Bioenergy systems for the future 7 catalysts for conversion of synthesis gas Bioenergy systems for the future 7 catalysts for conversion of synthesis gas Bioenergy systems for the future 7 catalysts for conversion of synthesis gas Bioenergy systems for the future 7 catalysts for conversion of synthesis gas Bioenergy systems for the future 7 catalysts for conversion of synthesis gas Bioenergy systems for the future 7 catalysts for conversion of synthesis gas
Catalysts for conversion of synthesis gas V Palma, C Ruocco, M Martino, E Meloni, A Ricca University of Salerno, Salerno, Italy Nomenclature BTL CTL CNT CSTR DME DMT FT FTS GHSV GTL GNS HTFTS HTS LTFTS LTS MMA MMT MTBE MTO MTP NCNT NP NW-FS O/P OCNT PEMFC PROX PSA RWGS biomass to liquid coal to liquid carbon nanotubes continuous stirred tank reactor dimethyl ether dimethyl terephthalate Fischer-Tropsch Fischer-Tropsch synthesis gas hourly space velocity gas to liquid graphene nanosheets high-temperature Fischer-Tropsch synthesis high-temperature shift (or high-temperature water-gas shift) low-temperature Fischer-Tropsch synthesis low-temperature shift (or low-temperature water-gas shift) methyl methacrylate million metric tons methyl tert-butyl ether methanol to olefin methanol to paraffin nitrogen-functionalized carbon nanotube narrow pore nanowires olefins/paraffins oxygen-functionalized carbon nanotube proton exchange membrane fuel cell preferential oxidation pressure swing adsorption reverse water-gas shift Bioenergy Systems for the Future http://dx.doi.org/10.1016/B978-0-08-101031-0.00007-7 © 2017 Elsevier Ltd All rights reserved 218 Bioenergy Systems for the Future SSA STP WGS WP 7.1 specific surface area standard temperature and pressure water-gas shift wide pore Introduction The synthesis gas (or simply syngas) is the reaction product of several transformation processes (Fig 7.1) such as reforming processes (Ghoneim et al., 2015), partial oxidation (Christian Enger et al., 2008) and gasification (Mahinpey and Gomez, 2016); the chemical composition of syngas depends on the raw materials and the production process used (Couto et al., 2013), however the main components are carbon oxides (CO and CO2) and hydrogen (H2) Syngas is recognized as the most suitable raw material for manufacturing a wide range of chemicals and fuels and is therefore involved in several catalytic processes (Fig 7.1) The wide use of the syngas, in recent decades, has been favored by the low cost of fossil sources; however, the increasingly severe restrictions on CO2 emissions, the growing worry of public opinion on climate changes, and the spread of alarming data on the reserves of crude oil have pushed the interest toward the use of alternative sources The best alternative to the fossil fuels are the biomass, renewable materials that contain considerable quantities of carbon, hydrogen, and oxygen, restorable by photosynthetic reaction (Maschio et al., 1994) Certainly, there are many disadvantages in using biomass with respect the fossil fuel, the presence of contaminants, a variable hydrogen to carbon ratio due to the composition of the sources, a low energy density and high costs make them uncompetitive; however, nowadays, there are no other real alternatives Theoretically, all biological materials (both animal and vegetable) represent a biomass; however, only cheap materials and wastes are conveniently converted into syngas, and wastes from wood processing, energy crops, agricultural residues, by-products from processing of biological materials, municipal and sludge wastes, and food industry wastes are normally used as raw materials for the syngas Methanol synthesis Raw materials (natural gas, coal, biomass) Ammonia synthesis, other processes Syngas Fisher Tropsch process (synthetic fuels) Fig 7.1 Syngas—production and transformation Catalysts for conversion of synthesis gas 219 production There exist two processes for converting the biomass in biofuel and biopower, the fermentation that produces mainly ethanol (biogas) and the thermochemical conversion to syngas The variability of the sources requires a flexibility in processing steps; however, the most of biomass contain a significant amount of water, so a preliminary