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TECHNOLOGY DEVELOPMENT FOR IRON AND CONBALT FISCHER-TROPSCH CATALYSTS

Description: The use of alkali promoters has been widely practiced. However, data to compare various promoters is limited for the iron-based catalysts and much of the available data were obtained at low pressure or under a variety of reaction conditions. The importance of the alkali promoter in determining catalytic activity, stability and selectivity merits a comparison of the promoters under suitable reaction conditions. The present study utilizes medium pressure synthesis conditions to compare the alkali promoters under the same reaction conditions and over a wide range of conversion levels. Iron-based Fischer-Tropsch (FT) catalysts undergo a series of phase transformations during activation and use. Activation with carbon monoxide or syngas typically results in the conversion of Fe{sub 2}O{sub 3} to Fe{sub 3}O{sub 4} and ultimately to one or more carbides. During FT synthesis, iron carbides can be oxidized to Fe{sub 3}O{sub 4} if the H{sub 2}O/H{sub 2} or CO{sub 2}/CO ratios are high enough. There has been considerable debate about the active phase of the FT synthesis. Some studies have indicated an active oxide species while most have supported a carbide species. Moessbauer spectroscopy has proven to be an effective technique for the analysis of iron-based FT catalysts. In situ Moessbauer studies have been reported; however, these studies have been performed at low pressure and low conversions. Studies performed at industrially relevant conditions have generally involved removing the catalyst from the reactor followed by passivation which, if not performed properly, will oxidize the catalyst. Herein are reported the Moessbauer results obtained on an unpromoted precipitated iron catalyst that was activated and reacted in a slurry phase, continuous stirred tank reactor at high conversion and under industrially relevant conditions.
Date: October 1, 2000
Creator: Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

TECHNOLOGY DEVELOPMENT FOR IRON FISCHER-TROPSCH CATALYSIS

Description: The goal of the proposed work is the development of iron-based Fischer-Tropsch catalysts that combined high activity, selectivity and life with physical robustness for slurry phase reactors that will produce either low-alpha or high-alpha products. The catalyst that is developed will be suitable for testing at the Advanced Fuels Development Facility at LaPorte, Texas or similar sized plant. Previous work by the offeror has produced a catalyst formulation that is 1.5 times as active as the ''standard-catalyst'' developed by German workers for slurry phase synthesis. The proposed work will optimize the catalyst composition and pretreatment operation for this low-alpha catalyst. In parallel, work will be conducted to design a high-alpha iron catalyst that is suitable for slurry phase synthesis. Studies will be conducted to define the chemical phases present at various stages of the pretreatment and synthesis stages and to define the course of these changes. The oxidation/reduction cycles that are anticipated to occur in large, commercial reactors will be studied at the laboratory scale. Catalyst performance will be determined for catalysts synthesized in this program for activity, selectivity and aging characteristics.
Date: April 1, 1998
Creator: Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

TECHNOLOGY DEVELOPMENT FOR IRON AND COBALT FISCHER-TROPSCH CATALYSTS

Description: The impact of activation procedure on the phase composition of precipitated iron Fischer-Tropsch (FT) catalysts has been studied. Catalyst samples taken during activation and FT synthesis have been characterized by Moessbauer spectroscopy. Formation of iron carbide is necessary for high FT activity. Hydrogen activation of precipitated iron catalysts results in reduction to predominantly metallic iron and Fe{sub 3}O{sub 4}. Metallic iron is not stable under FT 3 4 conditions and is rapidly converted to {epsilon}{prime}-Fe{sub 2.2}C. Activation with carbon monoxide or syngas 2.2 with low hydrogen partial pressure reduces catalysts to {chi}-Fe{sub 5}C{sub 2} and a small amount of 5 2 superparamagnetic carbide. Exposure to FT conditions partially oxidizes iron carbide to Fe{sub 3}O{sub 4}; however, catalysts promoted with potassium or potassium and copper maintain a constant carbide content and activity after the initial oxidation. An unpromoted iron catalyst which was activated with carbon monoxide to produce 94% {chi}-Fe{sub 5}C{sub 2}, deactivated rapidly as the carbide was oxidized to Fe{sub 3}O{sub 4}. No difference in activity, stability or deactivation rate was found for {chi}-Fe{sub 5}C{sub 2} and {epsilon}{prime}-Fe{sub 2.2}C.
Date: April 30, 1999
Creator: Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

TECHNOLOGY DEVELOPMENT FOR IRON AND COBALT FISCHER-TROPSCH CATALYSTS

Description: The effects of copper on Fischer-Tropsch activity, selectivity and water-gas shift activity were studied over a wide range of syngas conversion. Three catalyst compositions were prepared for this study: (a) 100Fe/4.6Si/1.4K, (b) 100Fe/4.6Si/0.10Cu/1.4K and (c) 100Fe/4.6Si/2.0Cu/1.4K. The results are reported in Task 2. The literature review for cobalt catalysts is approximately 90% complete. Due to the size of the document, it has been submitted as a separate report labeled Task 6.
Date: January 30, 1999
Creator: Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

