Fischer–Tropsch: Product Selectivity–The Fingerprint of Synthetic Fuels

Towards understanding the lower CH4 selectivity of HCP-Co than FCC-Co in Fischer-Tropsch synthesis

In Fischer-Tropsch synthesis (FTS), the cobalt catalyst has higher C5+ and lower CH4 selectivity in the hcp phase than in the fcc phase. However, a detailed explanation of the intrinsic mechanism is still missing. The underlying reason was explored combining density functional theory, Wulff construction, and a particle-level descriptor based on the slab model of surfaces that are prevalent in the Wulff shape to provide single-particle level understanding. Using a particle-level indicator of the reaction rates, we have shown that it is more difficult to form CH4 on hcp-Co than on fcc-Co, due to the larger effective barrier difference of CH4 formation and C-C coupling on hcp-Co particles, which leads to the lower CH4 selectivity of hcp-Co in FTS. Among the exposed facets of fcc-Co, the (311) surface plays a pivotal role in promoting CH4 formation. The reduction of CH4 selectivity in cobalt-based FTS is achievable through phase engineering of Co from fcc to hcp or by tuning the temperature and size of the particles.

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.

New reaction path for long-chain hydrocarbons by electrochemical CO2 and CO reduction over Au/stainless steel

The Fischer-Tropsch (F-T) synthesis is recognized for its ability to produce long-chain hydrocarbons. In this study, we aimed to replicate F-T synthesis using electrochemical CO2 reduction and CO reduction reactions on a stainless steel (SS) support with a gold (Au) overlayer. Under CO2-saturated conditions, the presence of Au on the SS surface led to the formation of CH4 and a range of hydrocarbons (CnH2n and CnH2n+2, n = 2-7), while bare SS primarily produced hydrogen. The Au(10 nm)/SS exhibited the highest hydrocarbon production in CO2-saturated phosphate, indicating a synergistic effect at the Au-SS interface. In CO-saturated conditions, bare SS also produced long-chain hydrocarbons, but increasing Au thickness resulted in decreased production due to poor CO adsorption. Hydrocarbons were formed through both direct and indirect CO adsorption pathways. Anderson-Schulz-Flory analysis confirmed surface CO hydrogenation and C-C coupling polymerization following conventional F-T synthesis. The C2 hydrocarbons exhibited distinct behavior compared to C3-5 hydrocarbons, suggesting different reaction pathways. Despite low reduction product levels, our EC method successfully replicated F-T synthesis using the Au/SS electrode, providing valuable insights into C-C coupling mechanisms and electrochemical production of long-chain hydrocarbons. Depth-profiling X-ray photoelectron spectroscopy revealed significant changes in surface elemental compositions before and after EC reduction.

Two-Step Conversion of CO2 to Light Olefins: Laboratory-Scale Demonstration and Scale-Up Considerations

The highly selective production of light olefins from CO2 was demonstrated for the first time with a laboratory-scale process comprising consecutive reverse water gas shift (RWGS) and Fischer–Tropsch (FT) reactors. The RWGS reaction, catalyzed by rhodium washcoated catalyst at 850 °C yielded good quality syngas with conversion values close to the thermodynamic equilibrium and without experiencing catalyst deactivation from carbon formation or sintering. For the FT synthesis, a packed bed Fe-Na-S/α-Al2O3 catalyst was used. The highest light olefin selectivity observed for the FT-synthesis was 52% at 310 °C, GHSV of 2250 h−1 and H2/CO ratio of 1. However, the optimal conditions for the light olefin production were determined to be at 340 °C, a GHSV of 3400 h−1 and a H2/CO ratio of 2, as the CO conversion was markedly higher, while the light olefin selectivity remained at a suitably high level. In addition to the experimental results, considerations for the further optimization and development of the system are presented. The combined RWGS–FT process seems to work reasonably well, and initial data for basic process design and modeling were produced.

Fe Nanoparticle Size Control of the Fe-MOF-Derived Catalyst Using a Solvothermal Method: Effect on FTS Activity and Olefin Production

