Fischer–Tropsch synthesis on ceramic monolith-structured catalysts

This paper reports recent research results about the impact of different catalyst bed configurations on Fischer–Tropsch (FT) synthesis product distributions. A powdered CoRe/γ-alumina catalyst with a particle size ranging from 60 to 100 mesh was prepared and tested in a packed bed reactor. The same catalyst was ball milled and coated on a ceramic monolith support structure of channel size about 1 mm. The monolith catalyst module was tested in two different ways, as a whole piece and as well-defined channels. Steady-state reaction conversion was measured at various temperatures under a constant H2/CO feed ratio of 2 and a reactor pressure of 25 bar. Detailed product analysis was performed. Significant formation of wax was evident with the packed particle bed and with the monolith catalyst that was improperly packed. By contrast, wax formation was not detected in the liquid product by confining the reactions inside the monolith channel. This study presents an important finding about the structured catalyst/reactor system, in that the product distribution highly depends on how the structured reactor is set up. Even if a catalyst is tested under identical reaction conditions (T, P, H2/CO ratio), hydrodynamics (or flow conditions) inside a structured channel may have a significant impact on the product distribution.