Effect of support surface treatment on the synthesis, structure, and performance of Co/CNT Fischer–Tropsch catalysts

Hydrogen spillover effects in the Fischer–Tropsch reaction over carbon nanotube supported cobalt catalysts

Support (CNTs) surface defect-induced hydrogen spillover significantly impacted the catalytic activity (turnover frequency, TOF) and methane selectivity evolution in cobalt-based Fischer–Tropsch synthesis.

Modulating the electrocatalytic CO2 reduction performances of bismuth nanoparticles with carbon substrates with controlled degrees of oxidation

The catalytic performances of metal nanoparticles can be widely tuned and promoted by the metal-support interactions. Here, we report that the morphologies and electrocatalytic CO₂ reduction reaction (CO₂RR) properties of bismuth nanoparticles (BiNPs) can be rationally modulated by their interactions with carbon black (CB) supports by controlling the degree of surface oxidation. Appropriately oxidized CB supports can provide sufficient oxygen-containing groups for anchoring BiNPs with tunable sizes and surface areas, desirable key intermediate adsorption abilities, appropriate surface wettability, and adequate electron transfer abilities. As a result, the optimized Bi/CB catalysts exhibited a promoted CO₂RR performance with a Faradaic efficiency of 94% and a current density of 16.7 mA cm^-2 for HCOO^- at -0.9 V versus a reversible hydrogen electrode. Our results demonstrate the significance of regulating the interactions between supports and metal nanoparticles for both synthesis of the catalyst and electrolysis applications, which may find broader applicability in more electrocatalyst designs.

Functionalized Carbon Materials in Syngas Conversion

Functionalized carbon materials are widely used in heterogeneous catalysis due to their unique properties such as adjustable surface properties, excellent thermal conductivity, high surface areas, tunable porosity, and moderate interactions with guest metals. The transformation of syngas into hydrocarbons (known as the Fischer-Tropsch synthesis) or oxygenates is an exothermic reaction and is typically catalyzed by transition metals dispersed on functionalized supports. Various carbon materials have been employed in syngas conversions not only for improving the performance or decreasing the dosage of expensive active metals but also for building model catalysts for fundamental research. This article provides a critical review on recent advances in the utilization of carbon materials, in particular the recently developed functionalized nanocarbon materials, for syngas conversions to either hydrocarbons or oxygenates. The unique features of carbon materials in dispersing metal nanoparticles, heteroatom doping, surface modification, and building special nanoarchitectures are highlighted. The key factors that control the reaction course and the reaction mechanism are discussed to gain insights for the rational design of efficient carbon-supported catalysts for syngas conversions. The challenges and future opportunities in developing functionalized carbon materials for syngas conversions are briefly analyzed.

The Effect of Cobalt Catalyst Loading at Very High Pressure Plasma-Catalysis in Fischer-Tropsch Synthesis

The influence of different catalyst cobalt loadings on the C1–C3 hydrocarbon product yields and energy consumption in plasma-catalytic Fischer-Tropsch synthesis (FTS) was investigated from the standpoint of various reactor operating conditions: pressure (0.5 to 10 MPa), current (250 to 450 mA) and inter-electrode gap (0.5 to 2 mm). This was accomplished by introducing a mullite substrate, coated with 2 wt%-Co/5 wt%-Al2O3, 6 wt%-Co/5 wt%-Al2O3 or 0 wt%-Co/5 wt%-Al2O3 (blank catalyst), into a recently developed high pressure arc discharge reactor. The blank catalyst was ineffective in synthesizing hydrocarbons. Between the blank catalyst, 2 wt%, and the 6 wt% Co catalyst, the 6 wt% improved C1–C3 hydrocarbon production at all conditions, with higher yields and relatively lower energy consumption at (i) 10 MPa at 10 s, and 2 MPa at 60 s, for the pressure variation study; (ii) 250 mA for the current variation study; and (iii) 2 mm for the inter-electrode gap variation study. The inter-electrode gap of 2 mm, using the 6 wt% Co catalyst, led to the overall highest methane, ethane, ethylene, propane and propylene yields of 22 424, 517, 101, 79 and 19 ppm, respectively, compared to 40 ppm of methane and <1 ppm of C1–C3 hydrocarbons for the blank catalyst, while consuming 660 times less energy for the production of a mole of methane. Furthermore, the 6 wt% Co catalyst produced carbon nanotubes (CNTs), detected via transmission electron microscopy (TEM). In addition, scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDX) and x-ray diffraction (XRD) showed that the cobalt catalyst was modified by plasma treatment.

