Ji Chan Park*ab,
Dong Hyun Chunab,
Jung-Il Yanga,
Ho-Tae Leea,
Sungjun Honga,
Geun Bae Rhima,
Sanha Janga and
Heon Jung*a
aClean Fuel Laboratory, Korea Institute of Energy Research, 152 Gajeong-Ro, Daejeon, 305-343, Korea. E-mail: jcpark@kier.re.kr; jungh@kier.re.kr; Tel: +82-42-860-3605
bAdvanced Energy and Technology, University of Science and Technology, 217 Gajeong-Ro, Daejeon, 305-350, Korea
First published on 12th May 2015
Cs promoted Fe5C2/charcoal nanocatalysts bearing small iron carbide particles of 8.5 and 14 nm were prepared through a simple melt-infiltration process and a wetness impregnation method; the resulting materials showed very high CO conversion (>95%) and good selectivity, especially at Cs/Fe = 0.025, resulting in a high liquid oil productivity (∼0.4 gliq gcat−1 h−1) in high-temperature Fischer–Tropsch synthesis.
In FT synthesis, an Fe-based catalyst has a big advantage applicable to wide range H2/CO feed ratios (0.5–2.5) owing to its water–gas-shift (WGS) reaction activity,17,18 which makes the catalyst widely used for various gas types, such as those derived from biomass- or coal-gasification. In particular, high-temperature FT synthesis, normally operated at temperatures of 300–350 °C in the presence of an Fe-based catalyst, can more strongly shift the hydrocarbon product selectivity from long carbon chains to short ones.19 Although the cheaper Fe catalyst has been known to be less active than the much more expensive Co catalyst (Co price is approximately 200 times the price of Fe) under similar reaction temperature conditions (200–240 °C), the elevated reaction temperature conditions (>300 °C) can make the activity of an Fe-based catalyst much higher due to the enhanced mass transfer and reaction speed.
In terms of the catalyst activity, formation of Hägg-carbide (Fe5C2) species by controlling the activation process using CO or mixed gas was crucial.20–22 For the catalyst preparation, a few colloidal methods for the synthesis of active and uniform Fe5C2 nanoparticles have been reported,23,24 but still had problems in the scale-up process due to the high price of the metal precursors and solvents, as well as the complicated preparation method. Recently, a melt-infiltration method without use of any solvent has been found to be an effective way to prepare uniform supported catalysts such as Co/SBA-15 and Pd/C with enhanced metal dispersion and distribution.25–27 Among the various support materials (e.g., Al2O3, SiO2, MgO, activated carbon), an activated charcoal made of wood can be a good carbon-based support; this material is commercially applicable because of its low cost, thermal stability, high surface area (∼1000 m2 g−1), and large pore volume (∼0.8 cm3 g−1).
Alkali and alkali-earth metals (e.g., Na, K, Ca) as base promoters donating electrons to active surfaces have led to the enhanced performance of Fe-based catalysts in terms of activity and selectivity.28–30 For instance, the addition of a small amount of K greatly enhanced the activity and selectivity of the Fe-based catalyst by facilitating CO dissociation and increasing the carbon-chain growth on the catalyst surface.31 The effect of K as a base promoter has been studied extensively,32 but fewer studies have dealt with the positive effect of Cs, which has been found to have a higher basicity than those of Na, K and Rb, thus far.33 The catalyst carburization and olefin selectivity were also correlated to the basicity of the promoter in the order Cs > Rb > K > Na > unpromoted.28,34 In particular, although a few studies on effects of Cs on Fe and Co catalysts have been attempted, the effect for Cs contents especially in the Hägg-carbide structure has not been clearly reported in experiment. In the present work, we report a facile synthetic method for active and selective Cs promoted Fe5C2 nanoparticles via melt-infiltration and a wetness impregnation process that exploits a porous charcoal support. The Cs promoted Fe5C2/charcoal catalysts show very high activity and liquid productivity as well as good stability without deactivation for 90 h in high-temperature FT reaction conditions under 320 °C at 15 bar.
