Water-induced deactivation of cobalt-based Fischer–Tropsch catalysts

Understanding and Tuning the Effects of H2O on Catalytic CO and CO2 Hydrogenation

Catalytic COx (CO and CO2) hydrogenation to valued chemicals is one of the promising approaches to address challenges in energy, environment, and climate change. H2O is an inevitable side product in these reactions, where its existence and effect are often ignored. In fact, H2O significantly influences the catalytic active centers, reaction mechanism, and catalytic performance, preventing us from a definitive and deep understanding on the structure-performance relationship of the authentic catalysts. It is necessary, although challenging, to clarify its effect and provide practical strategies to tune the concentration and distribution of H2O to optimize its influence. In this review, we focus on how H2O in COx hydrogenation induces the structural evolution of catalysts and assists in the catalytic processes, as well as efforts to understand the underlying mechanism. We summarize and discuss some representative tuning strategies for realizing the rapid removal or local enrichment of H2O around the catalysts, along with brief techno-economic analysis and life cycle assessment. These fundamental understandings and strategies are further extended to the reactions of CO and CO2 reduction under an external field (light, electricity, and plasma). We also present suggestions and prospects for deciphering and controlling the effect of H2O in practical applications.

Engineering Asymmetric Strain within C-Shaped CeO2 Nanofibers for Stabilizing Sub-3 nm Pt Clusters against Sintering

Ultrafine noble metals have emerged as advanced nanocatalysts in modern society but still suffer from unavoidable sintering at temperatures above 250 °C (e.g., Pt). In this work, closely packed CeO2 grains were confined elegantly in fibrous nanostructures and served as a porous support for stabilizing sub-3 nm Pt clusters. Through precisely manipulating the asymmetry of obtained nanofibers, uneven strain was induced within C-shaped CeO2 nanofibers with tensile strain at the outer side and compressive strain at the inner side. As a result, the enriched oxygen vacancies significantly improved adhesion of Pt to CeO2, thereby boosting the sinter-resistance of ultraclose sub-3 nm Pt clusters. Notably, no aggregation was observed even after exposure to humid air at 750 °C for 12 h, which is far beyond their Tammann temperature (sintering onset temperature, below 250 °C). In situ HAADF-STEM observation revealed a unique sintering mechanism, wherein Pt clusters initially migrate toward the grain boundaries with concentrated stain and undergo slight coalescence, followed by subsequent Ostwald ripening at higher temperatures. Moreover, the sinter-resistant Pt/C-shaped CeO2 effectively catalyzed soot combustion (over 700 °C) in a durable manner. This work provides a new insight for developing sinter-resistant catalysts from the perspective of strain engineering within nano-oxides.

Issues and challenges of Fischer-Tropsch synthesis catalysts

Depletion of oil and gas resources is a major concern for researchers and the global community. Researchers are trying to develop a way to overcome these issues using the Fischer-Tropsch synthesis (FTS) process. The FTS reaction converts a mixture of hydrogen and carbon monoxide gases into a liquid fuel. The reactions are performed in the reactor and in the presence of a catalyst. A series of catalysts, such as iron, cobalt, nickel, and ruthenium, have been used for the FTS process. In iron-based catalysts, the Fe5C phase is the active phase that produces C5+ hydrocarbons. At higher conversion rates, the presence of water in the products is a problem for cobalt catalysts because it can trigger catalyst deactivation mechanisms. Ni-based catalysts play key roles as base catalysts, promoters, and photothermal catalysts in FTS reactions to produce different useful hydrocarbons. Ruthenium catalysts offer not only high activity but also selectivity toward long-chain hydrocarbons. Moreover, depending on the Ru particle size and interaction with the oxide support, the catalyst properties can be tuned to enhance the catalytic activity during FTS. The detailed reaction pathways based on catalyst properties are explained in this article. This review article describes the issues and challenges associated with catalysts used for the FTS process.

