Search Results (231)

Interest in further developments of the classical Fischer–Tropsch technology has increased in recent years. The development of processes capable of producing synthetic fuels has become a highly attractive research area due to the continuous global growth in energy demand. An extensive review covering the full development chain (from laboratory-scale experiments to pilot-scale studies and plant-level implementations) is therefore of significant relevance. Consequently, this review aims to be a reference by integrating findings across different development levels of Fischer–Tropsch synthesis technologies, thereby enabling a holistic perspective of the pathway toward industrial-scale deployment. The present work thus critically reviews recent advances in catalyst development, including the role of active phases, particle size effects, supports, and promoters, as well as the growing contribution of in situ and operando characterization techniques. In parallel, progress in kinetic and mechanistic modeling is discussed, highlighting both classical approaches and emerging data-driven and optimization-based methods. Different reactor technologies, from classical to novel technologies, are also analyzed with respect to hydrodynamics, heat and mass transfer limitations, and reactor intensification strategies. At the process level, the review assesses integrated and intensified Fischer–Tropsch-based routes, with particular emphasis on CO₂ utilization pathways, process integration, polygeneration schemes, and optimization frameworks. The potential of artificial intelligence and machine learning tools to accelerate catalyst discovery, reactor optimization, and process design is also addressed. Overall, this review identifies key technological advances, remaining challenges, and research gaps that must be addressed to enable economically viable and environmentally sustainable, and scalable Fischer–Tropsch processes to meet future energy demands. Full article

The effect of palladium addition to a hybrid Co/SiO₂ + HZSM-5 + Al₂O₃ catalyst on the combined Fischer–Tropsch (FT) synthesis and hydrocarbon hydroconversion process was studied. Catalysts with a Pd content of 0.075–0.3 wt.% were characterized by a complex of physicochemical methods, including synchrotron radiation X-ray diffraction (SR-XRD), temperature-programmed reduction with hydrogen (H₂-TPR), temperature-programmed desorption of hydrogen with oxygen titration (H₂-TPD/O₂ titration), IR spectroscopy of adsorbed pyridine, and STEM-EDX analysis. It was found that the addition of palladium decreases the cobalt oxide reduction temperature due to interphase hydrogen transfer. Tests in hydrocarbon synthesis at 240–250 °C, a pressure of 2 MPa, and an H₂/CO ratio of 2 showed that the sample with 0.15% Pd exhibits the highest selectivity for C₅+ hydrocarbons (66.8% at 240 °C) and stability for 150 h. Analysis of the synthesis products revealed a fivefold decrease in the proportion of alkenes and an increase in isoalkanes with increasing Pd concentration. This effect enables the in situ hydroprocessing of primary FT products in a single reactor. The results demonstrate that the targeted introduction of palladium into the hybrid system is an effective strategy for regulating its functionality, allowing for the one-stage production of high-quality fuels with a controlled hydrocarbon composition from syngas. Full article

Double complex salts (DCSs) of the composition [Co(NH₃)₆][Fe(CN)₆] are a promising precursor for the preparation of catalysts for the hydrogenation of carbon oxides (CO and CO₂) by Fischer–Tropsch synthesis. The specific surface area is an important parameter for catalysts. Our article investigates the influence of mechanochemical activation (MCA) on this DCS in order to determine the conditions for obtaining the largest specific surface area of the intermetallic compound, a product of the DCS thermolysis. In this work, the effect of MCA on the physicochemical properties of the DCS [Co(NH₃)₆][Fe(CN)₆] and the products of its thermal decomposition in an argon atmosphere were investigated. It was shown that MCA leads to partial reduction of Fe⁺³ to Fe⁺², changes in the coordination of ammonia, amorphization of the structure and a decrease in the thermal stability of DCS. Thermolysis at 650 °C of samples subjected to MCA for 10 min results in the formation of nanocrystalline intermetallic compound Co_0.5Fe_0.5. The results demonstrate the potential of using MCA to control the properties of functional materials based on DCS. Full article

