skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: ATTRITION RESISTANT IRON-BASED FISCHER-TROPSCH CATALYSTS

Abstract

The Fischer-Tropsch (F-T) reaction provides a way of converting coal-derived synthesis gas (CO+H{sub 2}) to liquid fuels. Since the reaction is highly exothermic, one of the major problems in control of the reaction is heat removal. Recent work has shown that the use of slurry bubble column reactors (SBCRs) can largely solve this problem. Iron-based (Fe) catalysts are preferred catalysts for F-T when using low CO/H2 ratio synthesis gases derived from modern coal gasifiers. This is because in addition to reasonable F-T activity, the F-T catalysts also possess high water gas shift (WGS) activity. However, a serious problem with the use of Fe catalysts in a SBCR is their tendency to undergo attrition. This can cause fouling/plugging of downstream filters and equipment, making the separation of catalyst from the oil/wax product very difficult if not impossible, and results in a steady loss of catalyst from the reactor. The objectives of this research are to develop a better understanding of the parameters affecting attrition resistance of Fe F-T catalysts suitable for use in SBCRs and to incorporate this understanding into the design of novel Fe catalysts having superior attrition resistance. Catalyst preparations will be based on the use of spray dryingmore » and will be scalable using commercially available equipment. The research will employ among other measurements, attrition testing and F-T synthesis, including long duration slurry reactor runs in order to ascertain the degree of success of the various preparations. The goal is to develop an Fe catalyst which can be used in a SBCR having only an internal filter for separation of the catalyst from the liquid product, without sacrificing F-T activity and selectivity. The effect of silica addition via coprecipitation and as a binder to a doubly promoted Fischer-Tropsch synthesis iron catalyst (100 Fe/5 Cu/4.2 K) was studied. The catalysts were prepared by coprecipitation, followed by binder addition and drying in a 1 m diameter, 2 m tall spray dryer. The binder silica content was varied from 0 to 20 wt %. A catalyst with 12 wt % binder silica was found to have the highest attrition resistance. F-T reaction studies over 100 hours in a fixed-bed reactor showed that this catalyst maintained around 95 % CO conversion with a methane selectivity of less than 7 wt % and a C5 + selectivity of greater than 73 wt %. The effect of adding precipitated silica from 0 to 20 parts by weight to this catalyst (containing 12 wt % binder silica) was also studied. Addition of precipitated silica was found to be detrimental to attrition resistance and resulted in increased methane and reduced wax formation. An HPR series of proprietary catalysts was prepared to further improve the attrition resistance. Based on the experience gained, a proprietary HPR-43 catalyst has been successfully spray dried in 500 g quantity. This catalyst showed 95 % CO conversion over 125 h and had less than 4 % methane selectivity. Its attrition resistance was one of the highest among the catalyst tested.« less

Authors:
; ; ;
Publication Date:
Research Org.:
Federal Energy Technology Center Morgantown (FETC-MGN), Morgantown, WV (United States); Federal Energy Technology Center Pittsburgh (FETC-PGH), Pittsburgh, PA (United States)
Sponsoring Org.:
US Department of Energy (US)
OSTI Identifier:
8834
Report Number(s):
DE-FG22-96PC96217-05
TRN: AH200117%%168
DOE Contract Number:  
FG22-96PC96217
Resource Type:
Technical Report
Resource Relation:
Other Information: PBD: 29 Mar 1999
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; 10 SYNTHETIC FUELS; CATALYSTS; FISCHER-TROPSCH SYNTHESIS; IRON; ALKANES; SYNTHESIS GAS; FRAGMENTATION; CARBON MONOXIDE; HYDROGENATION; METHANATION; WEAR RESISTANCE; CATALYTIC EFFECTS

Citation Formats

Goodwin, Jr, James G, Spivey, James J, Jothimurugesan, K, and Gangwal, Santosh K. ATTRITION RESISTANT IRON-BASED FISCHER-TROPSCH CATALYSTS. United States: N. p., 1999. Web. doi:10.2172/8834.
Goodwin, Jr, James G, Spivey, James J, Jothimurugesan, K, & Gangwal, Santosh K. ATTRITION RESISTANT IRON-BASED FISCHER-TROPSCH CATALYSTS. United States. https://doi.org/10.2172/8834
Goodwin, Jr, James G, Spivey, James J, Jothimurugesan, K, and Gangwal, Santosh K. 1999. "ATTRITION RESISTANT IRON-BASED FISCHER-TROPSCH CATALYSTS". United States. https://doi.org/10.2172/8834. https://www.osti.gov/servlets/purl/8834.
@article{osti_8834,
title = {ATTRITION RESISTANT IRON-BASED FISCHER-TROPSCH CATALYSTS},
author = {Goodwin, Jr, James G and Spivey, James J and Jothimurugesan, K and Gangwal, Santosh K},
abstractNote = {The Fischer-Tropsch (F-T) reaction provides a way of converting coal-derived synthesis gas (CO+H{sub 2}) to liquid fuels. Since the reaction is highly exothermic, one of the major problems in control of the reaction is heat removal. Recent work has shown that the use of slurry bubble column reactors (SBCRs) can largely solve this problem. Iron-based (Fe) catalysts are preferred catalysts for F-T when using low CO/H2 ratio synthesis gases derived from modern coal gasifiers. This is because in addition to reasonable F-T activity, the F-T catalysts also possess high water gas shift (WGS) activity. However, a serious problem with the use of Fe catalysts in a SBCR is their tendency to undergo attrition. This can cause fouling/plugging of downstream filters and equipment, making the separation of catalyst from the oil/wax product very difficult if not impossible, and results in a steady loss of catalyst from the reactor. The objectives of this research are to develop a better understanding of the parameters affecting attrition resistance of Fe F-T catalysts suitable for use in SBCRs and to incorporate this understanding into the design of novel Fe catalysts having superior attrition resistance. Catalyst preparations will be based on the use of spray drying and will be scalable using commercially available equipment. The research will employ among other measurements, attrition testing and F-T synthesis, including long duration slurry reactor runs in order to ascertain the degree of success of the various preparations. The goal is to develop an Fe catalyst which can be used in a SBCR having only an internal filter for separation of the catalyst from the liquid product, without sacrificing F-T activity and selectivity. The effect of silica addition via coprecipitation and as a binder to a doubly promoted Fischer-Tropsch synthesis iron catalyst (100 Fe/5 Cu/4.2 K) was studied. The catalysts were prepared by coprecipitation, followed by binder addition and drying in a 1 m diameter, 2 m tall spray dryer. The binder silica content was varied from 0 to 20 wt %. A catalyst with 12 wt % binder silica was found to have the highest attrition resistance. F-T reaction studies over 100 hours in a fixed-bed reactor showed that this catalyst maintained around 95 % CO conversion with a methane selectivity of less than 7 wt % and a C5 + selectivity of greater than 73 wt %. The effect of adding precipitated silica from 0 to 20 parts by weight to this catalyst (containing 12 wt % binder silica) was also studied. Addition of precipitated silica was found to be detrimental to attrition resistance and resulted in increased methane and reduced wax formation. An HPR series of proprietary catalysts was prepared to further improve the attrition resistance. Based on the experience gained, a proprietary HPR-43 catalyst has been successfully spray dried in 500 g quantity. This catalyst showed 95 % CO conversion over 125 h and had less than 4 % methane selectivity. Its attrition resistance was one of the highest among the catalyst tested.},
doi = {10.2172/8834},
url = {https://www.osti.gov/biblio/8834}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Mar 29 00:00:00 EST 1999},
month = {Mon Mar 29 00:00:00 EST 1999}
}