studies on precipitated iron catalysts for fischer–tropsch synthesis
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www.elsevier.com/locate/apcata
Applied Catalysis A: General 310 (2006) 24–30
Studies on precipitated iron catalysts for Fischer–Tropsch synthesis
Hiroshi Hayakawa a,b,*, Hisanori Tanaka b, Kaoru Fujimoto a
a Department of Chemical Processes and Environment, The University of Kitakyushu, 1-1 Hibikino Wakamatsu-ku
Kitakyushu-shi, Fukuoka 808-0135, Japanb Wakamatsu Research Institute, Electric Power Development Co., Ltd., 1 Yanagisakimachi Wakamatsu-ku
Kitakyushu-shi, Fukuoka 808-0111, Japan
Received 8 February 2006; received in revised form 26 April 2006; accepted 27 April 2006
Available online 5 July 2006
Abstract
The silica-containing precipitated iron catalysts had higher STY (C5+ hydrocarbon productivity), but were more difficult to be reduced with
syngas (mixtures of hydrogen and carbon monoxide) than the silica-free precipitated iron catalyst. The results suggested that the added silicate
suppresses the crystal growth of hematite from the structure of catalyst precursor. X-ray diffraction (XRD) studies of catalysts after activation under
various conditions revealed that the presence of iron carbide (CFe2.5) was related to the active sites in the FT reaction, and that the relative quantity
of iron carbide (CFe2.5) to magnetite (Fe3O4) was closely related to the number of active sites available for FT synthesis. The effects of copper on
the silica-containing precipitated iron catalyst were to enhance the activity and the rate of reduction, as judged from the XRD and TPR studies.
# 2006 Elsevier B.V. All rights reserved.
Keywords: Fischer–Tropsch synthesis; Iron catalyst; Reduction behavior; Iron carbide
1. Introduction
Iron catalysts have been used for the commercial Fischer–
Tropsch Synthesis (FTS) process, especially for synthesis of the
coal-derived syngas. Many studies on iron catalysts have been
reported in which efforts were focused on the activation of
precipitated iron oxide by different reductant gases, such as
syngas (H2/CO), hydrogen or CO.
Ma et al. evaluated the influence of syngas, H2, and CO on
silica-supported iron catalysts and found that H2-pretreated
catalysts gave products with lower concentrations of olefins,
whereas CO-pretreated catalysts gave products with higher
concentrations of olefins [1]. Luo and Davis evaluated the
influence of different reductants, reduction temperature and
pressure on the Fe/K/SiO2 catalysts, and found that the CO-
activated catalysts had the highest CO conversions, and H2-
activated catalysts had the lowest ones [2]. Bukur and Sivaraj
studied the reduction behavior on silica- and alumina-supported
iron catalysts. They found that alumina inhibits the reduction of
iron, and that the reduction behavior of the silica-supported
* Corresponding author. Tel.: +81 93 741 0942; fax: +81 93 741 0959.
E-mail address: [email protected] (H. Hayakawa).
0926-860X/$ – see front matter # 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.apcata.2006.04.045
catalyst was similar to that of the precipitated iron catalyst [3].
Mansker et al. investigated the active form of catalysts by XRD
analysis using quantitative Rietveld structural refinement, and
claimed that the active Fe catalyst contained hexagonal carbide
(Fe7C3) with a small amount of a-iron [4].
Dry reported that the addition of copper enhanced the rate of
reduction [5]. Luo et al. conducted studies on the effect of
palladium on iron catalysts and found that the FTS rate constant
of the Pd-promoted catalyst was lower than that of the Cu-
promoted catalyst [6].
The purpose of this study was to investigate the activation
behavior of precipitated iron-based catalysts, especially the
effects of added sodium silicate and copper oxide on the
reduction behavior and catalytic performance (activity,
selectivity and productivity).