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.

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.

Effect of Manganese on Co–Mn/CNT Bimetallic Catalyst Performance in Fischer–Tropsch Reaction

Cobalt (Co) catalyst is supported by carbon nanotubes (CNT) using a strong electrostatic adsorption (SEA) method. To promote activity and selectivity as well as find the optimum loading percentage and its effect on catalyst performance, manganese (Mn) has been added to the Co/CNT catalyst. Samples were characterized by a scanning electron microscope (SEM-EDX), transmission electron microscope (TEM), hydrogen temperature programmed reduction (H2-TPR), Zeta potential, Brunauer–Emmett–Teller (BET) analysis, X-ray diffraction (XRD), and X-ray spectroscopy (XPS). TEM images illustrated an intake of metal particles which were highly dispersed, having a narrow particle size distribution of 6–8 nm to the external and internal CNT support. H2-TPR showed a lower temperature reduction with Mn at 420 °C for Fischer–Tropsch synthesis (FTS) reaction. The Co–Mn/CNT catalyst performance test for FTS was performed at a temperature of 240 °C in a fixed-bed micro-reactor at a pressure of 2.0 MPa. The addition of manganese resulted in a lower methane selectivity and a higher C5+ product with an optimum percentage of 5% of manganese. CO conversion was 86.6% and had a C5+ selectivity of 81.5%, which was higher than the catalysts obtained using only Co on pretreated CNT.

Adsorption of water and n-hexane on pristine and oxidized carbon nanotube supports of cobalt-based Fischer–Tropsch catalysts

Adsorption of water and n-hexane by oxidized and pristine CNTs at different stages of Co/CNT catalyst preparation has been studied to reveal the effect of the support surface functionalization on the catalyst selectivity in Fischer–Tropsch synthesis.

Attachment of iron oxide nanoparticles to carbon nanofibers studied by in-situ liquid phase transmission electron microscopy

By using liquid phase transmission electron microscopy (LP-TEM), the dynamics of iron oxide nanoparticle (Fe-NP) attachment to carbon nanofibers (CNFs) and oxygen functionalized CNFs (CNF-Ox) were studied in-situ. The beam effect on the stability of the sample in various liquids was examined, and it was found that toluene provided the highest stability and resolution to image both CNF supports and Fe-NPs. Flowing particles dispersed in toluene through the liquid cell allowed direct monitoring of the attachment process at ambient temperature. Using CNF-Ox as a support led to a large extent and irreversible attachment of iron nanoparticle compared to a lower extent and reversible attachment of Fe-NPs to pristine CNF, indicating the influence of surface functionalization on colloidal particle attachment. The results were confirmed by lab-scale experiments as well as experiments performed with the electron beam switched off, verifying the notion that beam effects did not affect the attachment. This study revealed previously unknown phenomena in colloidal particle - support interactions and demonstrates the power of LP-TEM technique for studying such nanoscale processes.

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.

