The influence of cobalt particle size in the range of 2.6-27 nm on the performance in Fischer-Tropsch synthesis has been investigated for the first time using well-defined catalysts based on an inert carbon nanofibers support material. X-ray absorption spectroscopy revealed that cobalt was metallic, even for small particle sizes, after the in situ reduction treatment, which is a prerequisite for catalytic operation and is difficult to achieve using traditional oxidic supports. The turnover frequency (TOF) for CO hydrogenation was independent of cobalt particle size for catalysts with sizes larger than 6 nm (1 bar) or 8 nm (35 bar), while both the selectivity and the activity changed for catalysts with smaller particles. At 35 bar, the TOF decreased from 23 x 10(-3) to 1.4 x 10(-3) s(-1), while the C5+ selectivity decreased from 85 to 51 wt % when the cobalt particle size was reduced from 16 to 2.6 nm. This demonstrates that the minimal required cobalt particle size for Fischer-Tropsch catalysis is larger (6-8 nm) than can be explained by classical structure sensitivity. Other explanations raised in the literature, such as formation of CoO or Co carbide species on small particles during catalytic testing, were not substantiated by experimental evidence from X-ray absorption spectroscopy. Interestingly, we found with EXAFS a decrease of the cobalt coordination number under reaction conditions, which points to reconstruction of the cobalt particles. It is argued that the cobalt particle size effects can be attributed to nonclassical structure sensitivity in combination with CO-induced surface reconstruction. The profound influences of particle size may be important for the design of new Fischer-Tropsch catalysts.

The effects of metal particle size in catalysis are of prime scientific and industrial importance and call for a better understanding. In this paper the origin of the cobalt particle size effects in Fischer-Tropsch (FT) catalysis was studied. Steady-State Isotopic Transient Kinetic Analysis (SSITKA) was applied to provide surface residence times and coverages of reaction intermediates as a function of Co particle size (2.6-16 nm). For carbon nanofiber supported cobalt catalysts at 210 degrees C and H(2)/CO = 10 v/v, it appeared that the surface residence times of reversibly bonded CH(x) and OH(x) intermediates increased, whereas that of CO decreased for small (<6 nm) Co particles. A higher coverage of irreversibly bonded CO was found for small Co particles that was ascribed to a larger fraction of low-coordinated surface sites. The coverages and residence times obtained from SSITKA were used to describe the surface-specific activity (TOF) quantitatively and the CH(4) selectivity qualitatively as a function of Co particle size for the FT reaction (220 degrees C, H(2)/CO = 2). The lower TOF of Co particles <6 nm is caused by both blocking of edge/corner sites and a lower intrinsic activity at the small terraces. The higher methane selectivity of small Co particles is mainly brought about by their higher hydrogen coverages.

Cobalt on carbon nanofiber model catalysts with very small dispersed cobalt particles of 5 nm were subjected to H(2)O/H(2) treatments at 20 bar and 220 degrees C. Using in situ Mossbauer spectroscopy we could unambiguously prove that oxidation of the nanoparticles by water will not occur when hydrogen is present. Only in a water/argon atmosphere did oxidation take place. This rules out oxidation as the deactivation mechanism in Fischer-Tropsch synthesis. Even more important, we define the relative humidity (RH) as a key parameter to understanding deactivation by water. At a RH below 25% sintering was absent even when measuring for 4 weeks, whereas at a high RH of 62% as much as half of the small super paramagnetic cobalt particles (<5 nm) sintered into larger particles in 1 week. Activity loss as measured at Fischer-Tropsch conditions amounted to 73%, which could be directly related to the metal dispersion loss 77% due to sintering as evidenced by detailed TEM analysis of the spent sample.

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Homogeneous deposition-precipitation on either a silica or carbon nanofiber (CNF) support of cobalt from basic solution using ammonia evaporation was studied and compared with conventional deposition from an acidic solution using urea hydrolysis. In the low-pH experiment, the interaction between precipitate and silica was too high; cobalt hydrosilicates were formed requiring a reduction temperature of 600 • C, resulting in low cobalt dispersion. Lower interaction in experiments performed in a basic environment yielded a well-dispersed Co 3 O 4 phase on silica, and after reduction at only 500 • C, a catalyst with 13-nm cobalt particles was obtained. On CNF from an acidic solution, cobalt hydroxy carbonate precipitated and displayed a low interaction with the support resulting after reduction at 350 • C in a catalyst with 25-nm particles. From basic solution we obtained high dispersion of cobalt on the CNF, probably related to the greater ion adsorption. After drying, Co 3 O 4 crystallites were obtained that, after reduction at 350 • C, resulted in a catalyst with 8-nm Co particles. Samples prepared in the high-pH experiment had 2-4 times higher cobalt-specific activity in the Fischer-Tropsch reaction than their low-pH counterparts. CNF support materials combined with the high-pH deposition-precipitation technique hold considerable potential for cobalt-based Fischer-Tropsch catalysis.

Microkinetic modeling is employed to predict catalytic turnover rates, product distributions, preferred mechanistic pathways, and rate- and selectivity-controlling elementary reaction steps for the Fischer-Tropsch (FT) reaction. We considered all relevant elementary reaction steps on Co(112̅1) step-edge and Co(0001) terrace sites as well as such important aspects as coverage-related lateral interactions, different chain-growth mechanisms, and the migration of adsorbed species between the two surfaces in the dual-site model. CH x –CH y coupling pathways relevant to the carbide mechanism have favorable barriers in comparison to the overall barriers for the CO insertion mechanism. A comparison of reaction barriers indicates why cobalt is such a good FT catalyst: CO bond scission and chain growth compete, while termination to olefins has a slightly higher barrier. The predicted kinetic parameters correspond well with experimental kinetic data. The Co(112̅1) model surface is highly active and selective for the FT reaction. Adding terrace Co­(0001) sites in a dual-site model approach leads to a substantially higher CH4 selectivity at the expense of the C2+-hydrocarbons selectivity. The chain-growth probability decreases with increasing temperature and H2/CO ratio, caused by faster hydrogenation of the hydrocarbon chains. The elementary reaction steps for O removal and CO dissociation significantly control the overall CO consumption rate. Chain growth occurs almost exclusively at step-edge sites, while additional CH4 stems from CH and CH3 migration from step-edge to terrace sites. Replacing CO by CO2 as the reactant shifts the product distribution nearly completely to CH4, which is related to the much higher H/CO coverage ratio during CO2 hydrogenation in comparison to CO hydrogenation. These findings highlight the importance of a proper balance of CO and H surface species during the FT reaction and pinpoint step-edge sites as the locus of the FT reaction with low-reactive terrace sites near step-edge sites being the origin of unwanted CH4.

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STEM-EELS and XPS investigation shows manganese oxide to be closely associated with cobalt nanoparticles supported on carbon nanofibers thereby improving selectivity in Fischer-Tropsch catalysis.