The study aims to develop a method for obtaining a high-performance catalyst for the synthesis of liquid hydrocarbons using the Fischer–Tropsch method based on ultradisperse cobalt powders obtained by the electric explosion method. To determine the catalytic activity of the obtained catalyst samples, the main process parameters, like temperature in the catalyst bed, the process pressure, the feedstock space velocity, and the ratio of reagents in the synthesis gas, were varied. It has been established that highly dispersed cobalt powder obtained by the electrical explosion method is a fairly active catalyst for the synthesis of liquid hydrocarbons via the Fischer–Tropsch process. It has been established that the overall CO conversion rate in the temperature range from 230 to 330 °C ranges from 25 to 90%. However, the formation of the main byproduct of the synthesis, carbon dioxide, is not observed below 270 °C. It was determined that for the developed catalyst sample, the optimal temperature range is from 230 to 260 °C, in which the yield of by-products of synthesis and gaseous hydrocarbons is quite low—the selectivity for methane does not exceed 20%, with the proportion of C₅₊ hydrocarbons in the liquid phase at the level of 80%. The CO conversion rate increases proportionally with growing pressure. It has been established that cobalt nanopowder exhibits high catalytic activity in reactions of liquid hydrocarbon formation with low hydrogen content in the initial synthesis gas. This fact allows us to conclude that it has potential for use in processing gases obtained during the pyrolysis of biomass or other non-traditional sources of synthesis gas, characterized by an H₂:CO ratio of 1:1 to 1.25:1. Catalysts obtained from ultradisperse cobalt powders were shown to be resistant to rapid deactivation under synthesis conditions at operating temperatures for 30 h. During long-term testing, CO conversion remained at 23.5% at 230 °C for the entire duration of the experiment. Full article

The direct synthesis of long-chain α-olefins from syngas offers a strategically vital pathway for producing high-value chemicals from alternative carbon resources. However, achieving high selectivity toward C₅₊ olefins remains challenging due to competing paraffin formation and difficulties in precisely regulating chain growth kinetics. To mitigate these critical challenges, a series of Rh-promoted Co-Mn catalysts supported on SiO₂ were synthesized using a carbon-mediated impregnation strategy for the direct conversion of syngas to long-chain α-olefins (C₅₊). The introduction of Rh significantly enhanced both catalytic activity and C₅₊ olefin selectivity. The optimal 1.1 wt% Rh-loaded catalyst achieved 24.6% CO conversion and 46.0% total olefin selectivity, with 34.2% of the selectivity toward C₅₊ olefins, while maintaining low CH₄ (6.2%) and CO₂ (<1%) selectivity. Comprehensive characterization techniques, including XRD, H₂-TPR, XPS, and TEM/HAADF-STEM, revealed that the carbon-mediated method facilitated the formation of highly dispersed Co₃O₄ nanoparticles with abundant oxygen vacancies and strengthened the Co-MnO_x interface. Rh promotion modulated the cobalt speciation (Co⁰/Co²⁺), improved reducibility, and enhanced the metal-support interaction. This promoted chain growth and olefin desorption while suppressing over-hydrogenation. This study demonstrates the efficacy of Rh promotion and carbon mediation in designing high-performance Fischer-Tropsch catalysts for selective α-olefin synthesis, offering new insights into the design of efficient metal-oxide interfacial catalysts. Full article

Amid growing concerns over fossil fuel depletion and environmental degradation, developing alternative energy sources is imperative. While MoS₂-based catalysts are known for their syngas conversion activity, their selectivity toward alcohols remains limited. This study addresses this gap by developing Cu-promoted MoS₂ catalysts to enhance alcohol synthesis. The results indicated that the introduction of copper significantly modulates the catalytic performance of MoS₂. We demonstrate that incorporating Cu significantly modulates the catalytic properties of MoS₂. The optimized catalyst with 9 wt% Cu loading exhibited a CO conversion of 17.9% and a markedly improved total alcohol selectivity of 46.4%, with a space-time yield of 67.6 mg·g⁻¹·h⁻¹. Although Cu addition slightly reduced CO conversion, it markedly improved alcohol selectivity by facilitating active site dispersion, suppressing Fischer-Tropsch side reactions, and stabilizing heteroatomic active phases. Finally, a catalytic mechanism for the synthesis of low-carbon alcohols from syngas on MoS₂-based catalysts was proposed based on the catalyst analysis and reaction results. Full article

The Allam power cycle is a groundbreaking elevated-pressure power generation unit that utilizes oxygen and fossil fuels to generate low-cost electricity while capturing carbon dioxide (CO₂) inherently. In this project, we utilize the CO₂ generated from the Allam cycle as feedstock for a newly envisioned industrial complex dedicated to producing renewable hydrocarbons. The industrial complex (FAAR) comprises four subsystems: (i) a Fischer–Tropsch synthesis plant (FTSP), (ii) an alkaline water electrolysis plant (AWEP), (iii) an Allam power cycle plant (APCP), and (iv) a reverse water-gas shift plant (RWGSP). Through effective material, heat, and power integration, the FAAR complex, utilizing 57.1% renewable energy for its electricity needs, can poly-generate sustainable hydrocarbons (C₁–C₃₀), pure hydrogen, and oxygen with near-zero emissions from natural gas and water. Economic analysis indicates strong financial performance of the development, with an internal rate of return (IRR) of 18%, a discounted payback period of 8.7 years, and a profitability index of 2.39. The complex has been validated through rigorous modeling and simulation using Aspen Plus version 14, including sensitivity analysis. Full article