Transition-Metal Porphyrin-Based MOFs In Situ-Derived Hybrid Catalysts for Electrocatalytic CO2 Reduction

Excellent electrocatalytic CO2 reduction reaction activity has been demonstrated by transition metals and nitrogen-codoped carbon (M-N-C) catalysts, especially for transition-metal porphyrin (MTPP)-based catalysts. In this work, we propose to use one-step low-temperature pyrolysis of the isostructural MTPP-based metal-organic frameworks (MOFs) and electrochemical in situ reduction strategies to obtain a series of hybrid catalysts of Co nanoparticles (Co NPs) and MTPP, named Co NPs/MTPP (M = Fe, Co, and Ni). The in situ introduction of Co NPs can efficiently enhance the electrocatalytic ability of MTPP (M = Fe, Co, and Ni) to convert CO2 to CO, particularly for FeTPP. Co NPs/FeTPP endowed a high CO faradaic efficiency (FECOmax = 95.5%) in the H cell, and the FECO > 90.0% is in the broad potential range of -0.72 to -1.22 VRHE. In addition, the Co NPs/FeTPP achieved 145.4 mA cm-2 at a lower potential of -0.70 VRHE with an FECO of 94.7%, and the CO partial currents increased quickly to reach 202.2 mA cm-2 at -0.80 VRHE with an FECO of 91.6% in the flow cell. It is confirmed that Co NPs are necessary for hybrid catalysts to get superior electrocatalytic activity; Co NPs also can accelerate H2O dissociation and boost the proton supply capacity to hasten the proton-coupled electron-transfer process, effectively adjusting the adsorption strength of the reaction intermediates.

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.

Compositional Evolution of Individual CoNPs on Co/TiO2 during CO and Syngas Treatment Resolved through Soft XAS/X-PEEM

The nanoparticle (NP) redox state is an important parameter in the performance of cobalt-based Fischer-Tropsch synthesis (FTS) catalysts. Here, the compositional evolution of individual CoNPs (6-24 nm) in terms of the oxide vs metallic state was investigated in situ during CO/syngas treatment using spatially resolved X-ray absorption spectroscopy (XAS)/X-ray photoemission electron microscopy (X-PEEM). It was observed that in the presence of CO, smaller CoNPs (i.e., ≤12 nm in size) remained in the metallic state, whereas NPs ≥ 15 nm became partially oxidized, suggesting that the latter were more readily able to dissociate CO. In contrast, in the presence of syngas, the oxide content of NPs ≥ 15 nm reduced, while it increased in quantity in the smaller NPs; this reoxidation that occurs primarily at the surface proved to be temporary, reforming the reduced state during subsequent UHV annealing. O K-edge measurements revealed that a key parameter mitigating the redox behavior of the CoNPs were proximate oxygen vacancies (Ovac). These results demonstrate the differences in the reducibility and the reactivity of Co NP size on a Co/TiO2 catalyst and the effect Ovac have on these properties, therefore yielding a better understanding of the physicochemical properties of this popular choice of FTS catalysts.

Dry reforming of methane over gallium-based supported catalytically active liquid metal solutions

Gallium-rich supported catalytically active liquid metal solutions (SCALMS) were recently introduced as a new way towards heterogeneous single atom catalysis. SCALMS were demonstrated to exhibit a certain resistance against coking during the dehydrogenation of alkanes using Ga-rich alloys of noble metals. Here, the conceptual catalytic application of SCALMS in dry reforming of methane (DRM) is tested with non-noble metal (Co, Cu, Fe, Ni) atoms in the gallium-rich liquid alloy. This study introduces SCALMS to high-temperature applications and an oxidative reaction environment. Most catalysts were shown to undergo severe oxidation during DRM, while Ga-Ni SCALMS retained a certain level of activity. This observation is explained by a kinetically controlled redox process, namely oxidation to gallium oxide species and re-reduction via H2 activation over Ni. Consequentially, this redox process can be shifted to the metallic side when using increasing concentrations of Ni in Ga, which strongly suppresses coke formation. Density-functional theory (DFT) based ab initio molecular dynamics (AIMD) simulations were performed to confirm the increased availability of Ni at the liquid alloy-gas interface. However, leaching of gallium via the formation of volatile oxidic species during the hypothesised redox cycles was identified indicating a critical instability of Ga-Ni SCALMS for prolonged test durations.

