Fischer-Tropsch synthesis over iron catalysts

Because of the decreased profitability of making synthetic fuels, Sasol intends expanding its production of the higher valued chemicals, in particular waxes and olefins. The advantages and disadvantages of using Fe, Co and Ru catalysts are discussed from the point of view of costs, availability, product selectivity, activity and sensitivity to poisons.The loss of activity and selectivity of iron based catalysts in both fixed and fluidized bed reactors is discussed. The main contributing factors are sulfur poisoning, oxidation and coke fouling. In fixed bed reactors sulfur poisoning and “coke” laydown deactivates the front end of the bed while hydrothermal sintering/oxidation deactivates the back end. In fluidized beds the deposition of large amounts of Boudouard carbon doesnot markedly lower the activity. The smaller catalyst particles end up consisting of small iron carbide entities embedded in a matrix of carbon. The larger catalyst particles consist of cores of inert magnetite surrounded by the carbide/carbon matrix.FT reactor development at Sasol is briefly reviewed.