Australia has set a new climate target of reducing emissions by 62–70% below 2005 levels by 2035, with sustainable aviation fuel (SAF) central to achieving this goal. This review critically examines techno-economic analysis (TEA) and life cycle assessment (LCA) of Power-to-Liquid (PtL) electrofuels (e-fuels), which synthesize atmospheric CO₂ and renewable hydrogen (H₂) via Fischer-Tropsch (FT) synthesis. Present PtL pathways require ~0.8 kg of H₂ and 3.1 kg of CO₂ per kg SAF, with ~75% kerosene yield. While third-generation feedstocks could cut greenhouse gas emissions by up to 93% (as low as 8 gCO₂e/MJ), real world reductions have been limited (~1.5%) due to variability in technology rollout and feedstock variability. Integrated TEA–LCA studies demonstrate up to 20% energy efficiency improvements and 40% cost reductions, but economic viability demands costs below $3/kg. In Australia, abundant solar resources, vast transport networks, and supportive policy frameworks present both opportunities and challenges. This review provides the first comprehensive assessment of PtL-FT SAF for Australian conditions, highlighting that large-scale development will require technological advancement, feedstock development, infrastructure investment, and coordinated policy support. Full article

When renewable resources such as biomass, waste, or carbon dioxide together with renewable electrical energy are used, Fischer–Tropsch (FT) synthesis is a promising option for the sustainable production of fuels and petrochemicals conventionally derived from crude oil. As such renewable resources generally do not occur in large point sources like fossil fuels, future sustainable FT facilities will likely be substantially smaller in scale than their fossil counterparts, which will have a significant impact on their design. A core topic in the reimagination of such smaller-scale facilities will be the reduction in complexity of the FT gas loop. To this end, three simple gas loop designs for the conversion of syngas from biomass gasification were conceived, simulated in DWSIM, and compared regarding their performance. Concepts only employing an internal recycle were found to be inherently limited in terms of efficiency. To achieve high efficiencies, an external recycle with a tail gas reformer and high tail gas recycling ratios (>3) were required. Thereby, the carbon dioxide content of the syngas had a considerable influence on the required syngas H₂/CO ratio, making the separation efficiency of the carbon dioxide removal unit a suitable control parameter in this respect. Full article

This research explores the effect of a composite support of SiO₂ and Al₂O₃ with Fe and Co incorporated as catalysts for Fischer–Tropsch synthesis (FTS) using a 3D-printed stainless steel (SS) microchannel microreactor. Two mesoporous catalysts, FeCo/SiO₂Al₂O₃ and Co/SiO₂Al₂O₃, were synthesized via a one-pot (OP) method and extensively characterized using N₂ physisorption, XRD, SEM, TEM, H₂-TPR, TGA-DSC, FTIR, and XPS. H₂-TPR results revealed that the synthesis method significantly affected the reducibility of metal oxides, thereby influencing the formation of active FTS sites. SEM-EDS and TEM further revealed a well-defined hexagonal matrix with a porous surface morphology and uniform metal ion distribution. FTS reactions, carried out in the 200–350 °C temperature range at 20 bar with a H₂/CO molar ratio of 2:1, exhibited the highest activity for FeCo/SiO₂Al₂O₃, with up to 80% CO conversion. Long-term stability was evaluated by monitoring the catalyst performance for 30 h on stream at 320 °C under identical reaction conditions. The catalyst was initially active for the methanation reaction for up to 15 h, after which the selectivity for CH₄ declined. Correspondingly, the C₄⁺ selectivity increased after 15 h of time-on-stream, indicating a shift in the product distribution toward longer-chain hydrocarbons. This trend suggests that the catalyst undergoes gradual activation or restructuring under reaction conditions, which enhances chain growth over time. The increase in C₄⁺ products may be attributed to the stabilization of the active sites and suppression of methane or light hydrocarbon formation. Full article

