Fischer-Tropsch synthesis methanation reaction

The compositional modulation technique has been applied to the Fischer-Tropsch synthesis (FTS) reaction [2-5], It was found that the cyclic feeding of CO/H2 had an influence on the selectivity of the FTS products. Among the conclusions was that for an iron catalyst the selectivity for methane increased under periodic operation compared to the steady state operation [5], In the study [5] it was found that the propane/propene ratio increased under periodic operation and the largest changes were with periods between one and ten minutes. Due to the limitations of the anal5dical technique utilized, they could not separate ethane and ethene so that the selectivity basis was for the C3 hydrocarbons. In this study the analytical procedure permitted analysis of products only to the Cg-compoimds. 

Fischer Tropsch synthesis is catalyzed by a variety of transition metals such as iron, nickel, and cobalt. Iron is the preferred catalyst due to its higher activity and lower cost. Nickel produces large amounts of methane, while cobalt has a lower reaction rate and lower selectivity than iron. By comparing cobalt and iron catalysts, it was found that cobalt promotes more middle-distillate products. In FTS, cobalt produces... 

Iron-based Fischer-Tropsch synthesis (FTS) catalysts are preferred for synthesis gas with a low H2/CO ratio (e.g., 0.7) because of their excellent activity for the water-gas shift reaction, lower cost, lower methane selectivity, high olefin... 

Group II The activity drops more than the Ni surface concentration (Fig. 13), i.e., at least about 20 times. However, for several reactions this drop is two or more orders of magnitude. The reactions included in this group are methanation and Fischer-Tropsch synthesis, isomerization, de-hydrocyclization or hydrogenolysis of alkanes, ether formation from alcohols, metathesis of alkylamines, and possibly other reactions. 

The methanation reaction is a highly exothermic process (AH = —49.2 kcal/ mol). The high reaction heat does not cause problems in the purification of hydrogen for ammonia synthesis since only low amounts of residual CO is involved. In methanation of synthesis gas, however, specially designed reactors, cooling systems and highly diluted reactants must be applied. In adiabatic operation less than 3% of CO is allowed in the feed.214 Temperature control is also important to prevent carbon deposition and catalyst sintering. The mechanism of methanation is believed to follow the same pathway as that of Fischer-Tropsch synthesis. 

Reasons for interest in the catalyzed reactions of NO, CO, and COz are many and varied. Nitric oxide, for example, is an odd electron, hetero-nuclear diatomic which is the parent member of the environmentally hazardous oxides of nitrogen. Its decomposition and reduction reactions, which occur only in the presence of catalysts, provide a stimulus to research in nitrosyl chemistry. From a different perspective, the catalyzed reactions of CO and COz have attracted attention because of the need to develop hydrocarbon sources that are alternatives to petroleum. Carbon dioxide is one of the most abundant sources of carbon available, but its utilization will require a cheap and plentiful source of hydrogen for reduction, and the development of catalysts that will permit reduction to take place under mild conditions. The use of carbon monoxide in the development of alternative hydrocarbon sources is better defined at this time, being directly linked to coal utilization. The conversion of coal to substitute natural gas (SNG), hydrocarbons, and organic chemicals is based on the hydrogen reduction of CO via methanation and the Fischer-Tropsch synthesis. Notable successes using heterogeneous catalysts have been achieved in this area, but most mechanistic proposals remain unproven, and overall efficiencies can still be improved. 

The higher hydrocarbon formation from syngas has long been industrialized as the Fischer-Tropsch synthesis [27]. Yet, syngas production from the C02 reforming of methane is an endothermic reaction, and requires a high temperature (ca. 1073 K) for a favorable equilibrium ... 

Ruthenium supported on oxides is a catalyst of various reactions. It is active in methanation reactions [e.g. 1, 2, 3], in Fischer-Tropsch synthesis [e.g. 4, 5, 6], in CO oxidation [7, 8], in the synthesis of methyl alcohol [9], 1" the redu ction of NO to nitrogen CIO] and in hydrogenolysis of ethane [11] and of butane [12]. Ru supported on carbon is supposed to replace the iron in ammonia synthesis [13]. Lately ruthenium supported on oxides is intensively investigated as a potential... 

Sulfur poisoning is a key problem in hydrocarbon synthesis from coal-derived synthesis gas. The most important hydrocarbon synthesis reactions include methanation, Fischer-Tropsch synthesis, and methanol synthesis, which occur typically on nickel, iron, or cobalt, and ZnO-Cu catalysts, respectively. Madon and Shaw (2) reviewed much of the early work dealing with effects of sulfur in Fischer-Tropsch synthesis. Only the most important conclusions of their review will be summarized here. 

Although metals or even promoted metals have very low sulfur tolerances in synthesis reactions, other materials, such as metal oxides, nitrides, borides, and sulfides, may have greater tolerance to sulfur poisoning because of their potential ability to resist sulfidation (18). The extremely low steady-state activities of Co, Ni, and Ru metals in a sulfur-contaminated stream actually correspond to the activities of the sulfided metal surfaces. However, if more active sulfides could be found, their activity/selectivity properties would be presumably quite stable in a reducing, H2S-containing environment. This is, in fact, the basis for the recent development of sulfur active synthesis catalysts (211-215), which are reported to maintain stable activity/ selectivity properties in methanation and Fischer-Tropsch synthesis at H2S levels of 1% or greater. Happel and Hnatow (214), for example, reported in a recent patent that rare-earth and actinide-metal-promoted molybdenum oxide catalysts are reasonably active for methanation in the presence of 1-3% H2S. None of these patents, however, have reported intrinsic activities... 

Metal-support interactions have been recently reviewed by Bond (93), who drew special attention to catalysts that gave evidence for strong metal-support interactions (SMSI). This condition was first observed in 1978 by Tauster et al. (94) for Pt on titania catalysts. The catalysts seemed to lose their capacity for H2 and CO chemisorption but nevertheless retained and enhanced their activity for only two types of reaction methanation and Fischer-Tropsch synthesis. Since then a considerable number of papers devoted to SMSI studies have been published all over the world. 

Because the expressions for methanation are easier to interpret than those for Fischer-Tropsch synthesis, we first present the equations for the former reaction. The rate of methanation is given by Equation (1)... 

The adsorption of CO is probably the most extensively investigated surface process. CO is a reactant in many catalytic processes (methanol synthesis and methanation, Fischer-Tropsch synthesis, water gas shift, CO oxidation for pollution control, etc. (1,3-5,249,250)), and CO has long been used as a probe molecule to titrate the number of exposed metal atoms and determine the types of adsorption sites in catalysts (27,251). However, even for the simplest elementary step of these reactions, CO adsorption, the relevance of surface science results for heterogeneous catalysis has been questioned (43,44). Are CO adsorbate structures produced under typical UHV conditions (i.e., by exposure of a few Langmuirs (1 L = 10 Torrs) at 100—200 K) at all representative of CO structures present under reaction conditions How good are extrapolations over 10 or more orders of magnitude in pressure Such questions are justified, because there are several scenarios that may account for differences between UHV and high-pressure conditions. Apart from pressure, attention must also be paid to the temperature. 

CO2 reforming of methane (equation 1) has been proposed as one of the most promising technologies for utilization of these two greenhouse gases, and this synthesis gas is suitable for Fischer-Tropsch synthesis and oxygenated chemicals. A serious problem is carbon deposition via Boudouard reaction (equation 2) and/or methane decomposition (equation 3). 

---