Attrition of precipitated iron Fischer-Tropsch catalysts

Kalakkad, D. S.; Shroff, Mehul D.; Kohler, S. D.; Jackson, Nancy B.; Datye, Abhaya K.

doi:10.1016/0926-860x(95)00200-6

Cited by 91 publications

(54 citation statements)

References 18 publications

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“…Thermal stresses occur as catalyst particles are heated and/or cooled rapidly; they are magnified by temperature gradients across particles and by differences in thermal expansion coefficients at the interface of two different materials, e.g., catalyst coating/monolith interfaces; in the latter case the heating or cooling process can lead to fracture and separation of the catalyst coating. Chemical stresses occur as phases of different density are formed within a catalyst particle via chemical reaction; for example, carbiding of primary iron oxide particles increases their specific volume and micromorphology leading to stresses that break up these particles [164]. A further example occurs in supported metal catalysts when large quantities of filamentous carbon (according to reaction mechanisms discussed earlier) overfill catalysts pores, generating enormous stresses that can fracture primary particles and agglomerates.…”

Section: Forms and Mechanisms Of Failurementioning

confidence: 99%

Heterogeneous Catalyst Deactivation and Regeneration: A Review

2015

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Deactivation of heterogeneous catalysts is a ubiquitous problem that causes loss of catalytic rate with time. This review on deactivation and regeneration of heterogeneous catalysts classifies deactivation by type (chemical, thermal, and mechanical) and by mechanism (poisoning, fouling, thermal degradation, vapor formation, vapor-solid and solid-solid reactions, and attrition/crushing). The key features and considerations for each of these deactivation types is reviewed in detail with reference to the latest literature reports in these areas. Two case studies on the deactivation mechanisms of catalysts used for cobalt Fischer-Tropsch and selective catalytic reduction are considered to provide additional depth in the topics of sintering, coking, poisoning, and fouling. Regeneration considerations and options are also briefly discussed for each deactivation mechanism.

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Section: Forms and Mechanisms Of Failurementioning

confidence: 99%

Heterogeneous Catalyst Deactivation and Regeneration: A Review

2015

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“…The major relevant finding from previous studies has been that precipitated unsupported Fe F-T catalysts disintegrate easily into smaller particles [6,14,15]. In several studies it was found that even some spray-dried Fe F-T catalysts are not attrition resistant [12,[16][17][18]. However, Goodwin and coworkers [4,13,19], and Pham and coworkers [11,15] were able to prepare Fe based F-T catalysts of sufficient attrition resistance using a spray drying method.…”

Section: Executive Summarymentioning

confidence: 89%

“…In recent years, several research groups have studied attrition properties of iron based F-T catalysts [4,[11][12][13]. The major relevant finding from previous studies has been that precipitated unsupported Fe F-T catalysts disintegrate easily into smaller particles [6,14,15].…”

Section: Executive Summarymentioning

confidence: 97%

Attrition Resistant Fischer-Tropsch Catalysts Based on FCC Supports

Adeyiga¹

2010

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“…In several of these studies it was found that precipitated Fe catalysts (both irregularly shaped and spherical particles) are not attrition resistant [5][6][7][8]10,11], whereas some researchers [10,12,13,15] were successful in preparing Fe F−T catalysts with adequate attrition strength using spray drying method to produce nearly spherical particles. Attrition and agglomerate strength are complex phenomena that are not well understood.…”

Section: Introductionmentioning

confidence: 99%

“…Attrition tests under these conditions provide information on relative physical attrition resistance (strength) of different materials. However, it is known [5,6] that Fe catalysts also undergo "chemical" attrition under reaction conditions due to volume changes and/or carbon formation that accompany phase transformation of oxide precursor into reduced Fe species. There have been only a few studies of attrition properties in a SBCR and/or STSR under F−T reaction conditions.…”

Section: Introductionmentioning

confidence: 99%

Improved Iron Catalysts for Slurry Phase Fischer-Tropsch Synthesis

Bukur¹,

Carreto-Vazquez²,

Ma³

2004

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This report describes research conducted to support the DOE program in development of improved (attrition resistant) catalysts for converting coal-derived synthesis gas to liquid fuels via slurry phase Fischer−Tropsch (F−T) synthesis. The primary objective of this research program is to develop highly active and selective attrition resistant iron F−T catalysts by spray drying.Attrition strength of various types of iron F−T catalysts was studied under reaction conditions in a stirred tank slurry reactor (STSR). The attrition behavior was evaluated on the basis of observed changes in morphological properties (via SEM), and changes in particle size distribution after F−T synthesis in the STSR.Three spray-dried catalysts (100 Fe/3 Cu/5 K/16 SiO 2 in parts by weight) prepared from wet precursors at Texas A&M University had excellent sphericity and smooth external surfaces. Their particle size distribution was rather broad ranging from 5 µm to 40 µm in diameter, regardless of the source of silica (colloidal silica, TEOS, or potassium silicate) employed in their preparation. The catalyst prepared from colloidal silica had the highest attrition strength among all catalysts studied during the course of this project. After 345 h of testing in the STSR its morphology remained practically unchanged, and it experienced small reductions in the volume mean diameter (5.4 %) and generation of particles smaller than 10 µm in diameter was very small (0.7 %). Catalytic performance of these catalysts was excellent. Syngas conversion was between 71 and 76 %, whereas methane selectivity was between 2.2 and 3.5 % and that of C 5 + hydrocarbons was 78 % to 86 % (all selectivities are on C−atom basis).Spray-dried catalysts, synthesized at Hampton University, with compositions 100 Fe/5 Cu/4.2 K/11 SiO 2 and 100 Fe/5 Cu/4.2 K/1.1 SiO 2 had excellent selectivity characteristics (methane selectivity of 2 %, and C 5 + selectivity of about 85 %) but their activity and stability (deactivation rate) need to be improved. Spray-dried HU1112 catalyst (100 Fe/3 Cu/4 K/16 SiO 2 produced more methane (3.5 %) and less C 5 + hydrocarbons (77 %) than the other two spray-dried catalysts.

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Attrition of precipitated iron Fischer-Tropsch catalysts

Cited by 91 publications

References 18 publications

Heterogeneous Catalyst Deactivation and Regeneration: A Review

Heterogeneous Catalyst Deactivation and Regeneration: A Review

Attrition Resistant Fischer-Tropsch Catalysts Based on FCC Supports

Improved Iron Catalysts for Slurry Phase Fischer-Tropsch Synthesis

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