drying process is commonly performed before going to the conversion processes; alternatively, a hydrothermal processing directly degrades the biomass (Tekin et al., 2014); similarly, the product gas stream, from thermochemical process (pyrolysis, combustion, and gasification), contains many unwanted by-products to be removed before going to next process (Kumar et al., 2009): l l l l l Particulate, removed according to the size by cyclone separators, wet scrubbers, electrostatic precipitators, and barrier filters Alkali compounds, removed by barrier filters (Turn et al., 2001) Nitrogen compounds, removed at high temperature with dolomites, Ni-based catalysts and Fe-based catalysts (Lepp€alahti and Koljonen, 1995) Sulfur compounds, removed by limestone, dolomite or calcium oxide Tar compounds, removed directly in the gasifier with the use of specific catalysts (Han and Kim, 2008) or alternatively in a separate reactor The fate of the syngas depends on the process in which it is involved and the desired final product (Fig 7.1); this chapter wants to provide a general overview on the primary catalytic systems involved in the most widespread conversion processes of the syngas, focusing on the results of the latest research The main process is the methanol synthesis that produces one of the most flexible chemical commodities and energy sources (Ajay et al., 2014) Methanol is used as feedstock in synthesis of formaldehyde and acetic acid; additives in adhesive, foams, plywood subfloors, and windshield washer; methyl tert-butyl ether (MTBE), a gasoline component; and dimethyl ether (DME), a clean-burning fuel Methanol is also used as additive into gasoline or as vehicle fuel itself The Fischer-Tropsch process (FT) converts the syngas into a mixture of products refined to synthetic fuels, lubricants, and petrochemicals (de Klerk, 2000); depending from the sources, the overall process, from the raw material to the final product, is named GTL (gas to liquid), CTL (coal to liquid), or BTL (biomass to liquid) (van de Loosdrecht and Niemantsverdriet, 2013) The Haber-Bosch process (Haber, 2002) allows to obtain ammonia by reacting nitrogen with pure hydrogen, usually obtained from syngas by removal of carbon monoxide with the water-gas shift reaction (Palma et al., 2016) eventually coupled with methanation (R€ onsch et al., 2016), preferential oxidation or by a hydrogen permselective membrane reactor (Piemonte et al., 2010), and CO2 sequestration Ammonia is an important commodity for the fertilizers industry, is the precursor of urea and ammonium salts (nitrates and phosphates), of the nitric acid and polyamides The carbonylation processes allow to introduce the carbonyl group (CO) into organic or inorganic substrate, by reacting with pure carbon monoxide, obtained from syngas by reverse water-gas shift reaction (De Falco et al., 2013) Interesting examples of carbonylation are the Monsanto process (Paulik and Roth, 1968), that allows to prepare the acetic acid by carbonylation of methanol and, the Mond process for the extraction and purification of Nickel (Mond et al., 1890) 220 7.2 Bioenergy Systems for the Future Fischer-Tropsch synthesis The Fischer-Tropsch synthesis (FTS) is an important catalytic process used for the conversion of syngas (derived from coal, natural gas, biomass, or other carboncontaining species) to hydrocarbons with different chain lengths The product selectivity is strongly dependent on temperature, pressure, and catalyst choice (Ghareghashi et al., 2013) Generally, low-temperature FTS is carried out over Co-based catalyst in the temperature interval of 190–250°C and at 20–40 bar yielding products with high average molecular weight (middle distillates and waxes) Conversely, iron-catalyzed process are driven at 340°C and 20 bar, with the aim of obtaining short-chain hydrocarbons (fuels and petrochemicals) (Delparish and Avci, 2016; Shin et al., 2013) In order to face the reaction exothermicity and avoid hot spots or rapid catalyst deactivation, multitubular fixed bed, with external cooling (for LTFTS), and slurry bubble column reactors (for HTFTS) are commercially selected for the FTS process (Park et al., 2011) In the first case, considerable fraction