Skip to main content
Log in

Effect of reduction and reaction conditions on the catalytic performance of Co–Ni/Al2O3 catalyst in CO hydrogenation: modeling of surface reaction rate

  • Original Paper
  • Published:
Chemical Papers Aims and scope Submit manuscript

Abstract

The effect of reduction and reaction conditions on catalytic performance and surface reaction rate of Fischer–Tropsch synthesis over Co–Ni/Al2O3 catalyst was studied in a stainless steel fixed-bed micro-reactor. Experiments were done over a collection of different reduction and reaction conditions, including reduction temperature (250–450 °C), reduction time (2–10 h), reducing agent (H2, CO and mixing of H2 and CO), reaction temperature (150–240 °C), H2/CO (1–4) and reaction pressure (1–5 bar). In particular, the modeling of the effect of reduction and reaction conditions on the CO consumption rate was studied by response surface methodology. The surface reaction rates are important in scale-up of a FT reactor, industrial design, and simulation. The accuracy of created models was proved by ANOVA and diagnostic plots. According to the obtained quadratic polynomial equations, the order of parameters influence on CO consumption rate response was argued. Regard to results obtained, the main effective reduction and reaction parameters on CO consumption rate were reducing agent and reaction pressure, respectively. Furthermore, the precursor and catalysts before and after the test were characterized by XRD and SEM.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7.
Fig. 8.
Fig. 9
Fig. 10

Similar content being viewed by others

References

  • Abbasi M, Mirzaei AA, Atashi H (2019) Hydrothermal synthesis of Fe-Ni-Ce nano-structure catalyst for Fischer-Tropsch synthesis: Characterization and catalytic performance. J Alloy Compd 799:546–555

    Article  CAS  Google Scholar 

  • Akbari M, Mirzaei AA, Atashi H, Arsalanfar M (2018) Effect of microemulsion parameters on product selectivity of MgO-supported iron–cobalt–manganese–potassium nanocatalyst for Fischer-Tropsch synthesis using response surface methodology. J Taiwan Inst Chem Eng 91:396–404

    Article  CAS  Google Scholar 

  • Akbari M, Mirzaei AA, Atashi H (2019) Evaluation of reverse microemulsion parameters over the catalytic performance of promoted Fe–Co catalysts for the production of light olefins from syngas using box–behnken design. Catal Lett, pp 1–14.

  • Arsalanfar M, Mirzaei A, Bozorgzadeh H, Atashi H (2012) Effect of process conditions on the surface reaction rates and catalytic performance of MgO supported Fe–Co–Mn catalyst for CO hydrogenation. J Ind Eng Chem 18:2092–2102

    Article  CAS  Google Scholar 

  • Arsalanfar M, Akbari M, Mirzaei N, Abdouss M (2020) Light olefin production on the Co–Ni catalyst: calcination conditions, and modeling and optimization of the process conditions by a statistical method. New J Chem 44:7467–7483

    Article  CAS  Google Scholar 

  • Atashi H, Rezaeian F (2019) Modeling of Fischer-Tropsch synthesis product over an industrial fe-mn catalyst in a spinning basket reactor. Pet Sci Technol 37:1952–1959

    Article  CAS  Google Scholar 

  • Atashi H, Razmjooei S, Khorashadizadeh M, Shiva M, Tabrizi FF, Mousavi SAHS (2015) Effects of operating conditions on selectivity of Fe–Co–Mn/MgO at high temperature CO hydrogenation. J Taiwan Inst Chem Eng 54:83–90

    Article  CAS  Google Scholar 

  • Azizi HR, Mirzaei AA, Kaykhaii M, Mansouri M (2014) Fischer-Tropsch synthesis: studies effect of reduction variables on the performance of Fe–Ni–Co catalyst. J Nat Gas Sci Eng 18:484–491