SEPARATION OF FISCHER-TROPSCH WAX PRODUCTS FROM ULTRAFINE IRON CATALYST PARTICLES

Description: In this reporting period, a fundamental filtration study was continued to investigate the separation of Fischer-Tropsch Synthesis (FTS) liquids from iron-based catalyst particles. The overall focus of the program is with slurry-phase FTS in slurry bubble column reactor systems. Hydrocarbon products must be separated from catalyst particles before being removed from the reactor system. An efficient wax product/catalyst separation system is a key factor for optimizing operating costs for iron-based slurry-phase FTS. Previous work has focused on catalyst particle attrition and the formation of ultra-fine iron carbide and/or carbon particles. With the current study, we are investigating how the filtration properties are affected by these chemical and physical changes of the catalyst slurry during activation/synthesis. The shakedown phase of the pilot-scale filtration platform was completed at the end of the last reporting period. A study of various molecular weight waxes was initiated to determine the effect of wax physical properties on the permeation rate without catalyst present. As expected, the permeation flux was inversely proportional to the nominal average molecular weight of the polyethylene wax. Even without catalyst particles present in the filtrate, the filtration membranes experience fouling during an induction period on the order of days on-line. Another long-term filtration test was initiated using a batch of iron catalyst that was previously activated with CO to form iron carbide in a separate continuous stirred tank reactor (CSTR) system. The permeation flux stabilized more rapidly than that experienced with unactivated catalyst tests.
Date: September 30, 2004
Creator: Neathery, James K.; Jacobs, Gary & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

SEPARATION OF FISCHER-TROPSCH WAX PRODUCTS FROM ULTRAFINE IRON CATALYST PARTICLES

Description: In this reporting period, a fundamental filtration study was started to investigate the separation of Fischer-Tropsch Synthesis (FTS) liquids from iron-based catalyst particles. Slurry-phase FTS in slurry bubble column reactor systems is the preferred mode of production since the reaction is highly exothermic. Consequently, heavy wax products must be separated from catalyst particles before being removed from the reactor system. Achieving an efficient wax product separation from iron-based catalysts is one of the most challenging technical problems associated with slurry-phase FTS. The separation problem is further compounded by catalyst particle attrition and the formation of ultra-fine iron carbide and/or carbon particles. Existing pilot-scale equipment was modified to include a filtration test apparatus. After undergoing an extensive plant shakedown period, filtration tests with cross-flow filter modules using simulant FTS wax slurry were conducted. The focus of these early tests was to find adequate mixtures of polyethylene wax to simulate FTS wax. Catalyst particle size analysis techniques were also developed. Initial analyses of the slurry and filter permeate particles will be used by the research team to design improved filter media and cleaning strategies.
Date: March 31, 2004
Creator: Neathery, James K.; Jacobs, Gary & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

SEPARATION OF FISCHER-TROPSCH WAX PRODUCTS FROM ULTRAFINE IRON CATALYST PARTICLES

Description: In this reporting period, a fundamental filtration study was continued to investigate the separation of Fischer-Tropsch Synthesis (FTS) liquids from iron-based catalyst particles. The overall focus of the program is with slurry-phase FTS in slurry bubble column reactor systems. Hydrocarbon products must be separated from catalyst particles before being removed from the reactor system. An efficient wax product/catalyst separation system is a key factor for optimizing operating costs for iron-based slurry-phase FTS. Previous work has focused on catalyst particle attrition and the formation of ultra-fine iron carbide and/or carbon particles. With the current study, we are investigating how the filtration properties are affected by these chemical and physical changes of the catalyst slurry during activation/synthesis. In this reporting period, a series of crossflow filtration experiments were initiated to study the effect of olefins and oxygenates on the filtration flux and membrane performance. Iron-based FTS reactor waxes contain a significant amount of oxygenates, depending on the catalyst formulation and operating conditions. Mono-olefins and aliphatic alcohols were doped into an activated iron catalyst slurry (with Polywax) to test their influence on filtration properties. The olefins were varied from 5 to 25 wt% and oxygenates from 6 to 17 wt% to simulate a range of reactor slurries reported in the literature. The addition of an alcohol (1-dodecanol) was found to decrease the permeation rate while the olefin added (1-hexadecene) had no effect on the permeation rate. A passive flux maintenance technique was tested that can temporarily increase the permeate rate for 24 hours.
Date: March 31, 2005
Creator: Neathery, James K.; Jacobs, Gary & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

Separation of Fischer-Tropsch Wax Products from Ultrafine Iron Catalyst Particles