Decarbonizing air transport is a major challenge in the global energy transition since electrification is not yet feasible. Sustainable aviation fuel (SAF) is a promising solution because it can reduce CO₂ emissions without major infrastructure changes. This study proposes a decentralized model for producing SAF in Spain through the gasification of residual lignocellulosic biomass followed by a refinement process using Fischer–Tropsch (FT) synthesis. The model uses underexploited agricultural residues such as cereal straw, vine pruning, and olive pruning, converting them into syngas in medium-scale facilities situated near biomass sources. The syngas is then transported to a central upgrading unit to produce SAF compliant with ASTM D7566 standards. The following two configurations were evaluated: one with a single gasification plant and upgrading unit and another with three gasification plants supplying one central FT facility. Energy yields, capital and operational expenditures (CAPEX and OPEX), logistic costs, and the levelized cost of fuel (LCOF) were assessed. Under a conservative scenario using one-third of the available certain types of biomass from three regions of Spain, annual SAF production could reach 517.6 million liters, with unit costs ranging from 1.63 to 1.24 EUR/L and up to 47,060 tonnes of CO₂ emissions avoided per year. The findings support the model’s technical and economic viability and its alignment with circular economy principles and climate policy goals. This approach offers a scalable and replicable pathway for decarbonizing the aviation sector using local renewable resources. Full article

This work focuses on the fabrication, characterization, and performance of a structured iron catalyst to produce hydrocarbons by the Fischer–Tropsch synthesis (FTS). The structured catalyst enhances the heat and mass transfer and provides a larger surface area and lower pressure drop. Iron-based structured catalysts indicate more activity in lower H₂/CO ratios and improve carbon conversion as compared to other metals. These catalysts were manufactured using the sponge replication method (powder metallurgy). The performance of the structured iron catalyst was assessed in a fixed-bed reactor under industrially relevant conditions (250 °C and 20 bar). The feed gas was a synthetic syngas with a H₂/CO ratio of 1.2, simulating a bio-syngas derived from lignocellulosic biomass gasification. Notably, the best result was reached under these conditions, obtaining a CO conversion of 84.8% and a CH₄ selectivity of 10.4%, where the catalyst exhibited a superior catalytic activity and selectivity toward desired hydrocarbon products, including light olefins and long-chain paraffins. The resulting structured catalyst reached a one-pass CO conversion of 84.8% with a 10.4% selectivity to CH₄ compared to a traditionally produced catalyst, for which the conversion was 18% and the selectivity was 19%, respectively. The results indicate that the developed structured iron catalyst holds considerable potential for efficient and sustainable hydrocarbon production, mainly C10–C20 (diesel-range hydrocarbons), via Fischer–Tropsch synthesis. The catalyst’s excellent performance and improved stability and selectivity offer promising prospects for its application in commercial-scale hydrocarbon synthesis processes. Full article

Fischer–Tropsch synthesis (FTS) facilitates the conversion of syngas, derived from feedstocks such as biomass, coal, and natural gas, into valuable hydrocarbons (HCs). This investigation employed optimization methods, specifically Gibbs energy minimization, to perform a thermodynamic characterization of the low-temperature Fischer–Tropsch (LTFT) reaction for HC generation. The CONOPT3 solver within GAMS 23.2.1 software was utilized for solving the developed model. To represent the complex FTS product spectrum, twenty-three compounds, encompassing C₂–C₂₀ aliphatic hydrocarbons, were considered using a stoichiometric framework. The study explored the impact of operational parameters, including temperature (350–550 K), pressure (5–30 bar), and H₂/CO molar feed ratio (1.0–2.0/0.5–1.0), on hydrocarbon synthesis. Evaluation of the outcomes focused on HC yield and product characteristics. A significant sensitivity of the reaction to operating parameters was observed. Notably, lower temperatures, elevated pressures, and a H₂/CO ratio of 2.0/1.0 were identified as optimal for fostering the formation of longer-chain HCs. The developed model demonstrated robustness and efficiency, with rapid computation times across all simulations. Full article

The biomass-to-liquid process is a promising alternative for sustainably meeting the growing demand for liquid fuels. This study focuses on the fabrication, characterization, and performance of a structured iron catalyst for producing hydrocarbons through Fischer–Tropsch synthesis (FTS). The catalyst was designed to address some drawbacks of conventional supported catalysts, such as low utilization, poor activity, and instability. The experimental investigation involved the manufacturing and characterization of both promoted and unpromoted iron-based catalysts. The performance of the structured iron catalyst was assessed in a fixed-bed reactor under relevant industrial conditions. Notably, the best results were achieved with a syngas ratio typical of the gasification of lignocellulosic biomass, where the catalyst exhibited superior catalytic activity and selectivity toward desired hydrocarbon products, including light olefins and long-chain paraffins. The resulting structured catalyst achieved up to 95% CO conversion in a single pass with 5% selectivity for CH₄. The results indicate that the developed structured iron catalyst has considerable potential for efficient and sustainable hydrocarbon production via the Fischer–Tropsch synthesis. The catalyst’s performance, enhanced stability, and selectivity present promising opportunities for its application in large-scale hydrocarbon synthesis processes. Full article