Thin-Film Catalysis Innovations in Fischer–Tropsch Synthesis for Enhanced Activity

Kunene A, Wei Y, van Steen E, Raza MH, El Arrouji I, Jimenez CE, Félix R, Toebbens DM, Malik AS, Padayachee V, De Oliveira D, Fadlalla MI, Bär M, Calnan S, Claeys M, Schlatmann R, Amkreutz D (2025)

Publication Type: Journal article

Publication year: 2025

Journal

Industrial & Engineering Chemistry Research American Chemical Society (ACS)

Book Volume: 64

Pages Range: 22939-22948

Journal Issue: 48

DOI: 10.1021/acs.iecr.5c02728

Abstract

For 100 years, Fischer–Tropsch synthesis (FTS) technology has been underpinned by cobalt- and iron-based powder catalyst systems. Nevertheless, due to cost efficiency and lower material requirements, thin-film cobalt catalysts are currently being evaluated as an alternative to traditional powder catalysts. In this study, we explore the catalytic performance of the Co-SiOx/Al thin-film catalyst under relevant FTS conditions. Thus, the cobalt active metal is deposited onto the aluminum foil substrate by magnetron sputtering. To avoid alloy formation between the cobalt and aluminum foil, the cobalt layer is supported by a SiOxbuffer layer deposited by plasma-enhanced chemical vapor deposition (PECVD). To evaluate the catalyst, the reduction of the cobalt moiety was assessed using in situ synchrotron grazing incident X-ray diffraction (GI-XRD) conducted at beamline KMC-2 at the BESSY II Light Source under flowing H2at 350 °C. Ultimately, the prepared thin film catalyst is tested for FTS at a total flow rate (H2/CO = 2:1) of 40, 20, and 5 sccm under relevant FTS conditions. CO conversion levels of 0.9, 1.2, and 2.7% were achieved at 40, 20, and 5 sccm, respectively. The observed low CO conversion levels are ascribed to low cobalt loadings of the thin-film catalyst. Upon considering the cobalt loading, the corresponding rates of CO consumption (−rCO) of 23, 40, and 61 gCO/gCo/h were obtained at 40, 20, and 5 sccm, respectively. This highlights that the Co-SiOx/Al thin-film catalyst performance is comparable and, in other cases, outperforms unpromoted Co-based powder catalysts.

Authors with CRIS profile

Marcus Bär

Involved external institutions

Helmholtz-Zentrum Berlin für Materialien und Energie (HZB) DE Germany (DE) University of Cape Town (UCT) ZA South Africa (ZA)

How to cite

APA:

Kunene, A., Wei, Y., van Steen, E., Raza, M.H., El Arrouji, I., Jimenez, C.E.,... Amkreutz, D. (2025). Thin-Film Catalysis Innovations in Fischer–Tropsch Synthesis for Enhanced Activity. Industrial & Engineering Chemistry Research, 64(48), 22939-22948. https://doi.org/10.1021/acs.iecr.5c02728

MLA:

Kunene, Avela, et al. "Thin-Film Catalysis Innovations in Fischer–Tropsch Synthesis for Enhanced Activity." Industrial & Engineering Chemistry Research 64.48 (2025): 22939-22948.

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