Performance studies of various cracking catalysts in the conversion of canola oil to fuels and chemicals in a fluidized-bed reactor

Studies were conducted at atmospheric pressure at temperatures in the range of 400–500°C and fluidizing gas velocities in the range of 0.37–0.58 m/min (at standard temperature and pressure) to evaluate the performance of various cracking catalysts for canola oil conversion in a fluidized-bed reactor. Results show that canola oil conversions were high (in the range of 78–98 wt%) and increased with an increase in both temperature and catalyst acid site density and with a decrease in fluidizing gas velocity. The product distribution mostly consisted of hydrocarbon gases in the C₁–C₅ range, a mixture of aromatic and aliphatic hydrocarbons in the organic liquid product (OLP) and coke. The yields of C₄ hydrocarbons, aromatic hydrocarbons and C₂–C₄ olefins increased with both temperature and catalyst acid site density but decreased with an increase in fluidizing gas velocity. In contrast, the yields of aliphatic and C₅ hydrocarbons followed trends completely opposite to those of C₂–C₄ olefins and aromatic hydrocarbons. A comparison of performance of the catalysts in a fluidized-bed reactor with earlier work in a fixed-bed reactor showed that selectivities for formation of both C₅ and iso-C₄ hydrocarbons in a fluidized-bed reactor were extremely high (maximum of 68.7 and 18 wt% of the gas product) as compared to maximum selectivities of 18 and 16 wt% of the gas product, respectively, in the fixed-bed reactor. Also, selectivity for formation of gas products was higher for runs with the fluidized-bed reactor than for those with the fixed-bed reactor, whereas the selectivity for OLP was higher with the fixed-bed reactor. Furthermore, both temperature and catalyst determined whether the fractions of aromatic hydrocarbons in the OLP were higher in the fluidized-bed or fixed-bed reactor.     

Slurry-phase CO2 hydrogenation to hydrocarbons over a precipitated Fe-Cu-Al/K catalyst: Investigation of reaction conditions

The hydrogenation of CO₂ to hydrocarbons over a precipitated Fe-Cu-Al/K catalyst was studied in a slurry reactor for the first time. Reducibility of the catalyst and effect of reaction variables (temperature, pressure and H₂/CO₂ ratio of the feed gas) on the catalytic reaction performance were investigated. The reaction results indicated that the Fe-Cu-Al/K catalyst showed a good CO₂ hydrogenation performance at a relatively low temperature (533 K). With the increase of reaction temperature CO₂ conversion and olefin to paraffin (O/P) ratio in C₂-C₄ hydrocarbons as well as the selectivity to C₂-C₄ fraction increased, while CO and CH₄ selectivity showed a reverse trend. With the increase in reaction pressure, CO₂ conversion and the selectivity to hydrocarbons increased, while the CO selectivity and O/P ratio of C₂-C₄ hydrocarbons decreased. The investigation of H2/CO₂ ratio revealed that CO₂ conversion and CH₄ selectivity increased while CO selectivity and O/P ratio of C₂-C₄ decreased with increasing H₂/CO₂ ratio.     

Production of C4 hydrocarbons from Fischer–Tropsch synthesis in a follow bed reactor consisting of Co–Ni–ZrO2 and sulfated-ZrO2 catalyst beds

Fischer–Tropsch synthesis was performed in a fixed-bed microreactor over a single bed consisting of Co–Ni–ZrO₂ catalyst as well as over a follow bed configuration consisting of Co–Ni–ZrO₂ and sulfated-ZrO₂ catalyst beds for the selective production of C₄ hydrocarbons. A maximum C₄ hydrocarbon selectivity of 14.6 wt.% was obtained using the single bed approach at 250°C and weight hourly space velocities (WHSV) of 15 h⁻¹. When a follow bed approach was used, there was an impressive increase in the selectivity for C₄ hydrocarbons to a maximum of 24 wt.% and that for iso-C₄ hydrocarbons to a maximum of 13.8 wt.% from 14.6 and 5.5 wt.%, respectively. However, there was a rapid deactivation of the sulfated-ZrO₂ catalyst due to coking and sulfate reduction.     