2. Experimental
2.1. Catalyst preparation
All precipitated iron-based catalysts were obtained by
precipitation from an aqueous nitrate solution by adding an
aqueous solution of NH4(CO3)2; this method was similar to that
of Kunugi et al. [7]. The precipitates were filtered and washed
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H. Hayakawa et al. / Applied Catalysis A: General 310 (2006) 24–30 25
Table 1
Physical properties of precipitated iron catalysts
Catalyst Component (on mass basis) BET results
Analyzed Surface area
(m2/g)
Pore volume
(cm3/g)Fe Cu K SiO2
Cat.A 100 0.7 2.2 – 55 0.330
Cat.B0 100 0 N/A N/A N/A N/A
Cat.B1 100 0.3 2.0 8.8 175 0.273
Cat.C0 100 0 N/A N/A N/A N/A
Cat.C1 100 1.2 N/A N/A 250 0.271
Cat.C2 100 2.8 N/A N/A 198 0.264
N/A: not analyzed.
Fig. 1. XRD patterns of the fresh catalysts (a) cat.A and (b) cat.B1.
with distilled water. The washed filter cakes were dried in air
and subsequently calcined in air at high temperatures.
Copper-promoted catalysts were prepared by mixing
aqueous solutions of Cu(NO3)2�3H2O and Fe(NO3)3�9H2O,
prior to precipitation. Potassium-promoted catalysts were
prepared by impregnating heated samples with an aqueous
solution of K2CO3. Silica-containing catalysts were prepared
by adding sodium silicate in a precipitation process.
2.2. Activation and reaction procedure
Activation in the slurry phase was performed in a 100 cm3
continuously stirred tank reactor (CSTR). Three grams of the
catalyst precursor were suspended in 50 ml of n-C16H34. The
system was purged with 150 cm3/min of N2, then
the pressure and temperature were raised to 0.5 MPa and
523 K, respectively, and these conditions were retained for
0.5 h, after which time the temperature was raised to 573 K
at a rate of 2 K/min. Subsequently, catalyst activation was
conducted by switching the feed gas from N2 to syngas.
Activation was carried out at 0.5 MPa, 573 K, and a H2/CO
ratio of 1.0; the space velocity (W/F) was 7.5 g h/mol for a
certain period. The stirring speed in the reactor was
1800 rpm.
Activation in the gas phase was performed in a fixed bed
continuous flow reactor. The quantity of catalyst used was 3 g.
Activation was carried out at 0.1 MPa, 573 K, and a H2/CO
ratio of 1.0; the space velocity (W/F) was 7.5 g h/mol.
Following the activation, the reactor was brought to the
desired reaction conditions, which were 2.0 MPa, 533 K, and a
H2/CO ratio of 1.0; here too the space velocity (W/F) was 7.5 g
h/mol.
Light wax and water were collected by a separator
(cold trap), and heavy wax was collected in the reactor
with the initial solvent. These were analyzed with an off-line
FID gas chromatograph (GC) (column packing: Silicone SE-
30). Effluent gas from the separator was analyzed with an on-
line TCD GC (column packing: Molecular Sieve 5A
and Porapak N) and FID (column packing: PLOT Fused
Silica).
2.3. Characterization of the catalysts
The surface area of the catalysts were measured by the BET
method with QUANTA CHROME AUTOSORB-1MP.
XRD patterns of catalyst samples were measured by a
RIGAKU X-ray diffractometer. The samples after reduction
and reaction for XRD measurements were obtained from the
reactor. The reduced and reacted samples were separated from
the wax product and solvent by filtration in a glove box before
being transferred to the XRD instrument.
The temperature programmed reduction (TPR) study was
performed by a TPD/R/O 1110 Catalytic Surfaces Analyzer.
The catalyst sample was heated and purged with He, and was
then reduced by heating in a flow of 5% H2/95% N2 from 323 to
1023 K at a rate of 10 K/min. Hydrogen consumption was
determined by TCD GC.
3. Results and discussion
3.1. Catalytic performances for precipitated iron catalysts
Precipitated iron catalyst (Fe/Cu/K) and silica-containing
precipitated iron catalyst (Fe/Cu/K/SiO2) were subjected to the
activity tests and the characterization studies. Their physical
properties and the structures of the catalysts before use are
shown in Table 1 and Fig. 1.
