Development of promoted cobalt/alumina Fischer-Tropsch catalysts for increased activity and selectivity: Micro-reactor to piloting scale

The shift towards renewable and sustainable energy sources necessitates a simultaneous transition to highly selective and active Fischer-Tropsch (FT) catalysts, thus ensuring the optimal utilization of available syngas. The FT reactor conditions targeted for potential power-to-liquids (PtL) applications are focused on increasing syngas conversion and thus water partial pressure to maximise hydrocarbon production. The critical determinant in this pursuit lies in the meticulous formulation of the catalyst, encompassing promoter loading, the precise point of promoter addition, and the dispersion of the active metal within the Co/Ti/Mn/alumina catalysts specifically designed for PtL applications. To accomplish this, we elaborate on the targeted screening approach employed to select the most promising catalyst formulation at lab scale, which was subsequently scaled up to kilogram proportions. The evaluation of catalyst performance spanned various testing platforms, including micro-structured reactors, micro-slurry reactors, and pilot-scale slurry bubble column reactors. Such comprehensive assessment not only facilitated significant risk mitigation but also instilled confidence in the catalyst's efficacy and operational longevity under the chosen conditions.