Cobalt catalysts carbon deactivation

Gruver, V., Young, R., Engman, J., and Robota, H. J. 2005. The role of accumulated carbon in deactivating cobalt catalysts during FT synthesis in a slurry-bubble-column reactor. Prepr. Pap.-Am. Chem. Soc. Div. Pet. Chem. 50 164—66. 

Although the FTS is considered a carbon in-sensitive reaction,30 deactivation of the cobalt active phase by carbon deposition during FTS has been widely postulated.31-38 This mechanism, however, is hard to prove during realistic synthesis conditions due to the presence of heavy hydrocarbon wax product and the potential spillover and buildup of inert carbon on the catalyst support. Also, studies on supported cobalt catalysts have been conducted that suggest deactivation by pore plugging of narrow catalyst pores by the heavy (> 40) wax product.39,40 Very often, regeneration treatments that remove these carbonaceous phases from the catalyst result in reactivation of the catalyst.32 Many of the companies with experience in cobalt-based FTS research report that these catalysts are negatively influenced by carbon (Table 4.1). 

Carbon Deactivation Postulated for Industrial Cobalt Catalysts... 

From the work reported in literature it can be thus concluded that there will be various forms of carbonaceous species, which vary in reactivity, that exist on the catalyst or support during FTS. Some forms of this carbon are active (atomic surface carbide and CHX species) and even considered as intermediate species in FTS. However, it is also clear that especially during extended runs there may be a build up/transformation to less reactive forms of carbon (e.g., polymeric carbon). The amounts of these species may be small, but depending on their location, they may be responsible for a part of deactivation observed on cobalt-based FTS catalysts. The electronic interaction of carbon with the catalyst surface may also result in decreased activity. 

Also, manganese added to cobalt on activated carbon catalysts resulted in a decrease in bulk carbide formation during reduction and a decrease in the subsequent deactivation rate.84 Magnesium and yttrium added to the support in alumina-supported cobalt catalysts showed a lower extent of carburization. This was explained by a decrease in Lewis acidity of the alumina surface in the presence of these ions.87... 

Agrawal, P. K., Katzer, J. R., and Manogue, W. H. 1981. Methanation over transition metal catalysts. II. Carbon deactivation of cobalt/alumina in sulfur-free studies. J. Catal. 69 312-26. 

Carbon deposition is much greater on Co/A1203 catalysts than on Ni/Al203 (240). The presence of MgO markedly decreased the carbon deposition on the surface of the cobalt catalyst (241). The role of MgO may be attributed to the formation of strongly adsorbed C02 species, which can easily react with the deposited carbon, thus preventing catalyst deactivation (241). 

Bartholomew and coworkers32 described deactivation of cobalt catalysts supported on fumed silica and on silica gel. Rapid deactivation was linked with high conversions, and the activity was not recovered by oxidation and re-reduction of the catalysts, indicating that carbon deposition was not responsible for the loss of activity. Based on characterization of catalysts used in the FTS and steam-treated catalysts and supports the authors propose that the deactivation is due to support sintering in steam (loss of surface area and increased pore diameter) as well as loss of cobalt metal surface area. The mechanism of the latter is suggested to be due to the formation of cobalt silicates or encapsulation of the cobalt metal by the collapsing support. 

Various polar and chemical compounds reportedly are capable of poisoning or deactivating disproportionation catalysts if present in the feed or allowed to contact the catalyst after activation. For example, propylene conversion over cobalt-molybdate catalyst was reduced when 300—2000 ppm of oxygen, water, carbon dioxide, hydrogen sulfide, ethyl sulfide, acetylene, or propadiene... 

Carbon monoxide has been found to poison cobalt molybdate catalysts. It causes not only instantaneous deactivation but a cumulative deactivation as well. It should be removed from treat gas entirely or at least reduced to a very low value. Carbon dioxide also must be removed since it is converted to CO in the reducing atmosphere employed in Hydrofining. Liquid water can damage the structural integrity of the catalyst. Water, in the form of steam does not necessarily hurt the catalyst. In fact 30 psig steam/air mixtures are used to regenerate the catalyst. Also, steam appears to enhance the catalyst activity in... 

Agrawal et al.33 performed studies of Co/A1203 catalysts using sulfur-free feed synthesis gas and reported a slow continual deactivation of Co/A1203 methanation catalysts at 300°C due to carbon deposition. They postulate that the deactivation could occur by carburization of bulk cobalt and formation of graphite deposits on the Co surface, which they observed by Auger spectroscopy. 

Carbon formation/deposition is a difficult deactivation mechanism to characterize on cobalt-based FTS catalysts. This is due to the low quantities of carbon that are responsible for the deactivation (<0.5 m%) coupled with the presence of wax that is produced during FTS. Furthermore, carbon is only detrimental to the FT performance if it is bound irreversibly to an active site or interacts electronically with it. Hence, not all carbon detected will be responsible for deactivation, especially if the carbon is located on the support. 

Borko, L., Horvath, Z. E., Schay, Z., and Guczi, L. 2007. The role of carbon nanospecies in deactivation of cobalt based catalysts in CH4 and CO transformation. Stud. Surf. Sci. Catal. 167 231-36... 

Moodley, D. J., van de Loosdrecht, J., Saib, A. M., Overett, M. J., Datye, A. K., and Niemantsverdriet, J. W. 2009. Carbon deposition as a deactivation mechanism of cobalt-based Fischer-Tropsch synthesis catalysts under reahstic conditions. Appl. Catal. A, 354 102-10. 

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