Direct synthesis of isoparaffin from synthesis gas under supercritical conditions

To produce isoparaffins from synthesis gas directly, modified Fischer–Tropsch (FT) synthesis was carried out under supercritical conditions using n-butane as a medium. One-step FT synthesis using a hybrid catalyst consisting of Co/SiO₂, HZSM-5 and Pd/SiO₂ was carried out. Introduction of supercritical-phase n-butane increased light isoparaffins significantly and suppressed the formation of the by-product, methane. Under supercritical-phase butane, hydrogenolysis and isomerization reactions were promoted. Due to the fact that the optimum temperatures for FT and HZSM-5 catalysts are different, 513 K and over 573 K, respectively, two-step FT synthesis was also carried out to optimize the reaction temperatures. The first-step reaction used Co/SiO₂ catalyst containing small amount of HZSM-5 for FT synthesis at 513 K, and the second-step reaction used a hybrid catalyst containing Pd/SiO₂ and zeolite for hydrogenolysis and isomerization of hydrocarbons at 573 K. Introduction of supercritical n-butane increased the isoparaffin selectivity, and decreased the methane selectivity significantly. The production of heavy hydrocarbons C₉+ was inhibited in both gas and supercritical phase. The isoparaffin selectivity in the gas phase decreased with time-on-stream, but very stable for the supercritical-phase reaction. Because water and heavy hydrocarbons were removed from active sites on zeolite and the zeolite acidity was promoted in the supercritical medium, the selectivity of isoparaffin was considered stable. Among zeolites added to the hybrid catalyst in the second-step reactor, HZSM-5 and H-beta zeolite were suitable for producing light isoparaffins. These results indicated that two-step FT synthesis under supercritical n-butane was superior for producing light isoparaffins from synthesis gas directly.     

Potassium and nickel doped β-Mo2C catalysts for mixed alcohols synthesis via syngas

Potassium and nickel doped β-Mo₂C catalysts were prepared and their performances of CO hydrogenation were investigated. The main products over β-Mo₂C catalyst were hydrocarbons, and only few alcohols were obtained. The potassium promoter resulted in remarkable selectivity shift from hydrocarbons to alcohols over β-Mo₂C. Moreover, it was found that the potassium promoter enhanced the ability of chain propagation of β-Mo₂C catalyst and resulted in a higher selectivity to C₂₊OH. When doped by potassium and nickel, β-Mo₂C catalyst showed high activity and selectivity for mixed alcohols synthesis, the Ni promoter further enhanced the whole chain propagation to produce alcohols especially for the step of C₁OH–C₂OH. From the XPS analysis, it had been proved that the formation of higher alcohols might be attributable to the presence of Mo^IV species, whereas the formation of hydrocarbons was closely associated with the presence of Mo^II species on the surface of the catalysts.     

Conversion of syngas to hydrocarbons in a tube-wall reactor using CoFe plasma-sprayed catalyst: experimental and modeling studies

Catalyst activity and product selectivity studies of the conversion of synthesis gas to various hydrocarbon fractions were performed in a single-tube tube-wall reactor (TWR) using a CoFe plasma-sprayed catalyst with the operating conditions: temperature 250–275°C, pressure 0.1–1.03 MPa, exposure velocity 139–722 μms⁻¹, and a H₂:CO ratio of 2.0. The catalyst activity in terms of CO conversion was highest (98.5% m/m) at an exposure velocity of 139 μms⁻¹, temperature of 275°C, and in the pressure range 0.69–1.03 MPa. The selectivity to hydrocarbons was 43–50% (m/m) in the pressure range 0.69–1.03 MPa whereas the selectivity to C₅ + hydrocarbons was over 40% of the total hydrocarbons produced. The production of propylene was higher than ethylene under similar process conditions. The performance of the TWR was predicted by a numerical model. The model is based on the complete two-dimensional transport equations and reaction rate equations, developed for the CoFe catalyst. Predictions are made for the temperature along the axis of the reactor, for CO and H₂ conversions as functions of the reactor length and the exposure velocity, and the axial H₂O and CO₂ concentrations.     