From the XRD results, the presence of hematite (Fe2O3) was
confirmed in the precipitated (silica-free) iron catalyst, while
there was no clear peak in the silica-containing catalyst. BET
results shows that the silica-containing catalyst had a much
larger surface area than the silica-free catalyst. These results
suggest that the silica-free iron catalyst contains large
crystallites of hematite. The added sodium silicate or silicate
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H. Hayakawa et al. / Applied Catalysis A: General 310 (2006) 24–3026
Fig. 2. Comparison of CO conversion of cat.A for (~) reaction after activation
for 3h, (~) reaction after non-activation: catalyst activity at 260 8C, 2 MPa, H2/
CO = 1 and W/F = 7.5 g h/mol; catalyst activation at 300 8C, 0.5 MPa, H2/
CO = 1 and W/F = 7.5 g h/mol.
Table 2
Catalytic performances of precipitated iron catalysts
Catalyst W/F
(g h/mol)
CO conversion
(%)
Hydrocarbon C5+
selectivity (%)
STY
(g/kg/h)
Cat.A 7.5 85.9 70.3 297
Cat.B1 7.5 66.0 73.5 268
Cat.C1 1.25 30.1 74.5 773
2.5 48.2 74.5 564
7.5 80.1 81.6 336
suppresses the crystal growth of hematite, probably by existing
as the precipitated iron catalyst precursor in the FeOOH (which
is the main species of precipitates of iron). The above
phenomenon may be the reason why hematite was not observed
in the XRD pattern of the silica-containing catalyst. The results
of reaction tests are shown in Figs. 2 and 3.
The results of the reaction tests showed that the activity of
the catalyst after reduction (activation) was higher than that
of non-activated catalysts in all catalysts. Such an activation
procedure at high temperature was effective to enhance
the activity of precipitated iron catalyst. The activity of
the silica-free catalyst (cat.A) was stable from the initial
stage, while the activity of the silica-containing catalysts
(cat.B1 and cat.C1) gradually increased with TOS. The
catalytic performances of all catalysts are summarized in
Table 2.
The silica-free catalyst (cat.A) has higher activity than the
silica-containing catalysts (cat.B1 and cat.C1), whereas the
selectivity of C5+ hydrocarbon on cat.A was lower than that on
cat.B1 and cat.C1. Table 2 shows that cat.C1 had higher STY
Fig. 3. Comparison of CO conversion of cat.B1 for (~) reaction after activa-
tion for 3h, (~) reaction after non-activation, (^) cat.C1 for reaction after
activation for 3 h: catalyst activity at 260 8C, 2 MPa, H2/CO = 1 and W/
F = 7.5 g h/mol; catalyst activation at 300 8C, 0.5 MPa, H2/CO = 1 and W/
F = 7.5 g h/mol.
(C5+ hydrocarbon productivity) than cat.A, due to the high C5+
selectivity.
3.2. Reduction behavior of precipitated iron catalysts
The structures of silica-free and silica-containing catalysts
after reduction are shown in Figs. 4 and 5.
The XRD results of the reduced catalysts (reduction
conditions for 3 h in the slurry phase) showed that iron carbide
(CFe2.5) was present in all reduced catalysts. As all catalysts
have high activity after reduction, the activated phase can be
observed as iron carbide (CFe2.5). Shroff et al. have also shown
that, as the catalyst becomes more active for FTS, iron carbide
is observed [8]. All of the hematite (Fe2O3) in cat.A was
reduced and rapidly transformed into active sites. As the
reduction of the catalyst proceeded, iron oxide was transformed
from Fe2O3! Fe3O4! a-Fe or iron carbide. a-Fe could not
be observed in our reduced catalyst, because the metallic iron
Fig. 4. XRD patterns of (a) fresh cat.A and (b) cat.A reduced in the slurry phase
for 3 h: reduction at 300 8C, 0.5MPa, H2/CO = 1 and W/F = 7.5 g h/mol.
