Fe catalyst particles

Regarding a historical perspective on carbon nanotubes, very small diameter (less than 10 nm) carbon filaments were observed in the 1970 s through synthesis of vapor grown carbon fibers prepared by the decomposition of benzene at 1100°C in the presence of Fe catalyst particles of 10 nm diameter [11, 12]. However, no detailed systematic studies of such very thin filaments were reported in these early years, and it was not until lijima s observation of carbon nanotubes by high resolution transmission electron microscopy (HRTEM) that the carbon nanotube field was seriously launched. A direct stimulus to the systematic study of carbon filaments of very small diameters came from the discovery of fullerenes by Kroto, Smalley, and coworkers [1], The realization that the terminations of the carbon nanotubes were fullerene-like caps or hemispheres explained why the smallest diameter carbon nanotube observed would be the same as the diameter of the Ceo molecule, though theoretical predictions suggest that nanotubes arc more stable than fullerenes of the same radius [13]. The lijima observation heralded the entry of many scientists into the field of carbon nanotubes, stimulated especially by the un-... 

Figure 2.The direction [121] in the o-Fe catalyst particle is oriented along the fiber growth axis.

SWCNTs, MWCNTs, and CNFs have been synthesized by a floating catalyst method with different tube diameters achieved by controlling the FcH/benzene mole ratio. It is evident that small FcH/C ratios yield SWCNTs, and higher ratios CNFs [35]. SWCNTs were synthesized by the CO disproportionation reaction on Fe catalyst particles formed by FcH vapor decomposition in a laminar flow aerosol (floating catalyst) reactor [31], A mixture of CH4/H2/Ar with added Fe(CO)j was reacted in the presence of a microwave plasma torch for the synthesis of MWCNTs covered by iron oxide nanoparticles (NPs) [33]. 

In this exercise we shall estimate the influence of transport limitations when testing an ammonia catalyst such as that described in Exercise 5.1 by estimating the effectiveness factor e. We are aware that the radius of the catalyst particles is essential so the fused and reduced catalyst is crushed into small particles. A fraction with a narrow distribution of = 0.2 mm is used for the experiment. We shall assume that the particles are ideally spherical. The effective diffusion constant is not easily accessible but we assume that it is approximately a factor of 100 lower than the free diffusion, which is in the proximity of 0.4 cm s . A test is then made with a stoichiometric mixture of N2/H2 at 4 bar under the assumption that the process is far from equilibrium and first order in nitrogen. The reaction is planned to run at 600 K, and from fundamental studies on a single crystal the TOP is roughly 0.05 per iron atom in the surface. From Exercise 5.1 we utilize that 1 g of reduced catalyst has a volume of 0.2 cm g , that the pore volume constitutes 0.1 cm g and that the total surface area, which we will assume is the pore area, is 29 m g , and that of this is the 18 m g- is the pure iron Fe(lOO) surface. Note that there is some dispute as to which are the active sites on iron (a dispute that we disregard here). 

At this point, the system was tested with catalyst for activation and FTS, in the hopes that the seal leak rates would be impeded by the presence of small catalyst particles. The FTFE 20-B catalyst (L-3950) (Fe, 50.2% Cu, 4.2% K, 1.5% and Si, 2.4%) was utilized. This is part of the batch used for LaPorte FTS run II.20 The catalyst was activated at 543 K with CO at a space velocity (SV) of 9 sl/h/g catalyst for 48 h. A total of 1,100 g of catalyst was taken and 7.9 L of C30 oil was used as the start-up solvent. At the end of the activation period, an attempt was made for Fischer-Tropsch synthesis at 503 K, 175 psig, syngas SV = 9 sl/h/g catalyst, and H2/CO = 0.7. However, the catalyst was found to be completely inactive for Fischer-Tropsch synthesis. Potential reasons for catalyst poisoning under present experimental conditions were investigated. Sulfur and fluorine are known to poison iron-based Fischer-Tropsch catalysts.21,22 Since the stator of the pump is... 

The synthesis of ammonia, N2 + 3H2 = 2NH3, like the oxidation of SO, (Section 1.5.4 and Figure 1.4), is an exothermic, reversible, catalytic reaction carried out in a multistage tubular flow reactor in which each stage consists of a (fixed) bed of catalyst particles. Unlike SO, oxidation, it is a high-pressure reaction (150-350 bar, at an average temperature of about 450°C). The usual catalyst is metallic Fe. 

