Plasma-Assisted Preparation of Highly Dispersed Cobalt Catalysts for Enhanced Fischer–Tropsch Synthesis Performance

X-ray standing wave characterization of the strong metal-support interaction in Co/TiOx model catalysts

The strong metal-support interaction (SMSI) is a phenomenon observed in supported metal catalyst systems in which reducible metal oxide supports can form overlayers over the surface of active metal nanoparticles (NPs) under a hydrogen (H2) environment at elevated temperatures. SMSI has been shown to affect catalyst performance in many reactions by changing the type and number of active sites on the catalyst surface. Laboratory methods for the analysis of SMSI at the nanoparticle-ensemble level are lacking and mostly based on indirect evidence, such as gas chemisorption. Here, we demonstrate the possibility to detect and characterize SMSIs in Co/TiOx model catalysts using the laboratory X-ray standing wave (XSW) technique for a large ensemble of NPs at the bulk scale. We designed a thermally stable MoNx/SiNx periodic multilayer to retain XSW generation after reduction with H2 gas at 600°C. The model catalyst system was synthesized here by deposition of a thin TiOx layer on top of the periodic multilayer, followed by Co NP deposition via spare ablation. A partial encapsulation of Co NPs by TiOx was identified by analyzing the change in Ti atomic distribution. This novel methodological approach can be extended to observe surface restructuring of model catalysts in situ at high temperature (up to 1000°C) and pressure (≤3 mbar), and can also be relevant for fundamental studies in the thermal stability of membranes, as well as metallurgy.

How to Survive at Point Nemo? Fischer-Tropsch, Artificial Photosynthesis, and Plasma Catalysis for Sustainable Energy at Isolated Habitats

Inhospitable, inaccessible, and extremely remote alike the famed pole of inaccessibility, aka Point Nemo, the isolated locations in deserts, at sea, or in outer space are difficult for humans to settle, let alone to thrive in. Yet, they present a unique set of opportunities for science, economy, and geopolitics that are difficult to ignore. One of the critical challenges for settlers is the stable supply of energy both to sustain a reasonable quality of life, as well as to take advantage of the local opportunities presented by the remote environment, e.g., abundance of a particular resource. The possible solutions to this challenge are heavily constrained by the difficulty and prohibitive cost of transportation to and from such a habitat (e.g., a lunar or Martian base). In this essay, the advantages and possible challenges of integrating Fischer-Tropsch, artificial photosynthesis, and plasma catalysis into a robust, scalable, and efficient self-contained system for energy harvesting, storage, and utilization are explored.

Photocatalyst Based on Nanostructured TiO2 with Improved Photocatalytic and Antibacterial Properties

This study shows an easy way to use electrochemistry and plasma layering to make Cobalt-Blue-TiO2 nanotubes that are better at catalysing reactions. Once a titanium plate has been anodized, certain steps are taken to make oxygen vacancies appear inside the TiO2 nanostructures. To find out how the Co deposition method changed the final catalyst's properties, it was put through electrochemical tests (to find the charge transfer resistance and flat band potential) and optical tests (to find the band gap and Urbach energy). The catalysts were also described in terms of their shape, ability to stick to surfaces, and ability to inhibit bacteria. When Cobalt was electrochemically deposited to Blue-TiO2 nanotubes, a film with star-shaped structures was made that was hydrophilic and antibacterial. The band gap energy went down from 3.04 eV to 2.88 eV and the Urbach energy went up from 1.171 eV to 3.836 eV using this electrochemical deposition method. Also, photodegradation tests with artificial doxycycline (DOX) water were carried out to see how useful the study results would be in real life. These extra experiments were meant to show how the research results could be used in real life and what benefits they might have. For the bacterial tests, both gram-positive and gram-negative bacteria were used, and BT/Co-E showed the best response. Additionally, photodegradation and photoelectrodegradation experiments using artificial doxycycline (DOX) water were conducted to determine the practical relevance of the research findings. The synergistic combination of light and applied potential leads to 70% DOX degradation after 60 min of BT/Co-E irradiation.

A review of the advances in catalyst modification using nonthermal plasma: Process, Mechanism and Applications

With the continuous development of catalytic processes in chemistry, biology, organic synthesis, energy generation and many other fields, the design of catalysts with novel properties has become a new paradigm in both science and industry. Nonthermal plasma has aroused extensive interest in the synthesis and modification of catalysts. An increasing number of researchers are using plasma for the modification of target catalysts, such as modifying the dispersion of active sites, regulating electronic properties, enhancing metal-support interactions, and changing the morphology. Plasma provides an alternative choice for catalysts in the modification process of oxidation, reduction, etching, coating, and doping and is especially helpful for unfavourable thermodynamic processes or heat-sensitive reactions. This review focuses on the following points: (i) the fundamentals behind the nonthermal plasma modification of catalysts; (ii) the latest research progress on the application of plasma modified catalysts; and (iii) main challenges in the field and a vision for future development.

Resolving the Effect of Oxygen Vacancies on Co Nanostructures Using Soft XAS/X-PEEM

Improving both the extent of metallic Co nanoparticle (Co NP) formation and their stability is necessary to ensure good catalytic performance, particularly for Fischer–Tropsch synthesis (FTS). Here, we observe how the presence of surface oxygen vacancies (O_vac) on TiO₂ can readily reduce individual Co₃O₄ NPs directly into CoO/Co⁰ in the freshly prepared sample by using a combination of X-ray photoemission electron microscopy (X-PEEM) coupled with soft X-ray absorption spectroscopy. The O_vac are particularly good at reducing the edge of the NPs as opposed to their center, leading to smaller particles being more reduced than larger ones. We then show how further reduction (and O_vac consumption) is achieved during heating in H₂/syngas (H₂ + CO) and reveal that O_vac also prevents total reoxidation of Co NPs in syngas, particularly the smallest (∼8 nm) particles, thus maintaining the presence of metallic Co, potentially improving catalyst performance.