of the liquid reaction products has to be recycled to the reactor to remove the reaction enthalpy, thus increasing pressure drops and making the reactor trickier to be operated and less flexible to be scaled On the other hand, in slurry reactors, the temperature is uniform and pressure drops are low, being related to the hydrostatic pressure of liquid, and the internal mass transfer limitations are ruled out by loading the catalyst as fine powder However, high aspect ratios (reactor height/diameter) and staging have to be used to limit back-mixing phenomena Also, particular attention has to be paid, especially during the size-scaling processes, both to the prevention of the catalyst attrition and to the design of an efficient tool for the separation of the catalyst from the liquid (Visconti et al., 2011) In addition, during FT synthesis, even though the reactants are in the gas phase, the pores of the catalyst are filled with liquid products, and the diffusion rates in the liquid phase are typically three orders of magnitude slower than in the gas phase; the increasing transport limitations may result in CO depletion and lower C5 + selectivity In a fixed-bed reactor, the selectivity problem can be solved by using catalyst pellets where the catalytic material is deposited in a thin outer layer (eggshell catalysts), while in a slurry reactor, the selectivity issue is faced by using small catalyst particles (Liu et al., 2009) However, in the attempt of overcoming the drawbacks of commercially available technologies for FT synthesis, different technologies including the adoption of structured fixed-bed reactors, based on honeycomb monolith foams, knitted wires, or cross flow structures, and microchannel reactors have been recently proposed (Pangarkar et al., 2009; Twigg and Richardson, 2002; Cao et al., 2009) For example, monolithic catalysts assure low pressure drop, high gas-liquid mass transfer rates in two-phase flow, the possibility of using high liquid and gas throughputs, and a good temperature control (Kapteijn et al., 2005; Hilmen et al., 2001) For intensification of mass transfer between synthesis gas, liquid products and solid catalysts, alternative catalyst geometries like honeycombs, structured packings, and foams have also been developed (Guettel et al., 2008a) All group VII metals have noticeable activity for the hydrogenation of carbon monoxide to hydrocarbons However, only ruthenium, iron, cobalt, and nickel have Catalysts for conversion of synthesis gas 221 catalytic characteristics that allow considering them for commercial production However, nickel catalysts, under practical conditions, produce too much methane; moreover, ruthenium is too expensive, and its worldwide reserves are insufficient (Khodakov et al., 2007) Cobalt and iron were proposed as the first catalyst by Fischer and Tropsch Fe-based catalysts, despite being less expensive than Co ones ( Jin and Datye, 2000; van Berge et al., 2000), strongly suffer for deactivation by coke and promote H2O formation by water-gas shift reaction (WGS) Sulfur content lower than 0.2 and 0.1 ppm are mandatory for normal operation of Fe- and Co-based catalysts, respectively (Khodakov et al., 2007) Co catalysts are generally more resistant to attrition and are widely preferred for use in slurry-type reactors Despite the industrialscale development of FTS process, the activity and stability of the catalyst need to be improved At that hand, the addition of suitable promoters and the selection of proper supports provide a reasonable route for the enhancement of FTS catalyst performances In the following sections, the performances of Co- and Fe-based catalysts were reviewed and discussed 7.2.1 Co-based catalysts Al2O3, despite having lower surface area than SiO2 and TiO2, is commonly used as support material for Co due to the strong metal-oxide interactions, its good mechanical performances, and resistance to attrition (de la Osa et al., 2011; Prieto et al., 2009) On the other hand, when Al2O3 is selected as support, it is mandatory to avoid the formation of hardly reducible cobalt aluminates that are responsible for activity reduction ( Jongsomjit et al., 2001) Iglesia et al (Iglesia, 1997) found that