The inner cavity of carbon nanotubes stimulated some research on utilization of the so-called confinement effect [33]. It was observed that catalyst particles selectively deposited inside or outside of the CNT host (Fig. 15.7) in some cases provide different catalytic properties. Explanations range from an electronic origin due to the partial sp3 character of basal plane carbon atoms, which results in a higher n-electron density on the outer than on the inner CNT surface (Fig. 15.4(b)) [34], to an increased pressure of the reactants in nanosized pores [35]. Exemplarily for inside CNT deposited catalyst particles, Bao et al. observed a superior performance of Rh/Mn/Li/Fe nanoparticles in the ethanol production from syngas [36], whereas the opposite trend was found for an Ru catalyst in ammonia decomposition [37]. Considering the substantial volume shrinkage and expansion, respectively, in these two reactions, such results may indeed indicate an increased pressure as the key factor for catalytic performance. However, the activity of a Ru catalyst deposited on the outside wall of CNTs is also more active in the synthesis of ammonia, which in this case is explained by electronic properties [34]. 

More recently, Koizumi et al. observed that Mn has an additional beneficial effect in unsupported Fe-based F-T catalysts. These authors studied the sulfur resistance of Mn-Fe catalysts and they observed superior catalysts stabilities, especially when the catalysts were pre-reduced in CO. This group also used IR spectroscopy in combination with CO as a probe molecule to compare Fe and Mn-Fe catalysts. It was found that the addition of Mn led to the appearance of several well-resolved bands upon CO adsorption. The appearance of the bands arising from bridged-bonded CO on Fe indicated that the size of the Fe particles were clearly larger than in the case of the unpromoted catalysts. They attributed the decreased reactivity towards H2S to the observed increase in Fe particle size. 

As reported elsewhere [22], similar to those found on other catalysts, the forms of carbon materials deposited on Fe-loading zeolite molecular sieves are carbon nanotube, carbon nanofiber and amorphous carbon. One obvious phenomenon of the carbon nanotubes formed on Fe/NaY or Fe/SiHMS catalysts is that almost all tips of these tubes are open, indicating the interaction between catalyst particles and supports is strong [23]. On the other hand, the optimal formation time of carbon nanotubes on Fe/SiHMS is longer than that on Fe/NaY. However, the size of carbon nanotubes is easily adjusted and the growth direction of carbon nanotubes on the former is more oriented than on the latter. 

Anderson et al. (33) found that the surface composition can be a function of particle size in supported Pt-Cu and Rh-Ag alloys. Bartholomew and Boudart (17) did not find enrichment in highly dispersed Pt-Fe catalysts. 

Fig. 17. Picture of the reduction process of a singly promoted iron catalyst, (a) Unreduced large catalyst particle with the promoter distributed homogeneously, (b) Catalyst after short reduction. Aluminum-rich regions appear, (c) Catalyst after further reduction consists of a-Fe and FcA1204 inclusions, (d) Fully reduced catalyst consists of small a-Fe particles with A1203 inclusions. Figure according to Tops e et al. (95).

Hydrocarbon distributions in the Fischer-Tropsch (FT) synthesis on Ru, Co, and Fe catalysts often do not obey simple Flory kinetics. Flory plots are curved and the chain growth parameter a increases with increasing carbon number until it reaches an asymptotic value. a-Olefin/n-paraffin ratios on all three types of catalysts decrease asymptotically to zero as carbon number increases. These data are consistent with diffusion-enhanced readsorption of a-olefins within catalyst particles. Diffusion limitations within liquid-filled catalyst particles slow down the removal of a-olefins. This increases the residence time and the fugacity of a-olefins within catalyst pores, enhances their probability of readsorption and chain initiation, and leads to the formation of heavier and more paraffinic products. Structural catalyst properties, such as pellet size, porosity, and site density, and the kinetics of readsorption, chain termination and growth, determine the extent of a-olefin readsorption within catalyst particles and control FT selectivity. 

The effective diffusivity Dn decreases rapidly as carbon number increases. The readsorption rate constant kr n depends on the intrinsic chemistry of the catalytic site and on experimental conditions but not on chain size. The rest of the equation contains only structural catalyst properties pellet size (L), porosity (e), active site density (0), and pore radius (Rp). High values of the Damkohler number lead to transport-enhanced a-olefin readsorption and chain initiation. The structural parameters in the Damkohler number account for two phenomena that control the extent of an intrapellet secondary reaction the intrapellet residence time of a-olefins and the number of readsorption sites (0) that they encounter as they diffuse through a catalyst particle. For example, high site densities can compensate for low catalyst surface areas, small pellets, and large pores by increasing the probability of readsorption even at short residence times. This is the case, for example, for unsupported Ru, Co, and Fe powders. 

In a 1953 study of material deposited on blast furnace brickwork, Davis et al. O) observed the presence of twisted carbon filaments about 0.01 ym thick. Since then, similar microscopic carbon filaments formed during the decomposition of CO and hydrocarbons have been observed by many other investigators. Typically, these filaments are formed by the decomposition of CO or other gaseous hydrocarbons on iron subgroup metal catalyst particles (Ni, Co, Fe, and Cr) (2). 

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