Effect of Vanadium Promotion on Activated Carbon-Supported Cobalt Catalysts in Fischer–Tropsch Synthesis

The effect of vanadium promotion on activated carbon (AC)-supported cobalt catalysts in Fischer–Tropsch synthesis has been studied by means of XRD, TPR, CO-TPD, H₂-TPSR of chemisorbed CO and F-T reaction. It was found that the CO conversion could be significantly increased from 38.9 to 87.4% when 4 wt.% V was added into Co/AC catalyst. Small amount of vanadium promoter could improve the selectivity toward C₁₀–C₂₀ fraction and suppress the formation of light hydrocarbon. The results of CO-TPD and H₂-TPSR of adsorbed CO showed that the addition of vanadium increased the concentration of surface-active carbon species by enhancing CO dissociation and further improved the selectivity of long chain hydrocarbons. However, excess of vanadium increased methane selectivity and decreased C₅⁺ selectivity.     

Fischer—tropsch studies on a plasma-sprayed iron catalyst in a tube-wall reactor

Conversion of synthesis gas to gaseous and liquid fuels via Fischer–Tropsch (FT) synthesis is becoming increasingly important for future energy needs. Tube-wall reactors (TWR) are gaining importance for FT synthesis because of simple construction and improved temperature control. In the literature, studies have been reported on the FT synthesis in a TWR using a flame-sprayed iron catalyst. In the present work, we have examined the effect of temperature (250–275°C), pressure (3.45 × 10⁵ – 6.89 × 10⁵ Pa), exposure velocity (0.61 – 2.44 m³/h of gas at STP/m² of catalyst superficial area) and feed composition (H₂/CO ratio of 2 and 3) on the product yield and selectivity using a plasma-sprayed iron catalyst in the TWR. The plasma-sprayed iron catalyst gave slightly lower conversions but showed much higher C₅ + product selectivity as compared to the flame-sprayed catalyst. The product distribution shifted towards higher hydrocarbons at lower temperatures, higher pressures and lower exposure velocities. The product distribution followed Shultz-Flory relationship and the chain growth probability factor α decreased slightly with increase in temperature. The catalyst also showed good regeneration characteristics.     

Selective synthesis of C2-C4 hydrocarbons from CO + H2 on composite catalysts

A copper-zinc-aluminum methanol synthesis catalyst has been prepared using a precipitated hydrotalcite-type precursor that decomposes to a mixture of the corresponding amorphous oxides at a low temperature. TPR studies show that such a mixture is easy to reduce giving a highly dispersed catalyst. When this is mixed with a zeolite, the resulting hybrid catalyst gives C₂-C₄ hydrocarbons with very high selectivity. This may be useful in obtaining LPG from synthesis gas.     

Comparative Study on CO2 Hydrogenation to Higher Hydrocarbons over Fe-Based Bimetallic Catalysts