The transmission electron microscopy (TEM) image shows the iron-carbide incorporated charcoal at an atomic ratio of Cs/Fe of 0.025 (Fig. 1a). The small iron-carbide nanoparticles were well-dispersed in the charcoal support; these nanoparticles were observed to be 8.5 ± 1.4 nm in average particle size (Fig. S1a and b, ESI†). The high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) image shows bright spots and relatively dark regions indicating iron-carbide nanoparticles and carbon support structures, respectively (Fig. 1b). High-resolution TEM (HRTEM) and corresponding Fourier-transform pattern analysis revealed that the final Cs promoted iron-carbide particle, with spherical shape, was a single crystal with a distance of 0.208 nm between neighboring fringes, well matched with the (021) planes of iron-carbide (Fig. 1c). The Cs promoted iron-carbide particles at a Cs/Fe ratio of 0.050 showed slightly irregular and enlarged particle size, which was measured and found to be 13.8 ± 2.8 nm (Fig. 1d, S1c and d†). The X-ray diffraction (XRD) spectra, with a broad peak at 2θ = 43–45°, show that the Cs promoted iron-carbide particles at ratios of both Cs/Fe = 0.025 and Cs/Fe = 0.050 are matched with two monoclinic Hägg-carbide (Fe5C2) phases (Fig. 1e, JCPDS no. 36-1248 and no. 51-0997). In the XRD spectra, no significant peaks related to any crystalline cesium compounds were observed.
To check the surface state of the Cs promoted Fe5C2 particles, the core-level X-ray photoelectron spectroscopy (XPS) spectrum of Fe and Cs were measured. The XPS spectra of the energy regions of the Cs and Fe bands exhibit two sets of assigned sharp peaks: from iron carbide (Fe(0)) at 707.9 eV and 721.0 eV, and from cesium (Cs(0)) at 725.7 and 739.5 eV (Fig. 2). Another weak peak at 710.8 eV shows that the iron oxide phase (Fe(3+)) originated from the slightly oxidized surfaces of the Fe5C2 during the sampling process.
All Fe-loading contents in the Cs promoted Fe5C2/charcoal catalysts were calculated and found to be approximately 20 wt% on the basis of Fe converted from iron nitrate salt after thermal decomposition. The Cs content in the total catalyst weight, which is the sum of Fe5C2, Cs, and the charcoal, was calculated and found to be ca. 1 wt% at Cs/Fe = 0.025 and 2 wt% at Cs/Fe = 0.050 on the basis of Cs converted from the cesium carbonate precursor. N2 sorption experiments at 77 K for the Cs promoted Fe5C2/charcoal catalysts exhibited type IV adsorption–desorption hysteresis with delayed capillary evaporation at a relative pressure of 0.5 (Fig. 3a). The Brunauer–Emmett–Teller (BET) surface areas of the Cs promoted Fe5C2/charcoal were calculated and found to be 541.1 m2 g−1 at Cs/Fe = 0.025 and 516.2 m2 g−1 at Cs/Fe = 0.050. The total pore volumes were also measured to be 0.42 cm3 g−1 at Cs/Fe = 0.025 and 0.37 cm3 g−1 at Cs/Fe = 0.050. The slightly decreased BET surface area and pore volume at Cs/Fe = 0.050 can be mainly attributed to the enlarged Fe5C2 particle size of 13.8 nm, which is larger than that of Cs/Fe = 0.025 (8.5 nm). Using the Barrett–Joyner–Halenda (BJH) method on the desorption branches, the small pore sizes of Cs promoted Fe5C2/charcoal catalysts were found to be equal at 3.8 nm (Fig. 3b).