The effect of the particle size on Fischer-Tropsch synthesis for ZSM-5 zeolite supported cobalt-based catalysts

A series of mesoporous ZSM-5 zeolite supported cobalt-based catalysts with the cobalt crystal sizes in the range of 4.5-18.1 nm were prepared for syngas conversion. The highly selective synthesis of various liquid fuels including gasoline, jet fuel and diesel range hydrocarbons is achieved with different cobalt nanoparticle sizes.

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.

Fischer–Tropsch Synthesis for Light Olefins from Syngas: A Review of Catalyst Development

Light olefins as one the most important building blocks in chemical industry can be produced via Fischer–Tropsch synthesis (FTS) from syngas. FT synthesis conducted at high temperature would lead to light paraffins, carbon dioxide, methane, and C5+ longer chain hydrocarbons. The present work focuses on providing a critical review on the light olefin production using Fischer–Tropsch synthesis. The effects of metals, promoters and supports as the most influential parameters on the catalytic performance of catalysts are discussed meticulously. Fe and Co as the main active metals in FT catalysts are investigated in terms of pore size, crystal size, and crystal phase for obtaining desirable light olefin selectivity. Larger pore size of Fe-based catalysts is suggested to increase olefin selectivity via suppressing 1-olefin readsorption and secondary reactions. Iron carbide as the most probable phase of Fe-based catalysts is proposed for light olefin generation via FTS. Smaller crystal size of Co active metal leads to higher olefin selectivity. Hexagonal close-packed (HCP) structure of Co has higher FTS activity than face-centered cubic (FCC) structure. Transition from Co to Co3C is mainly proposed for formation of light olefins over Co-based catalysts. Moreover, various catalysts’ deactivation routes are reviewed. Additionally, techno-economic assessment of FTS plants in terms of different costs including capital expenditure and minimum fuel selling price are presented based on the most recent literature. Finally, the potential for global environmental impacts associated with FTS plants including atmospheric and toxicological impacts is considered via lifecycle assessment (LCA).

Plasma-Catalytic Fischer–Tropsch Synthesis at Very High Pressure

This study explored Fischer–Tropsch synthesis (FTS) by combining a non-thermal plasma (NTP), generated by an arc discharge reactor at pressures >> 1 MPa, coupled with a mullite-coated 2 wt%-Co/5 wt%-Al2O3 catalyst. The FTS product yields and electrical energy consumption for the pure plasma (no catalyst) and plasma-catalytic FTS processes were compared under the scope of various reactor operating parameters, namely, pressure (0.5 to 10 MPa), current (250 to 450 mA) and inter-electrode gap (0.5 to 2 mm). The major products, obtained in low concentrations for both processes, were gaseous C1–C3 hydrocarbons, synthesised in the order: methane >> ethane > ethylene > propane. The hydrocarbon product yields were observed to increase, while the specific required energy generally decreased with increasing pressure, decreasing current and increasing inter-electrode gap. Plasma-catalysis improved the FTS performance, with the optimum conditions as: (i) 10 MPa at 10 s and 2 MPa at 60 s for the pressure variation study with the longer treatment time producing higher yields; (ii) 250 mA for the current variation study; (iii) 2 mm for the inter-electrode gap variation study. Plasma-catalysis at a gap of 2 mm yielded the highest concentrations of methane (15,202 ppm), ethane (352 ppm), ethylene (121 ppm) and propane (20 ppm), thereby indicating the inter-electrode gap as the most influential parameter.

Dehydrogenation of formic acid over Pd/C catalysts: insight into the cold plasma treatment

Non-thermal plasma treatment has great potential to open a fast and green route for controllable synthesis of highly active supported metal catalysts.

Highly Dispersed Co Nanoparticles Prepared by an Improved Method for Plasma-Driven NH3 Decomposition to Produce H2

Previous studies reveal that combining non-thermal plasma with cheap metal catalysts achieved a significant synergy of enhancing performance of NH3 decomposition, and this synergy strongly depended on the properties of the catalyst used. In this study, techniques of vacuum-freeze drying and plasma calcination were employed to improve the conventional preparation method of catalyst, aiming to enhance the activity of plasma-catalytic NH3 decomposition. Compared with the activity of the catalyst prepared by a conventional method, the conversion of NH3 significantly increased by 47% when Co/fumed SiO2 was prepared by the improved method, and the energy efficiency of H2 production increased from 2.3 to 5.7 mol(kW·h)−1 as well. So far, the highest energy efficiency of H2 formation of 15.9 mol(kW·h)−1 was achieved on improved prepared Co/fumed SiO2 with 98.0% ammonia conversion at the optimal conditions. The improved preparation method enables cobalt species to be highly dispersed on fumed SiO2 support, which creates more active sites. Besides, interaction of Co with fumed SiO2 and acidity of the catalyst were strengthened according to results of H2-TPR and NH3-probe experiments, respectively. These results demonstrate that employing vacuum-freeze drying and plasma calcination during catalyst preparation is an effective approach to manipulate the properties of catalyst, and enables the catalyst to display high activity towards plasma-catalytic NH3 decomposition to produce H2.

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.