Design, synthesis, and use of cobalt-based Fischer-Tropsch synthesis catalysts

Catalyst productivity and selectivity to C5+ hydrocarbons are critical design criteria in the choice of Fischer-Tropsch synthesis (FTS) catalysts and reactors. Cobalt-based catalysts appear to provide the best compromise between performance and cost for the synthesis of hydrocarbons from CO/H2 mixtures. Optimum catalysts with high cobalt concentration and site density can be prepared by controlled reduction of nitrate precursors introduced via melt or aqueous impregnation methods. FTS turnover rates are independent of Co dispersion and support identity over the accessible dispersion range (0.01–0.12) at typical FTS conditions. At low reactant pressures or conversions, water increases FTS reaction rates and the selectivity to olefins and to C5+ hydrocarbons. These water effects depend on the identity of the support and lead to support effects on turnover rates at low CO conversions. Turnover rates increase when small amounts of Ru (Ru/Co<0.008 at.) are added to Co catalysts. C5+ selectivity increases with increasing Co site density because diffusion-enhanced readsorption of α-olefins reverses, β-hydrogen abstraction steps and inhibits chain termination. Severe diffusional restrictions, however, can also deplete CO within catalyst pellets and decrease chain growth probabilities. Therefore, optimum C5+ selectivities are obtained on catalysts with moderate diffusional restrictions. Diffusional constraints depend on pellet size and porosity and on the density and radial location of Co sites within catalyst pellets. Slurry bubble column reactors and the use of eggshell catalyst pellets in packed-bed reactors introduce design flexibility by decoupling the characteristic diffusion distance in catalyst pellets from pressure drop and other reactor constraints.