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H. Hayakawa et al. / Applied Catalysis A: General 310 (2006) 24–30 27
Fig. 6. XRD patterns of cat.B1 (a) fresh, (b) after reduction for 0.5 h, (c) after
reduction for 1 h and (d) after reduction for 3 h: reduction at 300 8C, 0.5 MPa,
H2/CO = 1 and W/F = 7.5 g h/mol.
Fig. 5. XRD patterns of cat.B1 reduced in the slurry phase (a) fresh, (b) reduced
for 3 h, (c) reduced for 10 h and (d) reduced for 20 h: reduction at 300 8C,
0.5 MPa, H2/CO = 1 and W/F = 7.5 g h/mol.
was fairly reactive to carbon dissociated from carbon
monoxide.
Based on the chain growth mechanism of FTS, production of
carbides! hydrogenation of carbides! production of carbe-
ne! polymerization of carbene, [5,9], i.e. the FTS reaction
proceeds by the hydrogenation of carbides to form carbene. It is
suggested that a catalyst that has much iron carbide on its
surface will have the high activity and C5+ selectivity. The
results of the XRD studies indicate that the carbide on the
catalyst surface exists as CFe2.5.
Some models for FT reaction with the role of iron carbide
have been proposed. The literature suggests that the iron
carbide exists in surface and bulk of catalyst, and that the bulk
carbide is not necessarily the active phase, but carbide
formation need to occur before the catalyst surface can retain
enough carbon to become active [8].
In the case of reduced cat.B1, both magnetite (Fe3O4) and
iron carbide (CFe2.5) were observed. This indicates that
magnetite (Fe3O4) was unable to be reduced completely even
after 3 h reduction in the slurry phase, due to the presence of
Table 3
XRD results of the composition of reduced cat.B1 in the slurry phase with time
XRD result Reduction time (h)
0 3.0 10.0 20.0
Peak ratio of CFe2.5/Fe3O4 – 0.264 0.324 0.338
silica in this catalyst. The reason why the silica-containing
catalyst was difficult to be reduced could be because of the
strong interaction between the silica and iron oxide whose
crystallites are suppressed and exist in the silica network.
The results given so far indicate that the silica-containing
catalyst had the characteristic of being hard to reduce. As the
magnetite phase becomes more active transforms gradually to
a-Fe, the iron carbide phase. We assumed that the increase in
iron carbide corresponded to the appearance of active sites for
FTS. We observed the reduction behavior of the silica-
containing catalyst after activation under sufficiently reducing
conditions. The degrees of reduction in these samples are
shown in Table 3, calculated by the relative amounts of CFe2.5
and Fe3O4 on each peak base. From these results, we see that
the reduction proceeds with time, the amount of Fe3O4
decreased relative to CFe2.5.
Moreover, the reduction behavior of the silica-containing
catalyst was investigated under different conditions, such as the
shorter reduction times and other environments (slurry/gas
phase). The results of XRD analysis of the reduced samples
within 3 h in the slurry phase are shown in Fig. 6, and the
degrees of reduction are shown in Table 4.
As the reduction time became longer, the degree of reduction
and the activity increased, similar to the above results for over
3 h reduction tests. We found that the reduction proceeds
gradually within 3 h in the slurry phase. This indicates that the
presence of iron carbide (CFe2.5) is related to the active sites in
the FT reaction.
The XRD patterns of catalysts reduced for 3/10 h in the gas
phase are shown in Fig. 7. And the degree of reduction in these
samples is shown in Table 5, calculated by a similar method to
that given above. These results show that, as the reduction time
Table 4
XRD results of the degree of reduction for cat.B1 in the slurry phase
XRD result Reduction time (h)
0.5 1.0 3.0
Peak ratio of CFe2.5/Fe3O4 0.043 0.079 0.104
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H. Hayakawa et al. / Applied Catalysis A: General 310 (2006) 24–3028
Fig. 7. XRD patterns of cat.B1 reduced in the gas phase (a) fresh, (b) reduced
for 3 h and (c) reduced for 10 h: reduction at 300 8C, 0.1 MPa, H2/CO = 1 and
W/F = 7.5 g h/mol.