Reducibility of Al3+-Modified Co3O4: Influence of Aluminum Distribution

The reduction of Co-based oxides doped with Al3+ ions has been studied using in situ XRD and TPR techniques. Al3+-modified Co3O4 oxides with the Al mole fraction Al/(Co + Al) = 1/6; 1/7.5 were prepared via coprecipitation, with further calcination at 500 and 850 °C. Using XRD and HAADF-STEM combined with EDS element mapping, the Al3+ cations were dissolved in the Co3O4 lattice; however, the cation distribution differed and depended on the calcination temperature. Heating at 500 °C led to the formation of an inhomogeneous (Co,Al)3O4 solid solution; further treatment at 850 °C provoked the partial decomposition of mixed Co-Al oxides and the formation of particles with an Al-depleted interior and Al-enriched surface. It has been shown that the reduction of cobalt oxide by hydrogen occurs via the following transformations: (Co,Al)3O4 → (Co,Al)O → Co. Depending on the Al distribution, the course of reduction changes. In the case of the inhomogeneous (Co,Al)3O4 solid solution, Al stabilizes intermediate Co(II)-Al(III) oxides during reduction. When Al3+ ions are predominantly on the surface of the Co3O4 particles, the intermediate compound consists of Al-depleted and Al-enriched Co(II)-Al(III) oxides, which are reduced independently. Different distributions of elemental Co and Al in mixed oxides simulate different types of the interaction phase in Co3O4/γ-Al2O3-supported catalysts. These changes in the reduction properties can significantly affect the state of an active component of the Co-based catalysts.

Bioinspired Electrode for the Production and Timely Separation of Nitrile and Hydrogen

Replacing electrocatalytic oxygen evolution reaction (OER) with amine oxidation reaction is adopted to boost clean and environment-friendly energy source hydrogen (H₂ ) in water. However, the electrocatalytic reaction is severely restricted by the strong adsorption of product on the catalyst surface. Inspired by the cooperation of flavin adenine dinucleotide and mitochondria membrane in biological system, the catalysis-separation complex electrodes are introduced to promote the desorption of product and hinder its readsorption by applying polytetrafluoroethylene (PTFE)-separation membrane on the one side of electrode, which is benefit for the cleanness of active sites on the catalyst surface for the continuous production and timely separation of nitrile and hydrogen. With the intermolecular force between PTFE and nitrile, the nitrile droplets can be quickly desorbed and separated from catalyst surface of anode, and the size of nitrile droplets on the catalyst surface is only 0.23% to that without PTFE. As a result, the current at 1.49 V_RHE from the catalyst with PTFE membrane is about 33 times to that of catalyst without PTFE after long-term operation. Moreover, the cathode with PTFE membrane also achieves the rapid desorption of H₂ bubbles and stable cathodic current because of the strong absorption of PTFE to H₂ .

Co3O4/TiO2 catalysts studied in situ during the preferential oxidation of carbon monoxide: the effect of different TiO2 polymorphs

This study reveals the influence of different TiO2 supports on the catalytic performance and phase transformations of Co3O4 during CO-PrOx.

Physical mixing of a catalyst and a hydrophobic polymer promotes CO hydrogenation through dehydration

In many reactions restricted by water, selective removal of water from the reaction system is critical and usually requires a membrane reactor. We found that a simple physical mixture of hydrophobic poly(divinylbenzene) with cobalt-manganese carbide could modulate a local environment of catalysts for rapidly shipping water product in syngas conversion. We were able to shift the water-sorption equilibrium on the catalyst surface, leading to a greater proportion of free surface that in turn raised the rate of syngas conversion by nearly a factor of 2. The carbon monoxide conversion reached 63.5%, and 71.4% of the hydrocarbon products were light olefins at 250°C, outperforming poly(divinylbenzene)-free catalyst under equivalent reaction conditions. The physically mixed CoMn carbide/poly(divinylbenzene) catalyst was durable in the continuous test for 120 hours.

Revealing synergetic structural activation of a CuAu surface during water-gas shift reaction

Significance Atomic-level in situ environmental transmission electron microscopy observation of the dynamic activation process on a low-indexed CuAu surface under water-gas shift reaction (WGSR) condition has been revealed. The atomic-scale structural activation of a CuAu surface features a gas-dependent periodic surface restructuring and elemental ordering, explaining the "synergy effect" from the structural point of view. These real-time changes under relevant reactant gases and temperature are correlated with the reaction route of WGSR corroborated by density functional theory-based calculation and ab initio molecular dynamics simulation and can provide insights for atom-precision catalyst design.

