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Abstract: This study investigated the performance of supported Co3O4 catalysts during the preferential oxidation of carbon monoxide (CO-PrOx) in a H2-rich environment, focusing on the effects of different catalyst synthesis methods, namely, wetness impregnation (WI) and solution combustion synthesis (SCS), and different support materials, namely, Al2O3 and SiC. During CO-PrOx, the SiC-supported Co3O4 catalysts attained higher CO2 yields when compared with the Al2O3-supported Co3O4 catalysts possibly because of the existence of weaker interactions between Co3O4 and SiC. Moreover, the catalysts prepared via SCS achieved higher CO2 yields than the catalysts prepared via WI likely due to the presence of smaller and well-dispersed Co3O4 particles in the SCS-prepared catalysts. Significantly high amounts of unwanted CH4 were produced over the SiC-supported catalysts between 225 and 250 °C. The high CO methanation activity was also attributed to the weaker Co3O4-SiC interactions, which enabled the easier reduction of Co3O4 to methanation active metallic Co.

Open Access

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Abstract: The Fischer–Tropsch (FT) synthesis is traditionally associated with fossil fuel consumption, but recently this technology has emerged as a keystone that enables the conversion of captured CO2 with sustainable hydrogen to energy-dense fuels and chemicals for sectors which are challenging to be electrified. Iron-based FT catalysts are promoted with alkali and transition metals to improve reducibility, activity, and selectivity. Due to their low concentration and the metastable state under reaction conditions, the exact speciation and location of these promoters remain poorly understood. We now show that the selectivity promoters such as potassium and manganese, locked into an oxidic matrix doubling as a catalyst support, surpass conventional promoting effects. La1–xKxAl1–yMnyO3−δ (x = 0 or 0.1; y = 0, 0.2, 0.6, or 1) perovskite supports yield a 60% increase in CO conversion comparable to conventional promotion but show reduced CO2 and overall C1 selectivity. The presented approach to promotion seems to decouple the enhancement of the FT and the water–gas shift reaction. We introduce a general catalyst design principle that can be extended to other key catalytic processes relying on alkali and transition metal promotion.

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Abstract: We have studied the effect of different supports (CeO2, ZrO2, SiC, SiO2 and Al2O3) on the catalytic performance and phase stability of Co3O4 nanoparticles during the preferential oxidation of CO (CO-PrOx) under different H2-rich gas environments and temperatures. Our results show that Co3O4/ZrO2 has superior CO oxidation activity, but transforms to Co0 and consequently forms CH4 at relatively low temperatures. The least reduced and least methanation active catalyst (Co3O4/Al2O3) also exhibits the lowest CO oxidation activity. Co-feeding H2O and CO2 suppresses CO oxidation over Co3O4/ZrO2 and Co3O4/SiC, but also suppresses Co0 and CH4 formation. In conclusion, weak nanoparticle-support interactions (as in Co3O4/ZrO2) favour high CO oxidation activity possibly via the Mars-van Krevelen mechanism. However, stronger interactions (as in Co3O4/Al2O3) help minimise Co0 and CH4 formation. Therefore, this work reveals the bi-functional role required of supports used in CO-PrOx, i.e., to enhance catalytic performance and improve the phase stability of Co3O4.

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Abstract: The formation of mixed-metal cobalt oxides, representing potential metal–support compounds for cobalt-based catalysts, has been observed at high conversion levels in the Fischer–Tropsch synthesis over metal oxide-supported cobalt catalysts. An often observed increase in the carbon dioxide selectivity at Fischer–Tropsch conversion levels above 80% has been suggested to be associated to the formation of water–gas shift active oxidic cobalt species. Mixed-metal cobalt oxides, namely cobalt aluminate and cobalt titanate, were therefore synthesised and tested for potential catalytic activity in the water–gas shift reaction. We present a preparation route for amorphous mixed-metal oxides via thermal treatment of metal precursors in benzyl alcohol. Calcination of the as prepared nanoparticles results in highly crystalline phases. The nano-particulate mixed-metal cobalt oxides were thoroughly analysed by means of X-ray diffraction, Raman spectroscopy, temperature-programmed reduction, X-ray absorption near edge structure spectroscopy, extended X-ray absorption fine structure, and high-resolution scanning transmission electron microscopy. This complementary characterisation of the synthesised materials allows for a distinct identification of the phases and their properties. The cobalt aluminate prepared has a cobalt-rich composition (Co1+xAl2−xO4) with a homogeneous atomic distribution throughout the nano-particulate structures, while the perovskite-type cobalt titanate (CoTiO3) features cobalt-lean smaller particles associated with larger ones with an increased concentration of cobalt. The cobalt aluminate prepared showed no water–gas shift activity in the medium-shift temperature range, while the cobalt titanate sample catalysed the conversion of water and carbon monoxide to hydrogen and carbon dioxide after an extended activation period. However, this perovskite underwent vast restructuring forming metallic cobalt, a known catalyst for the water–gas shift reaction at temperatures exceeding typical conditions for the cobalt-based Fischer–Tropsch synthesis, and anatase-TiO2. The partial reduction of the mixed-metal oxide and segregation was identified by means of post-run characterisation using X-ray diffraction, Raman spectroscopy, and transmission electron microscopy energy-dispersive spectrometry.

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Abstract: Herein we present a comparative study on the water-induced formation of metal-support compounds from metallic cobalt in a simulated high conversion Fischer-Tropsch environment. Literature on the deactivation of supported cobalt catalysts via oxidation to cobalt(II) oxide or cobalt-support compounds is contradictory due to a lack of use in suitable model catalysts and insufficient direct characterization of the metallic cobalt phase under reaction conditions. The particular carrier materials stabilize the active cobalt nanoparticles, but also dictate the likelihood of the formation of non-active cobalt-support compounds. In this study, well-defined cobalt nanoparticles of 5 nm were deposited on alumina, silica, and three titania carriers. The stability of the reduced nanoparticles against water-rich H2 atmospheres during exposure to simulated high Fischer-Tropsch conversion levels was monitored in an in situ magnetometer. Co/SiO2 was shown to be the most stable model catalyst, while various Co/TiO2 model systems readily formed large amounts of cobalt-support compounds at low ratios of the Fischer-Tropsch product H2O to reactant H2 or even during the preceding reduction of the oxidic precursor. Co/Al2O3 displayed a surprisingly high stability at industrially relevant conditions, in contradiction to thermodynamic predictions. However, cobalt aluminate forms at increased concentrations of water. The existence of hard-to-reduce metal-support compounds in the spent catalysts was confirmed and characterized by means of X-ray absorption near edge structure spectroscopy and high-resolution scanning transmission electron microscopy of the exposed and passivated model catalysts.