This paper reports on notable promotion of C₂ ⁺ hydrocarbons formation from CO₂ hydrogenation induced by combining Fe and a small amount of selected transition metals. Al₂O₃-supported bimetallic Fe–M (M = Co, Ni, Cu, Pd) catalysts as well as the corresponding monometallic catalysts were prepared, and examined for CO₂ hydrogenation at 573 K and 1.1 MPa. Among the monometallic catalysts, C₂ ⁺ hydrocarbons were obtained only with Fe catalyst, while Co and Ni catalysts yielded higher CH₄ selectively than other catalysts. The combination of Fe and Cu or Pd led to significant bimetallic promotion of C₂ ⁺ hydrocarbons formation from CO₂ hydrogenation, in addition to Fe–Co formulation discovered in our previous work. CO₂ conversion on Ni catalyst nearly reached equilibrium for CO₂ methanation which makes this catalyst suitable for making synthetic natural gas. Fe–Ni bimetallic catalyst was also capable of catalyzing CO₂ hydrogenation to C₂ ⁺ hydrocarbons, but with much lower Ni/(Ni+Fe) atomic ratio compared to other bimetallic catalysts. The addition of a small amount of K to these bimetallic catalysts further enhanced CO₂ hydrogenation activity to C₂ ⁺ hydrocarbons. K-promoted Fe–Co and Fe–Cu catalysts showed better performance for synthesizing C₂ ⁺ hydrocarbons than Fe/K/Al₂O₃ catalyst which has been known as a promising catalyst so far.     

Low methane selectivity using Co/MnO catalysts for the Fischer-Tropsch reaction: Effect of increasing pressure and Co-feeding ethene

CO hydrogenation using cobalt/ manganese oxide catalysts is described and discussed. These catalysts are known to give low methane selectivity with high selectivity to C₃ hydrocarbons at moderate reaction conditions (GHSV < 500 h^–1, < 600 kPa). In this study the effect of reaction conditions more appropriate to industrial operation are investigated. CO hydrogenation at 1–2 MPa using catalyst formulations with Co/Mn = 0.5 and 1.0 gives selectivities to methane that are comparable to those observed at lower pressures. At the higher pressure the catalyst rapidly deactivates, a feature that is not observed at lower pressures. However, prior to deactivation rates of CO + CO₂ conversion > 8 mol/1-catalyst h can be observed. Co-feeding ethene during CO hydrogenation is investigated by the reaction of¹³C0-¹²C₂H₄-H₂ mixtures and a significant decrease in methane selectivity is observed but the hydrogenation of ethene is also a dominant reaction. The results show that the co-fed ethene can be molecularly incorporated but in addition it can generate a C, species that can react further to form methane and higher hydrocarbons.     

Catalytic conversion of canola oil to fuels and chemicals over various cracking catalysts

The catalytic conversion of canola oil to fuels and chemicals was studied over HZSM-5, H-mordenite, H-Y, silicalite, aluminum-pillared clay (AL-PILC) and silica-alumina catalysts in a fixed bed micro-reactor. The reactor was operated at atmospheric pressure, a temperature range of 375?500°C and weight hourly space velocity (WHSV) of 1.8 and 3.6 h^?1. An organic liquid product (OLP), light hydrocarbon gases and water were the major products. The objective was to maximize the amount of OLP and its hydrocarbon content as well as optimize the selectivity for gas phase olefinic hydrocarbons. In addition, the performance of each catalyst in terms of minimizing the coke formation was examined. Among the six catalysts, HZSM-5 gave the highest amount of OLP of 63 mass% at 1.8 WHSV and 400°C. The hydrocarbon content of this OLP product was 83.8 mass%. With the exception of silica-alumina and aluminum-pillared clay catalysts, the other catalysts gave high concentrations of aromatic hydrocarbons which ranged between 23.1–95.6 mass% of OLP. The gas products consisted mostly C₃ and C₄ hydrocarbons. Ethylene, propylene and butanes were some of the valuable hydrocarbon gases. The olefin/paraffin ratio of the gas products was highest for AL-PILC catalysts but it never exceeded unity. The results showed that it was possible to significantly alter the yield and selectivity for the different hydrocarbon products by using different catalysts or changing the catalyst functionality such as acidity, pore size and crystallinity. Reaction pathways based on these results are proposed for the conversion of canola oil     

Effect of co-feeding carbon dioxide on Fischer–Tropsch synthesis over an iron–manganese catalyst in a spinning basket reactor

