Development of promoted cobalt/alumina Fischer-Tropsch catalysts for increased activity and selectivity: Micro-reactor to piloting scale

• Published in: Catalysis today Vol. 432; p. 114554
• Main Authors: Potgieter, Jana Heloïse, Moodley, Denzil, Botha, Thys, Visagie, Jacobus, Manong, Tebogo, Frank, Marco, Claeys, Michael, van Steen, Eric, Böltken, Tim, Pfeifer, Peter
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 15.04.2024
• Subjects: Alumina; Cobalt; Fischer-Tropsch; Magnetometer; Micro-structured reactor; Pilot-scale; Promoter; Slurry bubble column; Promoter; Micro-structured reactor; Fischer-Tropsch; Magnetometer; Slurry bubble column; Cobalt; Alumina; Pilot-scale
• ISSN: 0920-5861; 1873-4308
• DOI: 10.1016/j.cattod.2024.114554

The shift towards renewable and sustainable energy sources necessitates a simultaneous transition to highly selective and active Fischer-Tropsch (FT) catalysts, thus ensuring the optimal utilization of available syngas. The FT reactor conditions targeted for potential power-to-liquids (PtL) applications are focused on increasing syngas conversion and thus water partial pressure to maximise hydrocarbon production. The critical determinant in this pursuit lies in the meticulous formulation of the catalyst, encompassing promoter loading, the precise point of promoter addition, and the dispersion of the active metal within the Co/Ti/Mn/alumina catalysts specifically designed for PtL applications. To accomplish this, we elaborate on the targeted screening approach employed to select the most promising catalyst formulation at lab scale, which was subsequently scaled up to kilogram proportions. The evaluation of catalyst performance spanned various testing platforms, including micro-structured reactors, micro-slurry reactors, and pilot-scale slurry bubble column reactors. Such comprehensive assessment not only facilitated significant risk mitigation but also instilled confidence in the catalyst's efficacy and operational longevity under the chosen conditions. [Display omitted] •Highly active cobalt/alumina catalysts synthesized for power-to-liquids applications.•Promoters selected to maintain catalyst stability at high water partial pressures.•Intimate association of cobalt and promoters required to stabilise active metal phase.•Catalyst screened in multiple reactor configurations to mitigate demonstration risk.•Catalyst production and testing successfully demonstrated on pilot-scale.