Table 5
XRD results of the composition of reduced cat.B1 in the gas phase with time
XRD result Reduction time (h)
0 3.0 10.0
Peak ratio of CFe2.5/Fe3O4 – 1.870 3.286
Fig. 8. Comparison of CO conversion for cat.B1 after (^) reduction in the
slurry phase for 3 h, (~) reduction in the slurry phase for 10 h and (&)
reduction in the gas phase for 3 h: catalyst activity at 260 8C, 2 MPa, H2/CO = 1
and W/F = 7.5 g h/mol; catalyst activation in slurry phase at 300 8C, 0.5 MPa,
H2/CO = 1 and W/F = 7.5 g h/mol; catalyst activation in gas phase at 300 8C,
0.1 MPa, H2/CO = 1 and W/F = 7.5 g h/mol.
Table 6
Effect of different reduction conditions for cat. B1
Catalyst B Results (2 MPa, 260 8C, W/F = 7.5)
CO conversion
(%)
Hydrocarbon
selectivity (%)
STY
(g/kg/h)
CH4 C5+
RD-s3 66.0 4.1 73.5 268
RD-s10 69.9 6.5 60.9 215
RD-g3 81.3 6.3 59.8 247
RD-s(g)x: reduction for x h in the slurry(gas) phase.
was increased, the amount of Fe3O4 decreased relative to
CFe2.5. Catalytic performances under different reduction
conditions are shown in Fig. 8 and Table 6.
Comparing the activity of the gas phase with the slurry phase,
we see that the activity of the sample that was reduced in the gas
phase was higher and more stable initially. The sample reduced
for 3/10 h in the slurry phase slowly increased to stable activity.
The activity transition corresponds to the degree of reduction (the
ratio of iron carbide to magnetite) as given by XRD analysis.
Such data imply that the relative quantity of iron carbide is
closely related to the number of active sites available for FTS.
The catalytic activity after the gas phase reduction was
higher than the activity after the slurry phase reduction, due to
high degree of reduction, as shown in Tables 3–5, which
corresponds to a large amount of active sites.
On the other hand, the CH4 selectivity of the sample reduced
in the gas phase was quite different than that reduced in the slurry
phase for 3 h. These results suggest that the manner in which the
reduction is carried out has an impact on the selectivity in FTS.
3.3. Effect of copper on the reduction behavior of
precipitated iron catalysts
It has been reported that the addition of copper enhances the
rate of reduction of iron catalysts for FTS [5]. We inspected the
effect of copper on the reduction behavior of silica-containing
catalysts. Four samples of silica-containing catalysts were used
in this study. Cat.B0 and cat.C0 were copper-free catalysts,
Fig. 9. XRD patterns of (a) cat.B0, (b) cat.C0, (c) cat.B1 and (d) cat.C1, after
reduction: reduction at 300 8C, 0.1 MPa, H2/CO = 1 and W/F = 7.5 g h/mol.
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H. Hayakawa et al. / Applied Catalysis A: General 310 (2006) 24–30 29
Table 7
Effect of copper-promoted precipitated iron catalysts
Catalyst Results
CO conversion
(%)
Hydrocarbon
selectivity (%)
STY
(g/kg/h)
a
CH4 C5+
Cat.A 85.9 4.9 70.3 297 0.805
Cat.B0 34.1 6.8 53.2 114 N/A
Cat.B1 66.0 4.1 73.5 268 N/A
Cat.C0 45.4 7.4 50.9 125 N/A
Cat.C1 80.1 2.1 81.6 336 0.865
N/A: not analyzed.
Table 8
Quantitative TPR results
Catalyst Content
ratio of Cu/Fe
Peak area ratio Rate of reduction
RT to 800 8C (%)Theoretical Experimental
Cat.C0 0 8.00 2.57 39.6
Cat.C1 0.012 7.52 2.87 45.0
Cat.C2 0.028 6.97 3.43 54.8
whereas Cat.B1 and cat.C1 were copper-promoted catalysts.
The XRD results of samples reduced for 3 h in the slurry
phase are shown in Fig. 9, and Table 7 gives their catalytic
performance.
