A fundamental filtration study was started to investigate the separation of FischerTropsch Synthesis (FTS) liquids from iron-based catalyst particles. Slurry-phase FTS in slurry bubble column reactor systems is the preferred mode of operation since the reaction is highly exothermic. Consequently, heavy wax products in one approach may be separated from catalyst particles before being removed from the reactor system.Achieving an efficient wax product separation from iron-based catalysts is one of the most challenging technical problems associated with slurry-phase iron-based FTS and is a key factor for optimizing operating costs. The separation problem is further compounded by attrition of iron catalyst particles and the formation of ultra-fine particles.Existing pilot-scale equipment was modified to include a filtration test apparatus.After undergoing an extensive plant shakedown period, filtration tests with cross-flow filter modules using simulated FTS wax slurry were conducted. The focus of these early tests was to find adequate mixtures of polyethylene wax to simulate FTS wax. Analysis techniques for catalyst particle size distribution were also developed. Initial analyses of the slurry and filter permeate particles focused on catalyst particle attrition and the formation of ultra-fine iron carbide and/or carbon particles. The effects of chemical and physical changes of the catalyst slurry during activation/synthesis on the filtration properties were also studied.A study of various molecular weight waxes was initiated to determine the effect of wax physical properties on the permeation rate without catalyst present. It was found that the permeate flux was inversely proportional to the nominal average molecular 3 weight of the polyethylene wax. Even without catalyst particles present in the filtrate, the filter membranes experience fouling during an induction period on the order of several days on-line.Another long-term filtration test was initiated using a batch of ultrafine iron catalyst that was previously activated with CO in a separate continuous stirred tank reactor (CSTR) system. The permeate flux stabilized more rapidly than that experienced with unactivated catalyst tests.A series of crossflow filtration experiments were initiated to study the effect of olefins and oxygenate on the filtration flux and membrane performance. Iron-based FTS reactor waxes contain a significant amount of oxygenates, depending on the catalyst formulation and operating conditions. Mono-olefins and aliphatic alcohols were doped into an activated iron catalyst slurry (with Polywax) to test their influence on filtration properties. The olefin concentrations were varied from 5 to 25wt% and oxygenates from 6 to 17 wt% to simulate a range of reactor slurries reported in the literature. The addition of an alcohol (1-dodecanol) was found to decrease the permeation rate while the olefin added (1-hexadecene) had no effect on the permeation rate. A passive flux maintenance technique was tested that can temporarily increase the...