Dynamic structural evolution of iron catalysts involving competitive oxidation and carburization during CO2 hydrogenation

Identifying the dynamic structure of heterogeneous catalysts is crucial for the rational design of new ones. In this contribution, the structural evolution of Fe(0) catalysts during CO₂ hydrogenation to hydrocarbons has been investigated by using several (quasi) in situ techniques. Upon initial reduction, Fe species are carburized to Fe₃C and then to Fe₅C₂. The by-product of CO₂ hydrogenation, H₂O, oxidizes the iron carbide to Fe₃O₄. The formation of Fe₃O₄@(Fe₅C₂+Fe₃O₄) core-shell structure was observed at steady state, and the surface composition depends on the balance of oxidation and carburization, where water plays a key role in the oxidation. The performance of CO₂ hydrogenation was also correlated with the dynamic surface structure. Theoretical calculations and controll experiments reveal the interdependence between the phase transition and reactive environment. We also suggest a practical way to tune the competitive reactions to maintain an Fe₅C₂-rich surface for a desired C₂₊ productivity.

Hydrothermal synthesis of long-chain hydrocarbons up to C24 with NaHCO3-assisted stabilizing cobalt

Abiotic CO₂ reduction on transition metal minerals has been proposed to account for the synthesis of organic compounds in alkaline hydrothermal systems, but this reaction lacks experimental support, as only short-chain hydrocarbons (<C₅) have been synthesized in artificial simulation. This presents a question: What particular hydrothermal conditions favor long-chain hydrocarbon synthesis? Here, we demonstrate the hydrothermal bicarbonate reduction at ∼300 °C and 30 MPa into long-chain hydrocarbons using iron (Fe) and cobalt (Co) metals as catalysts. We found the Co⁰ promoter responsible for synthesizing long-chain hydrocarbons to be extraordinarily stable when coupled with Fe-OH formation. Under these hydrothermal conditions, the traditional water-induced deactivation of Co is inhibited by bicarbonate-assisted CoO_x reduction, leading to honeycomb-native Co nanosheets generated in situ as a new motif. The Fe-OH formation, confirmed by operando infrared spectroscopy, enhances CO adsorption on Co, thereby favoring further reduction to long-chain hydrocarbons (up to C₂₄). These results not only advance theories for an abiogenic origin for some petroleum accumulations and the hydrothermal hypothesis of the emergence of life but also introduce an approach for synthesizing long-chain hydrocarbons by nonnoble metal catalysts for artificial CO₂ utilization.

Passivation of Co/Al2O3 Catalyst by Atomic Layer Deposition to Reduce Deactivation in the Fischer–Tropsch Synthesis

The present work explores the technical feasibility of passivating a Co/γ-Al2O3 catalyst by atomic layer deposition (ALD) to reduce deactivation rate during Fischer–Tropsch synthesis (FTS). Three samples of the reference catalyst were passivated using different numbers of ALD cycles (3, 6 and 10). Characterization results revealed that a shell of the passivating agent (Al2O3) grew around catalyst particles. This shell did not affect the properties of passivated samples below 10 cycles, in which catalyst reduction was hindered. Catalytic tests at 50% CO conversion evidenced that 3 and 6 ALD cycles increased catalyst stability without significantly affecting the catalytic performance, whereas 10 cycles caused blockage of the active phase that led to a strong decrease of catalytic activity. Catalyst deactivation modelling and tests at 60% CO conversion served to conclude that 3 to 6 ALD cycles reduced Co/γ-Al2O3 deactivation, so that the technical feasibility of this technique was proven in FTS.

Thermodynamic assessment of the stability of bulk and nanoparticulate cobalt and nickel during dry and steam reforming of methane

The high reaction temperatures during steam and dry reforming of methane inevitably entail catalyst deactivation. Evaluation of the feasibility or potentially relevant mechanisms at play is of utmost importance to develop highly active and stable catalysts. Herein, various oxidation reactions of bulk-sized nickel and cobalt to the corresponding metal oxide or in the presence of a metal oxide carrier are evaluated thermodynamically and linked to approximated conditions during methane reforming. In particular cobalt aluminate, as well as cobalt or nickel titanates are likely to form. As oxidation to bulk-sized metal oxide is unlikely, a thermodynamic analysis of metallic nanoparticles was performed to calculate the size dependent stability against oxidation to nickel oxide or cobalt oxide in water and carbon dioxide-rich environments. The calculations indicate that nickel nanoparticles >3 nm and cobalt nanoparticles >10 nm are expected to withstand oxidation during steam and dry reforming of methane with stoichiometric feed compositions and methane conversion levels >10% at temperatures up to 1100 and 900 °C, respectively. Lastly, the reduced thermal stability of nanoparticles due to melting point suppression was assessed, leading to similar recommendations concerning minimum particle sizes.

