Lower olefins are key building blocks for the manufacture of plastics, cosmetics, and drugs. Traditionally, olefins with two to four carbons are produced by steam cracking of crude oil-derived naphtha, but there is a pressing need for alternative feedstocks and processes in view of supply limitations and of environmental issues. Although the Fischer-Tropsch synthesis has long offered a means to convert coal, biomass, and natural gas into hydrocarbon derivatives through the intermediacy of synthesis gas (a mixture of molecular hydrogen and carbon monoxide), selectivity toward lower olefins tends to be low. We report on the conversion of synthesis gas to C(2) through C(4) olefins with selectivity up to 60 weight percent, using catalysts that constitute iron nanoparticles (promoted by sulfur plus sodium) homogeneously dispersed on weakly interactive α-alumina or carbon nanofiber supports.

ABSTRACT:The Fischer−Tropsch synthesis of lower olefins (FTO) is an alternative process for the production of key chemical building blocks from non-petroleum-based sources such as natural gas, coal, or biomass. The influence of the iron carbide particle size of promoted and unpromoted carbon nanofiber supported catalysts on the conversion of synthesis gas has been investigated at 340−350°C, H 2 /CO = 1, and pressures of 1 and 20 bar. The surface-specific activity (apparent TOF) based on the initial activity of unpromoted catalysts at 1 bar increased 6−8-fold when the average iron carbide size decreased from 7 to 2 nm, while methane and lower olefins selectivity were not affected. The same decrease in particle size for catalysts promoted by Na plus S resulted at 20 bar in a 2-fold increase of the apparent TOF based on initial activity which was mainly caused by a higher yield of methane for the smallest particles. Presumably, methane formation takes place at highly active low coordination sites residing at corners and edges, which are more abundant on small iron carbide particles. Lower olefins are produced at promoted (stepped) terrace sites that are available and active, quite independent of size. These results demonstrate that the iron carbide particle size plays a crucial role in the design of active and selective FTO catalysts.

Depletion of crude oil resources and environmental concerns have driven a worldwide research on alternative processes for the production of commodity chemicals. Fischer-Tropsch synthesis is a process for flexible production of key chemicals from synthesis gas originating from non-petroleum-based sources. Although the use of iron-based catalysts would be preferred over the widely used cobalt, manufacturing methods that prevent their fast deactivation because of sintering, carbon deposition and phase changes have proven challenging. Here we present a strategy to produce highly dispersed iron carbides embedded in a matrix of porous carbon. Very high iron loadings (440 wt %) are achieved while maintaining an optimal dispersion of the active iron carbide phase when a metal organic framework is used as catalyst precursor. The unique iron spatial confinement and the absence of large iron particles in the obtained solids minimize catalyst deactivation, resulting in high active and stable operation.

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In this combined in situ XAFS, DRIFTS, and Mössbauer study, we elucidate the changes in structural, electronic, and local environments of Fe during pyrolysis of the metal organic framework Fe-BTC toward highly active and stable Fischer–Tropsch synthesis (FTS) catalysts (Fe@C). Fe-BTC framework decomposition is characterized by decarboxylation of its trimesic acid linker, generating a carbon matrix around Fe nanoparticles. Pyrolysis of Fe-BTC at 400 °C (Fe@C-400) favors the formation of highly dispersed epsilon carbides (ε′-Fe2.2C, d p = 2.5 nm), while at temperatures of 600 °C (Fe@C-600), mainly Hägg carbides are formed (χ-Fe5C2, d p = 6.0 nm). Extensive carburization and sintering occur above these temperatures, as at 900 °C the predominant phase is cementite (θ-Fe3C, d p = 28.4 nm). Thus, the loading, average particle size, and degree of carburization of Fe@C catalysts can be tuned by varying the pyrolysis temperature. Performance testing in high-temperature FTS (HT-FTS) showed that the initial turnover frequency (TOF) of Fe@C catalysts does not change significantly for pyrolysis temperatures up to 600 °C. However, methane formation is minimized when higher pyrolysis temperatures are applied. The material pyrolyzed at 900 °C showed longer induction periods and did not reach steady state conversion under the conditions studied. None of the catalysts showed deactivation during 80 h time on stream, while maintaining high Fe time yield (FTY) in the range of 0.19–0.38 mmolCO gFe –1 s–1, confirming the outstanding activity and stability of this family of Fe-based FTS catalysts.