The effect of co-feeding CO₂ on the catalytic properties of an Fe–Mn catalyst during Fischer–Tropsch synthesis (FTS) was investigated in a spinning basket reactor by varying added CO₂ partial pressure in the feed gas. It was found that co-feeding CO₂ to syngas did not decrease the activity of the catalyst, on the contrary, a dramatic increase of the activity and an increase of methane selectivity were observed over the catalyst after removal of CO₂ from the feed gas. The addition of CO₂ led to an increase in olefin/paraffin ratios of low carbon hydrocarbons and a slight decrease in C₁₉⁺ selectivity. It also slightly decreased CO₂ formation rate on the catalyst by increasing the rate of reverse step of the water–gas shift (WGS) reaction and pushing the reaction towards equilibrium, and did not remarkably influence the hydrocarbon formation rate. However, the co-feeding CO₂ can significantly increase the water formation rate and the overall oxygenate formation rate under these reaction conditions.     

Liquid fuel production from syngas using bifunctional CuO-CoO-Cr2O3 catalyst mixed with MFI zeolite

CuO-CoO-Cr₂O₃ mixed with MFI Zeolite (Si/Al = 35) prepared by co-precipitation was used for synthesis gas conversion to long chain hydrocarbon fuel. CuO-CoO-Cr₂O₃ catalyst was prepared by co-precipitation method using citric acid as complexant with physicochemical characterization by BET, TPR, TGA, XRD, H₂-chemisorptions, SEM and TEM techniques. The conversion experiments were carried out in a fixed bed reactor, with different temperatures (225-325 °C), gas hourly space velocity (457 to 850 h⁻¹) and pressure (28-38 atm). The key products of the reaction were analyzed by gas chromatography mass spectroscopy (GC-MS). Significantly high yields of liquid aromatic hydrocarbon products were obtained over this catalyst. Higher temperature and pressure favored the CO conversion and formation of these liquid (C₅-C₁₅) hydrocarbons. Higher selectivity of C₅ + hydrocarbons observed at lower H₂/CO ratio and GHSV of the feed gas. On the other hand high yields of methane resulted, with a decrease in C₅+ to C₁₁+ fractions at lower GHSV. Addition of MFI Zeolite (Si/Al = 35) to catalyst CuO-CoO-Cr₂O₃ resulted a high conversion of CO-hydrogenation, which may be due to its large surface area and small particle size creating more active sites. The homogeneity of various components was also helpful to enhance the synergistic effect of Co promoters.     

Catalytic conversion of canola oil to fuels and chemical feedstocks Part I. Effect of process conditions on the performance of HZSM-5 catalyst

The conversion of canola oil to hydrocarbons using a shape selective zeolite catalyst is reported in this work. Canola oil was passed over HZSM-5 catalyst in a fixed bed micro-reactor and the effects of reaction temperature and oil space velocity on the conversion and selectivity were studied using a statistical experimental design. The results show that 60–95 wt% of the canola oil can be converted to hydrocarbons in the gasoline boiling range, light gases and water. The gasoline fraction contained 60–70 wt% of aromatic hydrocarbons and the gases were mostly C₃ and C₄ paraffins. Furthermore, the spent catalyst could be regenerated completely at 600°C in 1 h with dry air.     

Conversion of natural gas to C2 product,hydrogen and carbon black using a catalytic plasma reaction

In the microwave and RF plasma catalytic reaction at room temperature, the decomposition of natural gas over Pd–NiO/γ-Al₂O₃ was carried out. The decomposition of methane is caused by collision by excitation of unstable electronic state. Measuring the flow rate and plasma power can represent kinetic data and mechanism. The conversion of C₂ hydrocarbons was increased from 47% to 63.7% in the microwave plasma catalytic reaction within electric field. Comparing the activities of catalysts, Pd–NiO/γ-Al₂O₃ bimetallic catalyst was more active than Pt–Sn/γ-Al₂O₃ catalyst because of modifying the surface of catalysts by carbon formation. In RF plasma catalytic reaction, we obtained high C₂ yield of 72%, in which the conversion and selectivity of C₂ hydrocarbons were related to the applied power and feed rate of natural gas.     

