Cobalt-Based Fischer–Tropsch Activity and Selectivity as a Function of Crystallite Size and Water Partial Pressure

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.

Effect of Pre-Treatment Conditions on the Activity and Selectivity of Cobalt-Based Catalysts for CO Hydrogenation

We investigated the effect of pre-treatment conditions on the activity and selectivity of cobalt catalysts for Fischer–Tropsch synthesis (FTS) by varying both the reduction atmosphere and the reduction temperature. Catalysts supported on SiO2, Al2O3, and TiO2, prepared via incipient wetness impregnation, were evaluated, and activation temperatures in the range 250–350 °C were considered. Activation with syngas led to a better product selectivity (low CH4, high selectivity to liquid hydrocarbons, and low paraffin to olefin ratio (P/O)) than the catalysts reduced in H2 at lower activation temperatures. The CoxC species suppressed the hydrogenation reaction, and it is hypothesised that this resulted in the high selectivity of olefins observed for the syngas pre-treated catalysts. On the basis of the experimental results, we postulated that a synergistic effect between Co0 and CoxC promotes the production of the long chain hydrocarbons and suppresses the formation of CH4. In addition, for systems aimed at producing lower olefins, syngas activation is recommended, and for the FTS plants that focus on maximising the production of higher molecular weight products, H2 activation might be considered. These results provide insights for the future FTS catalyst design and for target product-driven operations.

The Effect of Atomic Layer Deposited Overcoat on Co-Pt-Si/γ-Al2O3 Fischer–Tropsch Catalyst

Atomic layer deposition (ALD) was used to prepare a thin alumina layer on Fischer–Tropsch catalysts. Co-Pt-Si/γ-Al2O3 catalyst was overcoated with 15–40 cycles of Al2O3 deposited from trimethylaluminum (TMA) and water vapor, followed by thermal annealing. The resulting tailored Fischer–Tropsch catalyst with 35 cycle ALD overcoating had increased activity compared to unmodified catalyst. The increase in activity was achieved without significant loss of selectivity towards heavier hydrocarbons. Altered catalyst properties were assumed to result from cobalt particle stabilization by ALD alumina overcoating and nanoscale porosity of the overcoating. In addition to optimal thickness of the overcoat, thermal annealing was an essential part of preparing ALD overcoated catalyst.

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.

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.

Promotional effect of in situ generated hydroxyl on olefin selectivity of Co-catalyzed Fischer-Tropsch synthesis

The understanding of the water effect on olefin selectivity in Fischer-Tropsch synthesis (FTS) is limited by the complexity of the reaction network. Herein, we employ propene hydrogenation as a model reaction to isolate the water effect on olefin adsorption and hydrogenation from the complex reaction of FTS. It is clearly observed that the added water inhibits the activity of propene hydrogenation on two cobalt catalysts supported on high-surface-area alumina (HAS Al₂O₃) and low-surface-area alumina (LSA Al₂O₃), respectively. The inhibiting effect is much stronger for Co/HSA Al₂O₃. DFT investigation demonstrates that the in situ generated OH, rather than H₂O and O, impedes the adsorption of propene and thus decreases the activity of propene hydrogenation. The suppressive effect of OH on propene adsorption is attributed to the downshift of the d-band center and the Bader charge of the catalyst surface. The DFT-based kinetic analysis finds that the higher site coverage of OH results in the more pronounced negative effect on propene hydrogenation. Furthermore, the theory of OH-induced weak olefin adsorption and low olefin hydrogenation activity could rationalize the enhancement effect of water on the olefin selectivity and the particle size dependence of the water effect in FTS. The insights obtained here may inspire researchers to optimize olefin selectivity by manipulating the electronic properties of catalysts with hydroxyl species.

Effect of Co-Feeding Inorganic and Organic Molecules in the Fe and Co Catalyzed Fischer–Tropsch Synthesis: A Review

This short review makes it clear that after 90 years, the Fischer–Tropsch synthesis (FTS) process is still not well understood. While it is agreed that it is primarily a polymerization process, giving rise to a distribution of mainly olefins and paraffins; the mechanism by which this occurs on catalysts is still a subject of much debate. Many of the FT features, such as deactivation, product distributions, kinetics and mechanism, and equilibrium aspects of the FT processes are still subjects of controversy, regardless of the progress that has been made so far. The effect of molecules co-feeding in FTS on these features is the main focus of this study. This review looks at some of these areas and tries to throw some light on aspects of FTS since the inception of the idea to date with emphasis and recommendation made based on nitrogen, water, ammonia, and olefins co-feeding case studies.

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.

In-situ X-Ray Absorption Near Edge Structure Spectroscopy of a Solid Catalyst using a Laboratory-Based Set-up

An in-situ laboratory-based X-ray Absorption Near Edge Structure (XANES) Spectroscopy set-up is presented, which allows performing long-term experiments on a solid catalyst at relevant reaction conditions of temperature and pressure. Complementary to research performed at synchrotron radiation facilities the approach is showcased for a Co/TiO2 Fischer-Tropsch Synthesis (FTS) catalyst. Supported cobalt metal nanoparticles next to a (very small) fraction of cobalt(II) titanate, which is an inactive phase for FTS, were detected, with no signs of re-oxidation of the supported cobalt metal nanoparticles during FTS at 523 K, 5 bar and 200 h, indicating that cobalt metal is maintained as the main active phase during FTS.