Effect of Cobalt Catalyst Confinement in Carbon Nanotubes Support on Fischer-Tropsch Synthesis Performance

Pre-treating the multi-walled carbon nanotubes (CNTs) support by refluxing in 35 vol% nitric acid followed by heating at the temperature of 600 to 900 °C resulted in the formation of defects on the CNTs. Increasing the temperature of the pre-treatment of the CNTs from 600 °C to 900 °C, enhanced the fraction of cobalt-oxide nanoparticles encapsulated in the channels of CNTs from 31% to 70%. The performance of Co/CNTs in Fischer-Tropsch synthesis (FTS) was evaluated in a fixed-bed micro-reactor at a temperature of 240 °C and a pressure of 2.0 MPa. The highest CO conversion obtained over Co/CNTs.A.900 was 59% and it dropped by ~3% after 130 h of time-on-stream. However, maximum CO conversion using Co/CNTs.A.600 catalysts was 28% and it decreased rapidly by about 54% after 130 h of time-on-stream. These findings show that the combined acid and thermal pre-treatment of CNTs support at 900 °C has improved the stability and activity of the Co/CNTs catalyst in FTS.

Probing the enhanced catalytic activity of carbon nanotube supported Ni-LaOx hybrids for the CO2 reduction reaction

Oxygenated functionalized carbon nanotube (oCNT) supported LaO_x-promoted Ni nanoparticles (10Ni-xLa/oCNT) were prepared by the co-impregnation method and tested for synthetic natural gas from the CO₂ reduction reaction. Several advanced characterization methods, including atomic resolution scanning transmission electron microscopy (STEM), temperature programmed experiments (TPSR, CO₂-TPD, and H₂-TPR) and X-ray photoelectron spectroscopy (XPS), were applied to explore, for the first time, the origin of structure modulation of LaO_x species on oCNT supported Ni-LaO_x hybrids and the structure-activity relationship over the CO₂ reduction reaction. The Z-contrast STEM-HAADF results revealed that the LaO_x species are mostly in the size of the sub-nano scale and highly dispersed on the surface of Ni nanoparticles and oCNT, and consequently no diffraction peak of LaO_x was observed from XRD results. TEM analysis showed that the Ni nanoparticle sizes were similar among all samples either after reduction or after reaction due to the relatively strong interaction between Ni and oxygenated groups on CNT supports, regardless of the influence of the La mass loading. It was suggested that the catalytic performance trend was due to the structural variation rather than the size effect. The LaO_x modulation catalyst with 2 wt% of La metal loading not only presented low CO₂ activation temperature at only 163 °C, but also resulted in extremely high CH₄ selectivity (100%) compared with the initial supported Ni catalyst (52.7% of CH₄ selectivity at 300 °C).

The recent development of efficient Earth-abundant transition-metal nanocatalysts

Whereas noble metal compounds have long been central in catalysis, Earth-abundant metal-based catalysts have in the same time remained undeveloped. Yet the efficacy of Earth-abundant metal catalysts was already shown at the very beginning of the 20th century with the Fe-catalyzed Haber-Bosch process of ammonia synthesis and later in the Fischer-Tropsch reaction. Nanoscience has revolutionized the world of catalysis since it was observed that very small Au nanoparticles (NPs) and other noble metal NPs are extraordinarily efficient. Therefore the development of Earth-abundant metals NPs is more recent, but it has appeared necessary due to their "greenness". This review highlights catalysis by NPs of Earth-abundant transition metals that include Mn, Fe, Co, Ni, Cu, early transition metals (Ti, V, Cr, Zr, Nb and W) and their nanocomposites with emphasis on basic principles and literature reported during the last 5 years. A very large spectrum of catalytic reactions has been successfully disclosed, and catalysis has been examined for each metal starting with zero-valent metal NPs followed by oxides and other nanocomposites. The last section highlights the catalytic activities of bi- and trimetallic NPs. Indeed this later family is very promising and simultaneously benefits from increased stability, efficiency and selectivity, compared to monometallic NPs, due to synergistic substrate activation.

Influence of Metal Deposition and Activation Method on the Structure and Performance of Carbon Nanotube Supported Palladium Catalysts

The effects of the metal deposition and activation methods on metal particle size and distribution were investigated for carbon nanotube supported Pd catalysts. The Pd precursor was loaded by incipient wetness impregnation, ion adsorption, and deposition precipitation and was activated by thermal treatment under a nitrogen atmosphere or in the liquid phase by reduction by formaldehyde or sodium borohydride. Regardless of the metal precursor loading method, activation under a N₂ atmosphere at 500 °C led to homogeneously distributed 4 nm Pd particles. Liquid‐phase reduction by sodium borohydride provided a bimodal distribution with particle sizes of approximately 1 and >10 nm. A somewhat weaker reducing agent, formaldehyde, yielded particles approximately 1 nm in size. The activities of the catalysts for the hydrogenation of cinnamaldehyde correlated with the particle sizes.