Hydrothermal Sintering and Oxidation of an Alumina-Supported Nickel Methanation Catalyst Studied Using In Situ Magnetometry

The presented study investigated the effects of temperature (350–650 °C) and gas environment (pure Ar versus a H2O/H2 partial pressure ratio (PH2O/PH2) of 5) on the extent of sintering and oxidation of Al2O3-supported Ni0 nanoparticles (≈4 nm). We note that a PH2O/PH2 of 5 corresponds to a simulated CO conversion of 94% during methanation. Sintering and oxidation were studied using in situ magnetometry, while ex situ TEM analyses confirmed the particle sizes before and after the magnetometry-based experiments. It was found that increasing the temperature from 350 to 650 °C in Ar at atmospheric pressure causes a negligible change to the average size and degree of reduction (DOR) of the starting Ni0 nanoparticles. However, studying the same temperature window under hydrothermal conditions at 10 bar causes significant particle growth (≈9 nm) and the development of a bimodal distribution. Furthermore, the presence of steam decreases the DOR of Ni0 from 86.2% after initial activation to 22.2% due to oxidation. In summary, this study reports on the expected sintering and oxidation of Ni-based catalysts under high CO conversion conditions at elevated temperatures during methanation. Importantly, we were able to demonstrate how magnetometry-based analyses can provide similar size information (and changes thereof) as those observed with TEM but with the added advantage that this information can be obtained in situ.

Recognition of Water-Induced Effects toward Enhanced Interaction between Catalyst and Reactant in Alcohol Oxidation

Pickering emulsion stabilized by solid nanoparticles provides a diverse solvent microenvironment and enables to promote the phase transfer of reaction substrates/products in catalytic reactions, but the intrinsic role of solvent is still not clear. Herein, using benzyl alcohol (BA) as a model reactant, we demonstrate the nature of the water-promoted activity for alcohol oxidation over the Pd/MgAl-LDO catalyst. Depending on the water in the solvent, we observe different reactivities regarding the proportion of the water in the system. Kinetic isotope effects confirm the participation and positive effects of water for oxidation of BA. The water promotion effects are recognized and identified by the water vapor pulse adsorption coupled with temperature program desorption. Moreover, the adsorption behavior of BA or benzaldehyde at the interface of water and Pd/MgAl-LDO is also investigated by quasi-in-situ Raman spectroscopy. In addition, the mechanism of water-promoted alcohol oxidation is rationally proposed based on the Langmuir-Hinshelwood mechanism. The general applicability of the water promotion effects is further demonstrated over different supports and substrates, which well achieves excellent catalytic activity and selectivity in Pickering emulsion compared to that in the pure toluene system.

Preparation and High-Throughput Testing of TiO2-Supported Co Catalysts for Fischer‒Tropsch Synthesis

A series of Co/TiO2 catalysts was tested in a parameters field study for Fischer‒Tropsch synthesis (FTS). All catalysts were prepared by the conventional impregnation technique to obtain an industrially relevant Co content of 10 wt % or 20 wt %, respectively. In summary, 10 different TiO2 of pure anatase phase, pure rutile phase, as well as mixed rutile and anatase phase were used as supports. Performance tests were conducted with a 32-fold high-throughput setup for accelerated catalyst benchmarking; thus, 48 experiments were completed within five weeks in a relevant operation parameters field (170 °C to 233.5 °C, H2/CO ratio 1 to 2.5, and 20 bar(g)). The most promising catalyst showed a CH4 selectivity of 5.3% at a relevant CO conversion of 60% and a C5+ productivity of 2.1 gC5+/(gCo h) at 207.5 °C. These TiO2-based materials were clearly differentiated with respect to the application as supports in Co-catalyzed FTS catalysis. The most prospective candidates are available for further FTS optimization at a commercial scale.