X-ray physico-chemical imaging during activation of cobalt-based Fischer-Tropsch synthesis catalysts

The imaging of catalysts and other functional materials under reaction conditions has advanced significantly in recent years. The combination of the computed tomography (CT) approach with methods such as X-ray diffraction (XRD), X-ray fluorescence (XRF) and X-ray absorption near-edge spectroscopy (XANES) now enables local chemical and physical state information to be extracted from within the interiors of intact materials which are, by accident or design, inhomogeneous. In this work, we follow the phase evolution during the initial reduction step(s) to form Co metal, for Co-containing particles employed as Fischer-Tropsch synthesis (FTS) catalysts; firstly, working at small length scales (approx. micrometre spatial resolution), a combination of sample size and density allows for transmission of comparatively low energy signals enabling the recording of 'multimodal' tomography, i.e. simultaneous XRF-CT, XANES-CT and XRD-CT. Subsequently, we show high-energy XRD-CT can be employed to reveal extent of reduction and uniformity of crystallite size on millimetre-sized TiO₂ trilobes. In both studies, the CoO phase is seen to persist or else evolve under particular operating conditions and we speculate as to why this is observed.This article is part of a discussion meeting issue 'Providing sustainable catalytic solutions for a rapidly changing world'.

Chemical imaging of Fischer-Tropsch catalysts under operating conditions

Although we often understand empirically what constitutes an active catalyst, there is still much to be understood fundamentally about how catalytic performance is influenced by formulation. Catalysts are often designed to have a microstructure and nanostructure that can influence performance but that is rarely considered when correlating structure with function. Fischer-Tropsch synthesis (FTS) is a well-known and potentially sustainable technology for converting synthetic natural gas ("syngas": CO + H₂) into functional hydrocarbons, such as sulfur- and aromatic-free fuel and high-value wax products. FTS catalysts typically contain Co or Fe nanoparticles, which are often optimized in terms of size/composition for a particular catalytic performance. We use a novel, "multimodal" tomographic approach to studying active Co-based catalysts under operando conditions, revealing how a simple parameter, such as the order of addition of metal precursors and promoters, affects the spatial distribution of the elements as well as their physicochemical properties, that is, crystalline phase and crystallite size during catalyst activation and operation. We show in particular how the order of addition affects the crystallinity of the TiO₂ anatase phase, which in turn leads to the formation of highly intergrown cubic close-packed/hexagonal close-packed Co nanoparticles that are very reactive, exhibiting high CO conversion. This work highlights the importance of operando microtomography to understand the evolution of chemical species and their spatial distribution before any concrete understanding of impact on catalytic performance can be realized.

Effect of crystallite size on the performance and phase transformation of Co3O4/Al2O3 catalysts during CO-PrOx – an in situ study

The preferential oxidation of carbon monoxide has been identified as an effective route to remove trace amounts of CO (approx. 0.5–1.0 vol%) in the H₂-rich reformate gas stream after the low-temperature water–gas shift. Instead of noble metal-based catalysts, Co₃O₄-based catalysts were investigated in this study as cheaper and more readily available alternatives. This study aimed at investigating the effect of crystallite size on the mass- and surface area-specific CO oxidation activity as well as on the reduction behaviour of Co₃O₄. Model Co₃O₄ catalysts with average crystallite sizes between 3 and 15 nm were synthesised using the reverse micelle technique. Results from the catalytic tests revealed that decreasing the size of the Co₃O₄ crystallites increased the mass-specific CO oxidation activity in the 50–200 °C temperature range. On the other hand, the surface area-specific CO oxidation activity displayed a volcano-type behaviour where crystallites with an average size of 8.5 nm were the most active within the same temperature range. In situ characterisation in the magnetometer revealed that the Co₃O₄ crystallites are partially reduced to metallic Co above 225 °C with crystallites larger than 7.5 nm showing higher degrees of reduction under the H₂-rich environment of CO-PrOx. In situ PXRD experiments further showed the presence of CoO concurrently with metallic fcc Co in all the catalysts during the CO-PrOx runs. In all experiments, the formation of fcc Co coincided with the formation of CH₄. Upon decreasing the reaction temperature below 250 °C under the reaction gas, both in situ techniques revealed that the fcc Co previously formed is partially re-oxidised to CoO.

Preparation of SBA-15 with penetrating pores and their performance in Fischer–Tropsch synthesis

A novel SBA-15 material containing penetrating pores as supports of Co-based Fischer–Tropsch Synthesis (FTS) catalysts exhibits high catalytic performance due to improving access for reagent molecules to reach the active site, resulting in a facile transport of heavy hydrocarbons.

Combined Operando X-ray Diffraction/Raman Spectroscopy of Catalytic Solids in the Laboratory: The Co/TiO2 Fischer-Tropsch Synthesis Catalyst Showcase

A novel laboratory setup for combined operando X-ray diffraction and Raman spectroscopy of catalytic solids with online product analysis by gas chromatography is presented. The setup can be used with a laboratory-based X-ray source, which results in important advantages in terms of time-on-stream that can be measured, compared to synchrotron-based experiments. The data quality was much improved by the use of a relatively high-energy MoKα radiation instead of the more conventional CuKα radiation. We have applied the instrument to study the long-term deactivation of Co/TiO2 Fischer-Tropsch synthesis (FTS) catalysts. No sign of Co sintering or bulk oxidation was found during the experiments. However, part of the metallic Co was converted into cobalt carbide (Co2C), at elevated pressure (10 bar). Furthermore, graphitic-like coke species are clearly formed during FTS at atmospheric pressure, whereas at elevated pressure fluorescence hampered the interpretation of the measured Raman spectra.

On the performance of a Co-based catalyst supported on modified γ-Al2O3 during Fischer–Tropsch synthesis in the presence of co-fed water

The effect of water on the Fischer–Tropsch performance of a supported cobalt catalyst has been studied in a fixed bed reactor by running co-feeding experiments for more than 1000 h under industrially relevant process conditions.