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Fig. 3 (a) N2 adsorption/desorption isotherms and (b) pore size distribution diagrams of Cs promoted Fe5C2 on charcoal catalysts. |
To verify the basicity change on Cs promoted catalysts, the amount of CO2 uptake, which can reflect the intensity of the surface basicity, was measured by temperature-programmed desorption (TPD) using CO2. In the previous results, alkali metals such as Na and K played a crucial role in enhancing the surface basicity of iron-based catalysts because the alkali promoters strongly donate the single electron in their s-orbital to the d-orbital of iron.36–38 As expected, the more Cs promoted catalyst at Cs/Fe = 0.025 showed higher basicity with intensive peaks at higher temperatures of 250–300 °C than those of the Cs-poor catalyst at Cs/Fe = 0.010. The CO2 desorption amount was measured to be 0.291 mmol g−1 at Cs/Fe = 0.010 and 0.446 mmol g−1 at Cs/Fe = 0.025 (Fig. S2†). The strong peaks above 250 °C are ascribed to the strong adsorption of CO2 interacted with the surface basic site. At Cs/Fe = 0.050, the amount of CO2 desorption was obtained to be 0.493 mmol g−1 which is larger than those of Cs/Fe = 0.010–0.025.
nCO + (2n + 1)H2 → CnH2n+2 + nH2O: paraffins |
nCO + 2nH2 → CnH2n + nH2O: olefins |
CO2 could be also generated by the accompanied WGS reaction as follows:
CO + H2O ↔ CO2 + H2 |
Cs promoted Fe5C2/charcoal catalysts at Cs/Fe = 0.025 and Cs/Fe = 0.050 showed very high total CO conversions of 96.9% and 95.5% without deactivation. Moreover, the CO conversion quickly reached a steady-state within 12 h of reaction (Fig. 4b and c). But, the Fe5C2/charcoal catalyst at Cs/Fe = 0.010 exhibited lower CO conversion with longer induction period (∼30 h) during FT reaction (Fig. 4a). The promoter-free Fe5C2 catalyst have also showed a similar trend with long induction period (∼66 h) in our previous result.32 Although Cs is a very strong base promoter, which easily donate electrons to active iron carbide surfaces, the more Cs doped catalyst than Cs/Fe = 0.010 is needed to maximize its effect. The conversion rates of CO to HC and CO to CO2 for a time-on-stream (TOS) of 90 h were observed to be 56.4% and 40.5% at Cs/Fe = 0.025 (Fig. 4b) and 58.7% and 36.8% at Cs/Fe = 0.050 (Fig. 4c), respectively.
In the selectivity data, the graph of Cs/Fe = 0.025 shows the selectivity of CH4 (8.3%), C2–C4 (16.9%), and C5+ (33.1%) at TOS 90 h (Fig. 5b). On the other hand, at Cs/Fe = 0.050, lower CH4 selectivity (6.2%) and higher C5+ selectivity (38.2%) were obtained (Fig. 5c). The higher selectivity for heavy hydrocarbons at Cs/Fe = 0.050 can be mainly attributed to the higher surface basicity of the catalyst, as has been reported elsewhere.39 The surface basicity, which was controlled by the Cs/Fe atomic ratio, affected the dissociative adsorption of CO and the adsorption of H2, leading to a modification of the selectivity for the target hydrocarbon products. However, under the excess Cs promoted Fe5C2 catalyst at Cs/Fe = 0.1, much lower CO conversion (63.3%) and higher CO2 selectivity (43.9%) than those of Cs/Fe = 0.05 were observed (Fig. 4d and 5d). We believe that the low CO conversion and gradual deactivation at Cs/Fe = 0.100 after 54 h reaction are mainly attributed to the relatively poor CO dissociation property compared to its CO adsorption property.32
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Fig. 5 CO2 and hydrocarbon product selectivity graphs for Cs promoted Fe5C2/charcoal catalysts at (a) Cs/Fe = 0.010, (b) Cs/Fe = 0.025, (c) Cs/Fe = 0.050, and (d) Cs/Fe = 0.100. |
The catalytic activity was noted as iron-time-yield (FTY, i.e., the number of CO moles converted to hydrocarbons per gram of iron per second), which reflects the CO conversion and hydrocarbon selectivity of the catalyst during the FT reaction (Fig. S3†). The Cs promoted Fe5C2 catalyst at Cs/Fe = 0.050 showed a slightly higher FTY value of 1.454 × 10−4 molCO gFe−1 s−1 than that of the Cs/Fe = 0.025 (1.398 × 10−4 molCO gFe−1 s−1) due to its lower CO to CO2 selectivity (38.6%) than 40.4% at Cs/Fe = 0.025. The FT activities of the Cs promoted catalysts at both Cs/Fe = 0.025 and Cs/Fe = 0.050 were very high, compared to those of the previously reported values on supported iron catalysts reacted under high temperature conditions (Table S1†).
