Engineering Cobalt-Based Thin Films for Fischer–Tropsch Synthesis

Raza MH, Kunene A, Steigert A, Skaltsogiannis A, Jiménez CE, Ruske F, Shan Malik A, Schwiddessen R, Mettke JH, Frisch J, Wilks RG, Reichelt E, Bär M, Schlatmann R, Amkreutz D (2026)

Publication Type: Journal article

Publication year: 2026

Journal

Small Wiley-VCH Verlag

DOI: 10.1002/smll.75333

Abstract

We report on the synthesis of cobalt-based thin films via magnetron sputtering at varying conditions, including sputtering pressure, reactive gas composition, substrate temperature, and post-deposition annealing. The produced thin films exhibit diverse morphologies, crystalline phases, and oxidation states, such as metallic cobalt (Co0) and cobalt oxides (CoO and spinel-Co3O4). Two thin-film catalyst architectures, based on Co0 (TFCat1) and CoxOy (TFCat2), on Si/Al2O3/SiO2 support stacks are further developed as analogues of commercial powder-based Fischer–Tropsch synthesis (FTS) catalysts. The phase evolution in both of these model catalyst systems is investigated in situ under FTS-relevant reduction conditions using synchrotron-based grazing-incidence x-ray diffraction. Both catalysts (TFCat1 and TFCat2) were tested for their FTS catalytic performance at comparable operating conditions. A lined-out CO conversion level of ca. 4.6% and 4.9% was obtained for TFCat1 and TFCat2, respectively. These catalysts exhibited distinct steady-state product distributions: TFCat1 showed enhanced selectivity toward kerosene-range hydrocarbons, while TFCat2 produced a wider hydrocarbon distribution extending to C27. Moreover, Cobalt thin-film model catalyst (TFCat1) shows significantly reduced dewetting compared to its oxide counterpart (TFCat2) under FTS operating conditions. The well-defined and easy to tune cobalt-based thin films provide a robust foundation for the rational scale-up of next-generation catalysts.

Authors with CRIS profile

Marcus Bär

Involved external institutions

Helmholtz-Zentrum Berlin für Materialien und Energie (HZB) DE Germany (DE) Fraunhofer-Institut für Keramische Technologien und Systeme (IKTS) DE Germany (DE)

How to cite

APA:

Raza, M.H., Kunene, A., Steigert, A., Skaltsogiannis, A., Jiménez, C.E., Ruske, F.,... Amkreutz, D. (2026). Engineering Cobalt-Based Thin Films for Fischer–Tropsch Synthesis. Small. https://doi.org/10.1002/smll.75333

MLA:

Raza, Muhammad Hamid, et al. "Engineering Cobalt-Based Thin Films for Fischer–Tropsch Synthesis." Small (2026).

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