Description: The morphological and chemical nature of ultrafine iron catalyst particles (3-5 nm diameters) during activation/FTS was studied by HRTEM, EELS, and Moessbauer spectroscopy. With the progress of FTS, the carbide re-oxidized to magnetite and catalyst activity gradually decreased. The growth of oxide phase continued and average particle size also increased simultaneously. The phase transformation occurred in a ''growing oxide core'' manner with different nano-zones. The nano-range carbide particles did not show fragmentation or attrition as generally observed in micrometer range particles. Nevertheless, when the dimension of particles reached the micrometer range, the crystalline carbide phase appeared to be sprouted on the surface of magnetite single crystal. In the previous reporting period, a design and operating philosophy was developed for an integrated wax filtration system for a 4 liter slurry bubble column reactor to be used in Phase II of this research program. During the current reporting period, we have started construction of the new filtration system and began modifications to the 4 liter slurry bubble column reactor (SBCR) reactor. The system will utilize a primary wax separation device followed by a Pall Accusep or Membralox ceramic cross-flow membrane. As of this writing, the unit is nearly complete except for the modification of a moyno-type pump; the pump was shipped to the manufacturer to install a special leak-free, high pressure seal.
Date: March 31, 2006
Creator: Neathery, James K.; Jacobs, Gary; Sarkar, Amitava & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

Separation of Fischer-Tropsch Wax Products from Ultrafine Iron Catalyst Particles

Description: In the previous reporting period, modifications were completed for integrating a continuous wax filtration system for a 4 liter slurry bubble column reactor. During the current reporting period, a shakedown of the system was completed. Several problems were encountered with the progressive cavity pump used to circulate the wax/catalyst slurry though the cross-flow filter element and reactor. During the activation of the catalyst with elevated temperature (> 270 C) the elastomer pump stator released sulfur thereby totally deactivating the iron-based catalyst. Difficulties in maintaining an acceptable leak rate from the pump seal and stator housing were also encountered. Consequently, the system leak rate exceeded the expected production rate of wax; therefore, no online filtration could be accomplished. Work continued regarding the characterization of ultra-fine catalyst structures. The effect of carbidation on the morphology of iron hydroxide oxide particles was the focus of the study during this reporting period. Oxidation of Fe (II) sulfate results in predominantly {gamma}-FeOOH particles which have a rod-shaped (nano-needles) crystalline structure. Carbidation of the prepared {gamma}-FeOOH with CO at atmospheric pressure produced iron carbides with spherical layered structure. HRTEM and EDS analysis revealed that carbidation of {gamma}-FeOOH particles changes the initial nano-needles morphology and generates ultrafine carbide particles with irregular spherical shape.
Date: September 30, 2006
Creator: Neathery, James K.; Jacobs, Gary; Sarkar, Amitava; Crawford, Adam & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

Separation of Fischer-Tropsch Wax Products from Ultrafine Iron Catalyst Particles

Description: In this reporting period, a study of ultra-fine iron catalyst filtration was initiated to study the behavior of ultra-fine particles during the separation of Fischer-Tropsch Synthesis (FTS) liquids filtration. The overall focus of the program is with slurry-phase FTS in slurry bubble column reactor systems. Hydrocarbon products must be separated from catalyst particles before being removed from the reactor system. An efficient wax product/catalyst separation system is a key factor for optimizing operating costs for iron-based slurry-phase FTS. Previous work has focused on catalyst particle attrition and the formation of ultra-fine iron carbide and/or carbon particles. With the current study, we are investigating how the filtration properties are affected by these chemical and physical changes of the catalyst slurry during activation/synthesis. The change of particle size during the slurry-phase FTS has monitored by withdrawing catalyst sample at different TOS. The measurement of dimension of the HRTEM images of samples showed a tremendous growth of the particles. Carbon rims of thickness 3-6 nm around the particles were observed. This growth in particle size was not due to carbon deposition on the catalyst. A conceptual design and operating philosophy was developed for an integrated wax filtration system for a 4 liter slurry bubble column reactor to be used in Phase II of this research program. The system will utilize a primary inertial hydroclone followed by a Pall Accusep cross-flow membrane. Provisions for cleaned permeate back-pulsing will be included to as a flux maintenance measure.
Date: September 30, 2005
Creator: Neathery, James K.; Jacobs, Gary; Sarkar, Amitava & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department

Separation of Fischer-Tropsch Wax Products from Ultrafine Iron Catalyst Particles

Description: A fundamental filtration study was started to investigate the separation of Fischer-Tropsch Synthesis (FTS) liquids from iron-based catalyst particles. Slurry-phase FTS in slurry bubble column reactor systems is the preferred mode of operation since the reaction is highly exothermic. Consequently, heavy wax products in one approach may be separated from catalyst particles before being removed from the reactor system. Achieving an efficient wax product separation from iron-based catalysts is one of the most challenging technical problems associated with slurry-phase iron-based FTS and is a key factor for optimizing operating costs. The separation problem is further compounded by attrition of iron catalyst particles and the formation of ultra-fine particles.
Date: December 31, 2006
Creator: Sarkar, Amitava; Neathery, James K. & Davis, Burtron H.
Partner: UNT Libraries Government Documents Department