The design of a highly active Fe-supported catalyst with the optimum particle and pore size, dispersion, loading, and stability is essential for obtaining the desired product selectivity. This study employed a solvothermal method to prepare two Fe-MIL-88B metal-organic framework (MOF)-derived catalysts using triethylamine (TEA) or NaOH as deprotonation catalysts. The catalysts were analyzed using X-ray diffraction, N₂-physisorption, Fourier transform infrared spectroscopy, scanning electron microscopy, transmission electron microscopy, H₂ temperature-programed reduction, and thermogravimetric analysis and were evaluated for the Fischer-Tropsch synthesis performance. It was evident that the catalyst preparation in the presence of TEA produces a higher MOF yield and smaller crystal size than those produced using NaOH. The pyrolysis of MOFs yielded catalysts with different Fe particle sizes of 6 and 35 nm for the preparation in the presence of TEA and NaOH, respectively. Also, both types of catalysts exhibited a high Fe loading (50%) and good stability after 100 h reaction time. The smaller particle size TEA catalyst showed higher activity and higher olefin yield, with 94% CO conversion and a higher olefin yield of 24% at a lower reaction temperature of 280 °C and 20 bar at H₂/CO = 1. Moreover, the smaller particle size TEA catalyst exhibited higher Fe time yield and CH₄ selectivity but with lower chain growth probability (α) and C₅₊ selectivity.

Ag supported on alumina for the epoxidation of 1-hexene with molecular oxygen: the effect of Ag+/Ag0

The catalytic liquid-phase oxidation of 1-hexene with O2 using Ag/porous bowl-shaped alumina shows good selectivity for the epoxidation product.

Clay nanotube-metal core/shell catalysts for hydroprocesses

Catalytic hydroprocesses play a significant role in oil refining and petrochemistry. The tailored design of new metal nanosystems and optimization of their support, composition, and structure is a prospective strategy for enhancing the efficiency of catalysts. Mesoporous support impacts the active component by binding it to the surface, which leads to the formation of tiny highly dispersed catalytic particles stabilized from aggregation and with minimized leaching. The structural and acidic properties of the support are crucial and determine the size and dispersion of the active metal phase. Currently, research efforts are shifted toward the design of nanoscale porous materials, where homogeneous catalysts are displaced by heterogeneous. Ceramic materials, such as 50 nm diameter natural halloysite nanotubes, are of special interest for this. Much attention to halloysite clay is due to its tubular structure with a hollow 10-15 nm diameter internal cavity, textural characteristics, and different chemical compositions of the outer/inner surfaces, allowing selective nanotube modification. Loading halloysite with metal particles or placing them outside the tubes provides stable and efficient mesocatalysts. The low cost of this abundant nanoclay makes it a good choice for the scaled-up architectural design of core-shell catalysts, containing active metal sites (Au, Ag, Pt, Ru, Co, Mo, Fe₂O₃, CdS, CdZnS, Cu-Ni) located inside or outside the tubular template. These alumosilicate nanotubes are environment-friendly and are available in thousands of tons. Herein, we summarized the advances of halloysite-based composite materials for hydroprocesses, focusing on the selective binding of metal particles. We analyze the tubes' morphology adjustments and size selection, the physicochemical properties of pristine and modified halloysite (e.g., acid-etched or silanized), the methods of metal clusters formation, and their localization. We indicate prospective routes for the architectural design of stable and efficient nanocatalysts based on this safe and natural clay material.

Highly Active Fischer-Tropsch Synthesis Fe-BDC MOF-Derived Catalyst Prepared by Modified Solvothermal Method

Fe-MIL-88B was prepared by a method that utilizes ferric nitrate and terephthalic acid (TPA or H2BDC) as precursors. The catalyst was characterized by TEM, SEM, FTIR, XRD, BET, and TGA. The pyrolyzed MOF (Fe-MIL-88B/C) was then tested for FTS at 300 psi, 300/340°C and H2/CO=1 after reduction under flow of hydrogen at 400°C for 4 hours. GC product results show promising FTS performance and stability compared to previously reported Fe-MOF derived catalysts with CO conversion of 96.90% at 340°C for 40 hours and 97.45% at 300°C for 26 hours.

Advanced Biofuels Based on Fischer-Tropsch Synthesis for Applications in Diesel Engines

This paper focuses on the evaluation of the fuel properties of Fischer-Tropsch diesel blends with conventional diesel. Incorporating this advanced fuel into conventional diesel production will enable the use of waste materials and non-food materials as resources, while contributing to a reduction in dependence on crude oil. To evaluate the suitability of using Fischer-Tropsch diesel, cetane number, cetane index, CFPP, density, flash point, heat of combustion, lubricity, viscosity, distillation curve, and fuel composition ratios using multidimensional GC × GC-TOFMS for different blends were measured. It was found that the fuel properties of the blended fuel are comparable to conventional diesel and even outperform conventional fuel in some parameters. All measurements were performed according to current standards, thus ensuring the repeatability of measurements for other research groups or the private sector.

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.