Assembly and activation of supported cobalt nanocrystal catalysts for the Fischer–Tropsch synthesis

Low-temperature oxidation of cobalt nanocrystals is the preferred treatment to obtain the most uniformly distributed and active Fischer–Tropsch synthesis catalyst.

In-Situ 2p3d Resonant Inelastic X-ray Scattering Tracking Cobalt Nanoparticle Reduction

In-situ carbon-thermal reduction of cobalt oxide nanoparticles supported on carbon nanotubes was studied by cobalt 2p3d resonant inelastic X-ray scattering (RIXS). The in-situ 2p X-ray absorption spectroscopy (XAS) and RIXS measurements were performed at 500, 600, and 700 °C, where four consistent excitation energies were used for RIXS acquisitions. After 700 °C reduction, the XAS spectrum shows a cobalt metal-like shape, while the RIXS spectra reveal the minority cobalt monoxide phase. The holistic fit on both XAS and RIXS data reveals the respective contributions from metal and monoxide. We show that the relative precision to determine the monoxide content changes from ∼5.6% in XAS results to better than 0.8% in the RIXS analysis, suggesting that RIXS is a useful tool to track the oxidation state of nanoparticles under in situ conditions. We determined a relative radiative ratio (P) factor of approximately 5, where this factor gives the ratio between the relative strengths of the radiative decay channels compared to the nonradiative channels in CoO and Co metal.

Carbon Support Surface Effects in the Gold-Catalyzed Oxidation of 5-Hydroxymethylfurfural

Oxidation of 5-hydroxymethylfurfural into 2,5-furandicarboxylic acid is an important transformation for the production of bio-based polymers. Carbon-supported gold catalysts hold great promise for this transformation. Here we demonstrate that the activity, selectivity, and stability of the carbon-supported gold nanoparticles in the oxidation of 5-hydroxymethylfurfural strongly depend on the surface properties of the carbon support. Gold nanoparticles supported on basic carbon materials with a low density of functional groups demonstrate higher activity in 5-hydroxymethylfurfural oxidation (TOF_Au up to 1195 h^-1), higher selectivity to 2,5-furandicarboxylic acid, and better stability in comparison to gold nanoparticles supported on carbon materials with acidic surface groups. Surface groups of basic carbon supports that are positively charged under the reaction conditions result in a higher adsorption and local concentration of hydroxyl ions, which act as cocatalysts for gold and enhance gold-catalyzed dehydrogenation. Negatively charged surface groups of acidic carbons repel hydroxyls and the intermediate monoacid anions, which leads to lower reaction rates and a high selectivity toward 2,5-hydroxymethylfurancarboxylic acid. Understanding the role of support surface charge and local hydroxyl anion concentration provides a basis for the rational design of the optimal carbon support surface chemistry for highly active, selective, and stable catalysts for the oxidation of 5-hydroxymethylfurfural and related reactions.

Investigation of the highly tunable selectivity to linear α-olefins in Fischer–Tropsch synthesis over silica-supported Co and CoMn catalysts by carburization–reduction pretreatment

An efficient strategy to tune the selectivity to α-olefins in FTS over Co-based catalysts has been developed.

The recent development of efficient Earth-abundant transition-metal nanocatalysts

This review presents the recent remarkable developments of efficient Earth-abundant transition-metal nanocatalysts.

Highly selective production of heavy hydrocarbons over cobalt–graphene–silica nanocomposite catalysts

Cobalt–graphene–silica nanocomposites catalysts were applied in FTS and showed highly selective production of heavy hydrocarbons.