Enhanced Production of C2–C4 Olefins Directly from Synthesis Gas

An attempt made for the selective production of C₂–C₄ olefins directly from the synthesis gas (CO + H₂) has led to the development of a dual catalyst system having a Fischer–Tropsch (K/Fe–Cu/AlOx) catalyst and cracking (H-ZSM-5) catalyst operate in consecutive dual reactors. The flow rate (space velocity) and H₂/CO molar ratio of the feed have been optimized for achieving higher CO conversions and olefin selectivities. The selectivity to C₂–C₄ olefins is further enhanced by optimizing the reaction temperature in the second reactor (cracking), where the product exhibited 51% selectivity to C₂–C₄ hydrocarbons rich in olefins (77%) with a stable time-on-stream performance in a studied period of 100 h.     

Epoxidation of propylene by air over modified silver catalyst

Epoxidation of C₃H₆ to C₃H₆O by air was studied over a silver catalyst modified with alkali or alkaline earth chloride salts. The catalyst preparation factors and the operational conditions could affect obviously the catalytic epoxidation property of the silver catalyst. It was shown that, as a promoter of the silver catalyst, NaCl or BaCl₂ is more suitable than LiCl or NH₄Cl. The loading of NaCl should be controlled at about 3.8 wt%. Using a feed gas of 10% C₃H₆/air at a space velocity of 1.75×10⁴ h⁻¹, 18.6% C₃H₆ conversion and 33.4% selectivity to C₃H₆O were obtained at 350°C. Using a feed gas of 5% C₃H₆/air at a space velocity of 2.4×10⁴ h⁻¹, 54.0% C₃H₆ conversion and 26.3% selectivity to C₃H₆O were obtained at 390°C. This revised version was published online in July 2006 with corrections to the Cover Date.     

Carbon Monoxide Hydrogenation over Zirconia Supported Ni and Co-Ni Bimetallic Catalysts

Zirconia supported nickel and cobalt-nickel bimetallic catalysts were prepared and characterized for various physico-chemical properties. The hydrogenation of carbon monoxide was studied over these catalysts in the pressure range of 101.3–1654kPa, temperature range of 513–533K, weight hourly space velocity range of 8–14h^–1 and H2/CO mole ratio of 2. Catalysts containing both Co and Ni were found to give higher C₅₊ hydrocarbons selectivity compared to that containing only Ni. A maximum C₅₊ hydrocarbons selectivity of 55wt% was obtained at 655kPa pressure, 523K and 9.6h^–1 of WHSV with catalyst containing 4.03wt% Co and 2.64wt% Ni. The C₂ and C₃ olefin contents of the products decreased with increase in pressure. Improved deactivation behavior of the catalysts was observed when operated at high pressure.     

K/LaFeMnO3 Perovskite-Type Oxide Catalyst for the Production of C2–C4 Olefins via CO Hydrogenation

LaBO₃ (B?=?Fe, Mn, and FeMn) perovskite-type oxides were prepared by sol–gel method and then used as catalysts in CO hydrogenation for light olefins. The catalysts were characterized using XRD, H₂-TPR, SEM, CO (CO₂)-TPD, and XPS. The results showed that the lattice oxygen migration and oxygen vacancies promoted oxygen mobility by doping Mn²⁺ at the B site, Moreover, the presence of manganese as a promoter in the catalyst increased olefin selectivity compared with the olefin selectivity of the catalyst containing iron at the B-site and exhibited resistance to carbon deposition; while reducing the metal elements. In CO hydrogenation, potassium-promoted LaFeMnO₃ catalysts afforded high catalytic activity and C₂⁼–C₄⁼ selectivity. An O/P value of 5.0 and a C₂⁼–C₄⁼ fraction of 54% were achieved for all hydrocarbons with low methane selectivity.

Graphic Abstract