Interestingly, the Cs promoted Fe5C2 catalyst at Cs/Fe = 0.025 showed very high liquid oil productivity of 0.401 gliq gcat−1 h−1 after the FT reaction for 90 h, compared to that of Cs/Fe = 0.050 (0.296 gliq gcat−1 h−1) (Table S2†). On the contrary, the solid wax productivity of Cs/Fe = 0.025 was very low, compared to the high liquid oil productivity, observed to be 0.026 gsol gcat−1 h−1 which is a much lower value than that obtained using Cs/Fe = 0.050 (0.164 gsol gcat−1 h−1). The detailed composition of the liquid and solid hydrocarbons was analysed by ASTM D2887 (Fig. 6a). The chain growth probability (α) of the hydrocarbons was calculated using the Anderson–Schulz–Flory (ASF) chain growth mechanism in the following equation,40 in which Wn is the weight fraction of hydrocarbons with carbon number n (Fig. 6b):
log(Wn/n) = log(ln2α) + n![]() ![]() |
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Fig. 6 (a) Hydrocarbon product distribution and (b) ASF plots of C5+ hydrocarbons and chain growth probability. |
Two α values (α1 from C5 to C18 and α2 from C19 and C44) were obtained by the slope of the graph which is fitted by two linear regressions. Low α values of 0.744 at Cs/Fe = 0.025 and 0.762 at Cs/Fe = 0.050 and high α values of 0.852 at Cs/Fe = 0.025 and 0.877 at Cs/Fe = 0.050 are attributed to Cs-lean sites and Cs-rich sites of the catalysts, respectively. The α values (α1 = 0.762 and α2 = 0.877) at Cs/Fe = 0.050 were higher than those calculated at Cs/Fe = 0.025, demonstrating that a larger Cs doped Fe5C2 surface can provide more advantageous conditions for the growth of carbon chains during FT synthesis.
For the gaseous hydrocarbon products (C1–C4 gasses), the hydrocarbon product yields (grams of generated hydrocarbons per gram of iron per second) were calculated (Table S3†). For the Cs promoted Fe5C2 catalyst at Cs/Fe = 0.025, the total gas product yield was relatively high (8.56 × 10−4 gHC gFe−1 s−1) compared to that obtained at Cs/Fe = 0.050 (8.03 × 10−4 gHC gFe−1 s−1). But, the product yield ratio of C2–C4 olefins to C2–C4 paraffins at Cs/Fe = 0.025 was much lower (0.53) than that of Cs/Fe = 0.050 (1.82). In total weight portions of CH4, C2–C4 olefins, C2–C4 paraffins, C5–C12, C13–C18, and C19+ of the Cs promoted Fe5C2 catalysts, heavy hydrocarbon portion (C19+) was significantly low at Cs/Fe = 0.025, because of the relatively low surface basicity of the catalyst (Fig. S4†). Therefore, in high-temperature FT synthesis, because such a combination can increase the CO conversion rate and decrease the solid wax formation, a combination of proper reaction temperature (320 °C) and reaction pressure (15 bar), and use of Cs promoted Fe catalyst at Cs/Fe = 0.025 could be the best method for the selective production of liquid oil at high productivity. After the reactions, the Cs promoted catalysts showed slightly increased Fe5C2 particles in size which reflect the separated peaks in the XRD data, but still maintained their original structures without the severe particle aggregation (Fig. S5†).
Footnote |
† Electronic supplementary information (ESI) available: TEM images and particle size distribution histograms, CO2 TPD profiles, FTY graphs, hydrocarbon distribution (weight percent) data, TEM and XRD data of the recovered catalysts, hydrocarbon productivity, and gas product yields of Cs promoted Fe5C2 nanocatalysts. See DOI: 10.1039/c5ra03439f |
This journal is © The Royal Society of Chemistry 2015 |