for large cobalt particles supported on Al2O3, SiO2, and TiO2, the FT reaction rate depends on the number of available cobalt surface atoms and that hydrocarbon selectivity is only slightly affected by cobalt dispersion A different phenomenon is observed for small cobalt particles, having a strong impact on product selectivity: Particle size in the range ˚ improves olefinic products yields, while for smaller dimensions, C5 + selec60–80 A tivity also decreased (Khodakov, 2009) The synthesis of Co-based catalysts supported on alumina nanofibers was shown to assure a homogenous metal particle-size distribution After catalyst ultrasonication, more active cobalt particles were generated, which marked improved C5 + selectivity lowering methane production In addition, even at high reaction temperature and under much higher CO conversion (79%), a quite stable activity was observed at 230°C, 20 bar, and H2/CO ¼ over 300 h of reaction (Liu et al., 2016) Flame spray pyrolysis technique was also successfully employed for controlling catalytically active Co particles deposition on Al2O3: a good catalytic activity was recorded at the above operative conditions (Minnermann et al., 2013) Conversely, for Co/γ-Al2O3 catalysts, it was shown that partial pores prefilling by incipient wetness impregnation of Al(NO3)3 resulted in catalyst similar to the eggshell systems ( Jacobs et al., 2016), which are able to decrease C1–C4 light gas selectivity, improving, at the same time, C5 + selectivity Due to the need of limiting pressure drop and the consequent necessity of adopting “big” catalyst pellets, low-temperature Fischer-Tropsch synthesis in industrial fixedbed reactors may suffer of strong intraparticle mass transport limitations, which are 222 Bioenergy Systems for the Future known to result in decreased CO conversion rate and C5 + selectivity Upon decoupling the pellet diameter and the diffusive length, eggshell catalysts represent an engineering solution for the intensification of the Fischer-Tropsch reactors In this regard, Fratalocchi et al (Fratalocchi et al., 2015) showed that 600 μm pellets, with catalytically active layers, 75 μm thick, grant a remarkable combination of high CO conversion rate and high C5 + selectivity at 220–240°C, 25 bar, and H2/CO ratio of 1.73, thus resulting extremely interesting for operations in reactors 3–6 m long Concerning the impact of cobalt aluminate formation on catalyst activity, Moodley et al (Moodley et al., 2011) found an enhancement of aluminate content with water partial pressure during FTS at 230°C, 10 bar, and H2/CO ¼ 1.5 The presence of water is also regarded as one of the main causes of catalyst sintering during Fischer-Tropsch process (Bezemer et al., 2010) Sintering mechanism for Co/Al2O3 catalysts in slurry reactors was accelerated by the formation of intermediate surface cobalt-oxide species, and the deactivation was favored by increasing H2/CO ratios in syngas or by the presence of even small amounts of water (Sadeqzadeh et al., 2013) Beside sintering and aluminates formation, the activity drop commonly observed over FTS catalyst is related to the deposition of carbonaceous species on catalyst surface The research of Pena et al (Pen˜a et al., 2014) was focused on the identification of the molecular structure of carbon species formed over a Co/Al2O3 catalyst in a slurry reactor Carbon adsorbed on spent catalyst was mainly constituted by α-olefins, n-paraffins, branched alkanes/alkanes, aldehydes, and ketones, while carboxylic acids were mostly detected at high water partial pressures In particular, the increase in CO conversion enhanced the isomerization of α-olefins favoring the formation of branched alkanes/alkanes Carbon species are probably nucleated on the cobalt particles and then migrate to alumina support and coke localized on the support showed high reluctance toward hydrogenation The addition of promoters to Co/Al2O3 catalysts was shown on one hand, to prevent Co-aluminate formation due to establishment of an intimate contact with the metal (Nabaho et al., 2016a) and, on the other hand, to limit catalyst deactivation Park et al (Park et al., 2012) investigated the impact of phosphorous addition to Co/Al2O3 catalyst