    Article  CAS  Google Scholar 

  • Copperthwaite RG, Hutchings GJ, Van der Riet M, Woodhouse J (1987) Carbon monoxide hydrogenation using manganese oxide-based catalysts: Effect of operating conditions on alkene selectivity. Ind Eng Chem Res 26:869–874

    Article  CAS  Google Scholar 

  • Fazlollahi F, Sarkari M, Zare A, Mirzaei AA, Atashi H (2012) Development of a kinetic model for Fischer-Tropsch synthesis over Co/Ni/Al2O3 catalyst. J Ind Eng Chem 18:1223–1232

    Article  CAS  Google Scholar 

  • Feyzi M, Khodaei MM, Shahmoradi J (2012) Effect of preparation and operation conditions on the catalytic performance of cobalt-based catalysts for light olefins production. Fuel Process Technol 93:90–98

    Article  CAS  Google Scholar 

  • Jahangiri H, Bennett J, Mahjoubi P, Wilson K, Gu S (2014) A review of advanced catalyst development for Fischer-Tropsch synthesis of hydrocarbons from biomass derived syn-gas. Catal Sci Technol 4:2210–2229

    Article  CAS  Google Scholar 

  • Liu C, Chen Y, Zhao Y, Lyu S, Wei L, Li X, Zhang Y, Li J (2020a) Nano-ZSM-5-supported cobalt for the production of liquid fuel in Fischer-Tropsch synthesis: Effect of preparation method and reaction temperature. Fuel 263:116619

    Article  CAS  Google Scholar 

  • Liu Y, Chen Y, Yu H, Guan F, Hou Z, Cui D, Zhang Y (2020) Bimetallic Ni-Co catalysts for co-production of methane and liquid fuels from syngas, Catal. Today

  • Martinelli M, Karuturi SC, Garcia R, Watson CD, Shafer WD, Cronauer DC, Kropf AJ, Marshall CL, Jacobs G (2020) Substitution of Co with Ni in Co/Al2O3 Catalysts for Fischer-Tropsch Synthesis. Catalysts 10:334

    Article  CAS  Google Scholar 

  • Mirzaei A, Galavy M, Beigbabaei A, Eslamimanesh V (2007) Preparation and operating conditions for cobalt cerium oxide catalysts used in the conversion of synthesis gas into light olefins. J Iran Chem Soc 4:347–363

    Article  CAS  Google Scholar 

  • Mirzaei A, Rezazadeh E, Arsalanfar M, Abdouss M, Fatemi M, Sahebi M (2015) Study on the reaction mechanism and kinetics of CO hydrogenation on a fused Fe–Mn catalyst. RSC Adv 5:95287–95299

    Article  CAS  Google Scholar 

  • Moazami N, Wyszynski ML, Rahbar K, Tsolakis A, Mahmoudi H (2017) A comprehensive study of kinetics mechanism of Fischer-Tropsch synthesis over cobalt-based catalyst. Chem Eng Sci 171:32–60

    Article  CAS  Google Scholar 

  • Nisa MU, Chen Y, Li X, Li Z (2020) Highly efficient iron based MOFs mediated catalysts for Fischer-Tropsch synthesis: Effect of reduction atmosphere. J Taiwan Inst Chem Eng 107:44–53

    Article  Google Scholar 

  • Niu C, Xia M, Chen C, Ma Z, Jia L, Hou B, Li D (2020) Effect of process conditions on the product distribution of Fischer-Tropsch synthesis over an industrial cobalt-based catalyst using a fixed-bed reactor. Appl Catal A Gen, p 117630.