The activity on the copper-promoted catalyst, cat.B1, C1,
was higher than that on the copper-free catalyst, cat.B0, C0,
because copper-promoted catalyst includes a larger amount of
active sites than copper-free catalyst, due to the effect of
promoting by adding copper.
The results of the XRD analysis showed that Fe3O4 was
present in both copper-promoted and copper-free cat.B, while
Fe3O4 was not present in either copper-promoted or copper-free
cat.C. Cat.B and cat.C with variations in the other compositions
(K, SiO2) of catalyst were also examined. The peak of iron
carbide in the promoted catalyst was different from that of the
copper-free catalyst. Hexagonal iron carbide (Fe7C3) appeared
in the reduced cat.B0 and cat.C0 (copper-free), but was not
present in the reduced cat.B1 and cat.C1 (copper-promoted).
This result suggests that Fe7C3 is not required for catalytic
activity (being different than CFe2.5), and so copper may have
an effect on the formation of active sites of a catalyst
(producing different carbides), as well as promoting the
reduction.
ATPR study was carried out with copper-promoted catalysts
containing different amounts of copper. Fig. 10 shows the TPR
profiles. The profiles show two peaks associated with reduction
of oxides.
Fig. 10. TPR profiles of (a) cat.C0, (b) cat.C1 and (c) cat.C2 (different contents
of Cu/Fe).
It has been postulated that the first peak corresponds to
reduction of Fe2O3 to Fe3O4, and the second peak
corresponds to subsequent reduction of Fe3O4 to metallic
iron [10–12]. Bukur and Sivaraj suggested that only a small
portion of iron oxide is reduced to metallic iron during the
first peak, with most of the Fe3O4 being reduced during the
second peak [3].
Our results show that as the amount of copper was increased,
the temperature of the first and second peaks shifted to the
lower values. Especially, copper has a marked effect on the
reduction of Fe2O3 to Fe3O4 (first peak). Quantitative results of
hydrogen consumption are shown in Table 8. Assuming that the
first peak area corresponds to the reduction of Fe2O3 to Fe3O4
and CuO to Cu, and the second peak area corresponds to the
reduction of Fe3O4 to Fe, we concluded the experimental value
of the peak area ratio (Table 8). The rate of reduction was
determined from this experimental value. Compared to the
theoretical value, the experimental value was quite small. These
results are similar to those of a previous study of supported iron
catalysts [3], and suggest that a small amount of Fe2O3 was
reduced to metallic iron. The results clearly show that the effect
of adding copper to silica-containing precipitated iron catalysts
enhances the rate of reduction.
4. Conclusions
Our studies on the precipitated iron catalyst allow us to
conclude the following.
The silica-containing catalyst (Fe/Cu/K/SiO2) has quite a
different structure, in which iron oxide are not observed by
XRD, from the structure of the silica-free catalyst (Fe/Cu/K) in
which hematite is observed definitely.
The silica-containing catalysts have higher STY values (C5+
hydrocarbon productivity) than the silica-free catalysts after
activation procedure at high temperature. Without any
activation procedure, the activities of both catalysts are lower
at initial stage, and then increase gradually.
The XRD results of catalysts after activation show that the
silica-free catalyst transforms from hematite to iron carbide,
whereas the silica-containing catalysts transform to magnetite
and iron carbide. This indicates that silica-containing catalysts
are more difficult to be reduced than the silica-free catalyst.
These results suggest that the iron oxide particles which exist in
the silica-containing catalysts have strong interactions with the
added silica.
The activation (reduction) condition (slurry/gas phase)
impacted the activity and methane selectivity.
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H. Hayakawa et al. / Applied Catalysis A: General 310 (2006) 24–3030
According to the results of XRD patterns of copper-
promoted and copper-free precipitated iron catalysts, the
hexagonal iron carbide (Fe7C3) that only appeared in the
reduced sample of the copper-free catalyst might be less active
than CFe2.5.
The TPR results show that the reduction of silica-containing
material is facilitated by the addition of copper.
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