Recent developments in catalyst pretreatment technologies for cobalt based Fisher–Tropsch synthesis

Stringent environmental regulations and energy insecurity necessitate the development of an integrated process to produce high-quality fuels from renewable resources and to reduce dependency on fossil fuels, in this case Fischer–Tropsch synthesis (FTS). The FT activity and selectivity are significantly influenced by the pretreatment of the catalyst. This article reviews traditional and developing processes for pretreatment of cobalt catalysts with reference to their application in FTS. The activation atmosphere, drying, calcination, reduction conditions and type of support are critical factors that govern the reducibility, dispersion and crystallite size of the active phase. Compared to traditional high temperature H2 activation, both hydrogenation–carbidisation–hydrogenation and reduction–oxidation–reduction pretreatment cycles result in improved metal dispersion and exhibit much higher FTS activity. Cobalt carbide (Co2C) formed by CO treatment has the potential to provide a simpler and more effective way of producing lower olefins, and higher alcohols directly from syngas. Syngas activation or direct synthesis of the metallic cobalt catalyst has the potential to remove the expensive H2 pretreatment procedure, and consequently simplify the pretreatment process, which would make it more economical and thus more attractive to industry.

Quantitative carbon distribution analysis of hydrocarbons, alcohols and carboxylic acids in a Fischer-Tropsch product from a Co/TiO2 catalyst during gas phase pilot plant operation

Comprehensive two-dimensional gas chromatography (GCxGC) analysis for 1-alcohols and gas chromatography–mass spectrometry (GC-MS) analysis for carboxylic acids, derivatised as their methyl esters, have been applied to liquid and wax Fischer-Tropsch (FT) hydrocarbon products. These methods in combination with conventional one-dimensional gas chromatography (GC) analysis of the aqueous, gaseous, liquid hydrocarbon and wax products plus conventional high-performance liquid chromatography (HPLC) analysis of the aqueous phase has allowed a quantitative distribution analysis of FT hydrocarbon and oxygenated products to be demonstrated for a Co/TiO2 catalyst operating in a fixed bed gas phase pilot plant utilising CANSTM catalyst carrier devices. The GC-MS method used is, to the best of our knowledge, the first application of this derivatisation route for the quantification of individual carboxylic acids in FT hydrocarbon product streams.

Whilst the hydrocarbons and oxygenates that were identified are known compounds formed during the low temperature, Co catalysed, FT process the combination of the multiple analysis techniques used has allowed a level of detail to be gained on the product composition that is seldom reported.

Additionally, 1H nuclear magnetic resonance spectroscopy (NMR) and 13C NMR analyses were used to quantify the average concentration of 1-olefin, cis- and trans-2-olefins, 1-alcohol and aldehyde as appropriate for the technique used. Comparison of GCxGC versus 1H NMR and GC-MS versus a KOH titration confirmed the applicability of the chromatographic methods for the quantitative analysis of FT oxygenated compounds. Long-chain 1-alcohols and carboxylic acids, ≥ C3, were found to be present at levels of 1/10th and 1/1000th that of hydrocarbons of equivalent carbon chain length respectively. The 1-olefin:n-paraffin ratio in the hydrocarbon liquid and wax products was found to decrease significantly with increasing carbon chain length and much more so than those of the 2-olefin or 1-alcohol.

Bismuth as Smart Material and Its Application in the Ninth Principle of Sustainable Chemistry

This paper reports an overview of Green Chemistry and the concept of its twelve principles. This study focusses on the ninth principle of Green Chemistry, that is, catalysis. A report on catalysis, in line with its definition, background, classification, properties, and applications, is provided. The study also entails a green element called bismuth. Bismuth’s low toxicity and low cost have made researchers focus on its wide applications in catalysis. It exhibits smartness in all the catalytic activities with the highest catalytic performance among other metals.

Substitution of Co with Ni in Co/Al2O3 Catalysts for Fischer–Tropsch Synthesis

The effect of cobalt substitution with nickel was investigated for the Fischer–Tropsch synthesis reaction. Catalysts having different Ni/Co ratios were prepared by aqueous incipient wetness co-impregnation, characterized, and tested using a continuously stirred tank reactor (CSTR) for more than 200 h. The addition of nickel did not significantly modify the morphological properties measured. XRD, STEM, and TPR-XANES results showed intimate contact between nickel and cobalt, strongly suggesting the formation of a Co-Ni solid oxide solution in each case. Moreover, TPR-XANES indicated that nickel addition improves the cobalt reducibility. This may be due to H2 dissociation and spillover, but is more likely the results of a chemical effect of intimate contact between Co and Ni resulting in Co-Ni alloying after activation. FTS testing revealed a lower initial activity when nickel was added. However, CO conversion continuously increased with time on-stream until a steady-state value (34%–37% depending on Ni/Co ratio) was achieved, which was very close to the value observed for undoped Co/Al2O3. This trend suggests nickel can stabilize cobalt nanoparticles even at a lower weight percentage of Co. Currently, the cobalt price is 2.13 times the price of nickel. Thus, comparing the activity/price, the catalyst with a Ni/Co ratio of 25/75 has better performance than the unpromoted catalyst. Finally, nickel-promoted catalysts exhibited slightly higher initial selectivity for light hydrocarbons, but this difference typically diminished with time on-stream; once leveling off in conversion was achieved, the C5+ selectivities were similar (≈ 80%) for Ni/Co ratios up to 10/90, and only slightly lower (≈ 77%) at Ni/Co of 25/75.

