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Development of Attrition Resistant Iron-Based Fischer-Tropsch Catalysts
Final Report

Adeyiga, Adeyinka A.

Hampton University

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Table of Contents

1.0 INTRODUCTION

1
2.0 EXECUTIVE SUMMARY

4
3.0 EXPERIMENT 3
  3.1 Catalyst 3
3.2 Catalyst Characterization 4
4.0 RESULTS 6
  4.1 Catalyst Attrition 6
4.2 Catalyst Particle Properties 9
4.3 Catalyst Morphology 11
5.0 DISCUSSION 16
  5.1 Catalyst Attrition Resistance 16
5.2 SiO2 Structure 21
5.3 Slurry Reactor Tests 23
5.4 Catalyst Activity and Selectivity in STSR Tests 24
6.0 CONCLUSION 25
LITERATURE REFERENCES 34
APPENDIX A: Attrition Index Calculations 38
APPENDIX B: FE Reducibility Calculations 39
 
LIST OF FIGURES  
Figure 1 Jet Cup Attrition Results 8
Figure 2a SEM Micrographs of Fe/P(0) and Fe/P(3) Before and After Attrition 13
Figure 2b SEM Micrographs of Fe/P(5) and Fe/P(8) Before and After Attrition 14
Figure 2c SEM Micrographs of Fe/P(10) and Fe/P(12) Before and After Attrition 15
Figure 3 EDXS Results for the Cross Section of a Typical Fe/P(5) Particle 17
Figure 4 SEM Micrographs of Typical SiO2 Structures After Acide Leaching [Fe/P(12)]: (a) Typical Structure, (b) Particle with Interior 18
Figure 5 Weight percentage of Fines Lost vs. Total Concentration of SiO2 for Different Series of Spray-Dried Fe FT Catalysts 20
Figure 6 Weight Percentage of Fines Lost vs. Average Particle Density of Calcined Fe/P(y), Fe/B(x), and Fe/P(y)/B(10) Catalysts 22
Figure 7 Syngas Conversion with Time On-Stream for binder Silica 26
Figure 8 C1-C4 Selectivity with Time on stream for Binder Silica 27
Figure 9 C5+ Selectivity with Time on Stream for Binder Silica 28
Figure 10 Usage Ratio with Time on Stream for BInder Silica 29
Figure 11 Syngas Conversion with Time On-Stream for Binder Silica 30
Figure 12 C1-C4 Selectivity with Time On-Stream for Precipitated Silica 31
Figure 13 C5+ Selectivity with Time On-Stream for Precipitated Silica 32
Figure 14 Usage Ratio with Time On-Stream for Precipitated Silica 33
 
Table 1 Jet Cup Attrition Results 7
Table 2 BET Surface Area and Pore Volume of the Iron Catalysts Studied 10
Table 3 Macro Pore volume and Particle Density of Selected Iron Catalysts 12