirian models. Infrared bands indicate that adlayers nearly saturate and then gradually densify as pressure increases above 1 kPa CO, and rates become increasingly larger than those predicted from Langmuir treatments (15-fold at 25 kPa and 70-fold at 1 MPa CO). These strong rate enhancements are described here by adapting formalisms for reactions in nonideal and nearly incompressible media (liquids, ultrahigh-pressure gases) to handle the strong co-adsorbate interactions within the nearly incompressible CO* adlayer. These approaches show that rates are enhanced by densifying CO* adlayers because CO hydrogenation has a negative activation area (calculated by DFT), analogous to how increasing pressure enhances rates for liquid-phase reactions with negative activation volumes. Without these co-adsorbate effects and the negative activation area of CO activation, Fischer-Tropsch synthesis would not occur at practical rates. These findings and conceptual frameworks accurately treat dense surface adlayers and are relevant in the general treatment of surface catalysis as it is typically practiced at conditions leading to saturation coverages of reactants or products.

The effect of cobalt promoter on the CO methanation reaction over MoS2 catalyst: a density functional study

The potential mechanism of sulfur-resistant CO methanation reaction over Co-MoS₂ catalyst was investigated via density functional theory (DFT + D) calculations, and the effect of Co-promoter was studied.

First-principles study of structure sensitivity of chain growth and selectivity in Fischer–Tropsch synthesis using HCP cobalt catalysts

Co (0001) prefers the CO insertion mechanism with high methane selectivity, but Co (101̄1) prefers the carbide mechanism with high C₂-hydrocarbon selectivity.