The Influence of Preparation Method on the Physicochemical Characteristics and Catalytic Activity of Co/TiO2 Catalysts

Two Co/TiO2 catalysts with 7% CoO/g loading were prepared using equilibrium deposition filtration and the dry impregnation method. The two catalysts were characterized with various physicochemical techniques and tested for the degradation of sulfamethaxazole (SMX) using sodium persulfate (SPS) as the oxidant. It was found that the two catalysts exhibit different physicochemical characteristics. The equilibrium deposition filtration (EDF) catalyst had a higher dispersion of cobalt phase, more easily reduced Co(III) species, and a higher ratio of Co(III)/Co(II) species. The interactions between Co-deposited species and the titania surface were monitored with diffuse reflectance spectroscopy in all the preparation steps, and it was found that they increased during drying and calcination, while EDF favored the formation of surface species with strong interactions with the support. Finally, the EDF catalyst was more active for the degradation of sulfamethaxazole due to its better physicochemical characteristics.

Editorial: Cobalt and Iron Catalysis

Cobalt and iron have long history of importance in the field of catalysis that continues to this day [...]

The Preparation and Characterization of Co–Ni Nanoparticles and the Testing of a Heterogenized Co–Ni/Alumina Catalyst for CO Hydrogenation

Samples of well-controlled nanoparticles consisting of alloys of cobalt and nickel of different atomic ratios were synthesized using wet chemical methods with oleylamine as the solvent and the reducing agent. These materials were characterized by a variety of techniques, including high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM), X-ray energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). Small amounts of heterogenized catalysts were prepared using alumina as the support. However, the potential for use of Co–Ni catalysts in CO hydrogenation was explored using a larger amount of Co–Ni/alumina catalyst prepared from standard aqueous impregnation methods and tested in a continuously stirred tank reactor (CSTR) for Fischer–Tropsch synthesis (FTS). Results are compared to a reference catalyst containing only cobalt. The heterogenized catalysts were characterized using synchrotron methods, including temperature programmed reduction with extended X-ray absorption fine structure spectroscopy and X-ray absorption near edge spectroscopy (TPR-EXAFS/XANES). The characterization results support intimate contact between Co and Ni, strongly suggesting alloy formation. In FTS testing, drawbacks of Ni addition included decreased CO conversion on a per gram catalyst basis, although Ni did not significantly impact the turnover number of cobalt, and produced slightly higher light gas selectivity. Benefits of Ni addition included an inverted induction period relative to undoped Co/Al2O3, where CO conversion increased with time on-stream in the initial period, and the stabilization of cobalt nanoparticles at a lower weight % of Co.

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.

Kinetic Study Based on the Carbide Mechanism of a Co-Pt/γ-Al2O3 Fischer–Tropsch Catalyst Tested in a Laboratory-Scale Tubular Reactor

A Co-Pt/γ-Al2O3 catalyst was manufactured and tested for Fischer–Tropsch applications. Catalyst kinetic experiments were performed using a tubular fixed-bed reactor system. The operative conditions were varied between 478 and 503 K, 15 and 30 bar, H2/CO molar ratio 1.06 and 2.11 at a carbon monoxide conversion level of about 10%. Several kinetic models were derived, and a carbide mechanism model was chosen, taking into account an increasing value of termination energy for α-olefins with increasing carbon numbers. In order to assess catalyst suitability for the determination of reaction kinetics and comparability to similar Fischer–Tropsch Synthesis (FTS) applications, the catalyst was characterized with gas sorption analysis, temperature-programmed reduction (TPR), and X-ray diffraction (XRD) techniques. The kinetic model developed is capable of describing the intrinsic behavior of the catalyst correctly. It accounts for the main deviations from the typical Anderson-Schulz-Flory distribution for Fischer–Tropsch products, with calculated activation energies and adsorption enthalpies in line with values available from the literature. The model suitably predicts the formation rates of methane and ethylene, as well as of the other α-olefins. Furthermore, it properly estimates high molecular weight n-paraffin formation up to carbon number C80.