  • Ponec V (2001) Alloy catalysts: the concepts. Appl Catal A Gen 222:31–45

    Article  CAS  Google Scholar 

  • Rahmati M, Huang B, Mortensen MK Jr, Keyvanloo K, Fletcher TH, Woodfield BF, Hecker WC, Argyle MD (2018) Effect of different alumina supports on performance of cobalt Fischer-Tropsch catalysts. J Catal 359:92–100

    Article  CAS  Google Scholar 

  • Sari A, Zamani Y, Taheri SA (2009) Intrinsic kinetics of Fischer-Tropsch reactions over an industrial Co–Ru/γ-Al2O3 catalyst in slurry phase reactor. Fuel Process Technol 90:1305–1313

    Article  CAS  Google Scholar 

  • Sarkari M, Fazlollahi F, Ajamein H, Atashi H, Hecker WC, Baxter LL (2014) Catalytic performance of an iron-based catalyst in Fischer-Tropsch synthesis. Fuel Process Technol 127:163–170

    Article  CAS  Google Scholar 

  • Schulz H (2013) Principles of Fischer-Tropsch synthesis—Constraints on essential reactions ruling FT-selectivity. Catal Today 214:140–151

    Article  CAS  Google Scholar 

  • Sethuraman R, Bakhshi NN, Katikaneni SP, Idem RO (2001) Production of C4 hydrocarbons from Fischer-Tropsch synthesis in a follow bed reactor consisting of Co–Ni–ZrO2 and sulfated-ZrO2 catalyst beds. Fuel Process Technol 73:197–222

    Article  CAS  Google Scholar 

  • Shafer WD, Gnanamani MK, Graham UM, Yang J, Masuku CM, Jacobs G, Davis BH (2019) Fischer–Tropsch: Product selectivity–The fingerprint of synthetic fuels. Catalysts 9:259

    Article  CAS  Google Scholar 

  • Torres Galvis HM, de Jong KP (2013) Catalysts for production of lower olefins from synthesis gas: a review. ACS Catal 3: 2130–2149.

  • Tsakoumis NE, Rønning M, Borg Ø, Rytter E, Holmen A (2010) Deactivation of cobalt based Fischer-Tropsch catalysts: a review. Catal Today 154:162–182

    Article  CAS  Google Scholar 

  • Van Der Laan GP, Beenackers A (1999) Kinetics and selectivity of the Fischer-Tropsch synthesis: a literature review. Catal Rev Sci Eng 41:255–318

    Article  Google Scholar 

  • van Helden P, Prinsloo F, Van den Berg J-A, Xaba B, Erasmus W, Claeys M, van de Loosdrecht J (2020) Cobalt-nickel bimetallic Fischer-Tropsch catalysts: a combined theoretical and experimental approach. Catal Today 342:88–98

    Article  Google Scholar 

  • Weissman SA, Anderson NG (2014) Design of experiments (DoE) and process optimization. A review of recent publications. Org Process Res Dev 19: 1605–1633.

  • Yaghoobpour E, Zamani Y, Zarrinpashne S, Zamaniyan A (2020) Profound synergetic effect of metal oxide promoters and TiO2–SiO2 binary support in cobalt Fischer-Tropsch catalyst. J Chin Chem Soc 67:751–765

    Article  CAS  Google Scholar 

  • Zare A, Zare A, Shiva M, Mirzaei AA (2013) Effect of calcination and reaction conditions on the catalytic performance of Co–Ni/Al2O3 catalyst for CO hydrogenation. J Ind Eng Chem 19:1858–1868

    Article  CAS  Google Scholar 

  • Zarrin H, Sadeghi MT, Marvast MA (2009) Modeling and sensitivity analysis of a catalyst pellet with non-uniform activity distribution in Fischer-Tropsch synthesis. Int J Chem React Eng, 7

Download references

Acknowledgements

The authors acknowledge financial and instrumental support by the University of Sistan and Baluchestan.

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Maryam Akbari.

Ethics declarations

Conflict of interest

None.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mirzaei, A.A., Farahi, M. & Akbari, M. Effect of reduction and reaction conditions on the catalytic performance of Co–Ni/Al2O3 catalyst in CO hydrogenation: modeling of surface reaction rate. Chem. Pap. 75, 2087–2103 (2021). https://doi.org/10.1007/s11696-020-01469-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11696-020-01469-8

Keywords

Navigation