on deactivation induced by lumps formation in the presence of water γ-Al2O3, due to its hydrophilic properties, can undergo phase transformation to pseudoboehmite (with low attrition resistance) in the presence of water vapor produced during FT reaction, forming fragmented fine catalyst powder The deposition of heavy hydrocarbons on these fragments causes the formation of aggregate catalyst lumps Conversely, phosphorous addition is able to suppress alumina hydrophilic properties and reduce heavy hydrocarbon deposition on catalyst, thus preventing its deactivation (Fig 7.2) It was also reported (Tan et al., 2011) that the deposition of small boron quantities on Co/γ-Al2O3 catalyst can hinder the deposition, nucleation, and growth of resilient coke on catalyst surface, without affecting initial activity and selectivity at 240°C and 20 bar The addition of noble metal promoters (Pd, Pt, Re, and Ru) was shown to improve activity and stability of Co/Al2O3 catalysts (Ma et al., 2012) Improved CO conversion was observed at 220°C, 22 bar, and H2/CO ¼ over the promoted catalysts, with Pt and Pd enhancing oxygenate formation and Re and Ru slightly decreasing it At fixed Catalysts for conversion of synthesis gas 223 Phosphorous—unmodified catalyst Large phase transform γ-Al2O3 in boehmite Partial hydration responsible of fine powder Emulsion of water and hydrocarbons Catalyst particles Aggregated catalyst lump (co-presence of water and hydrocarbons) Liquid medium Phosphorous—modified catalyst Small phase transform γ-Al2O3 in boehmite Emulsion of water and hydrocarbons Catalyst particles Liquid medium No formation of aggregated catalysts Fig 7.2 Proposed mechanism for Co/Al2O3 catalyst deactivation in a slurry-phase reactor CO conversion (50%), Re and Ru improved CH4 and C5 + selectivity, whereas the opposite effect was observed for Pt and Pd promoters The latter metals also increased 2-C4 olefins selectivity and WGS activity of the final catalyst On the other hand, Pt addition had a negligible effect on C4 olefin isomerization Concerning Co catalysts supported on Al2O3 or SiO2 prepared via plasma technology (Chu et al., 2015), the promotion by noble metals was shown to improve both cobalt dispersion and reducibility, thus enhancing the FT reaction activity Other porous supports (including SiO2, TiO2, activated carbon, and zeolite) are usually selected for commercial Co-based catalysts (Lu et al., 2015; Shi et al., 2012; Eschemann et al., 2015) However, the combination of two types of oxides was found to improve the pore structure, cobalt dispersion, and reducibility The effect of alumina incorporation (0–3 wt%) into a Co/SiO2 catalysts on product gas distribution was investigated by Savost’yanov et al (2017) Trace of alcohols and olefins were only detected over the undoped catalyst and their content increase with alumina loading (Table 7.1) Over the wt% sample, the molecular weight distribution became narrower, increasing the C8–C25 fraction A further reduction of SiO2/Al2O3 ratio caused the opposite effect Combustion synthesis method was employed for the preparation of Co/SiO2 and Co/SiO2-Al2O3 catalysts, and a strong impact of preparation method on product gas distribution was observed (Ail and Dasappa, 2016): the innovative catalyst increased the yield to C6 + products at 230°C, 30 bar, and H2/CO ¼ 2.3, resulting in the formation of long-chain hydrocarbons waxes (C24+) with respect to the middle distillates (C10–C20), normally generated over impregnated catalysts However, the overall C6 + yield was further increased by Al2O3 addition, due to the marked improvement (48%) in cobalt dispersion promoted by alumina Venezia et al (Venezia et al., 2012) modified SiO2 support by TiO2 grafting and observed an improvement in C5 + selectivity especially at high space velocities 224 Bioenergy Systems for the Future C5+ product distribution in the FTS over Co/SiO2-Al2O3 catalysts at 210°C, 20 bar, and H2/CO ratio of (Savost’yanov et al., 2017) Table 7.1 Product distribution (wt%) Paraffins Olefins Alcohols Al2O3 content (wt%) C5–C18 C19–C35 C35+ C5–C18 C5–C18 49.6 54.9 48.1 47.6 42.1 37.5 2.4 2.3 2.2 0.4 0.7 10.1 0.04 0.07 1.2 (GHSV ¼ 7200 hÀ1 at 210°C, 20 bar, and H2/CO ¼ 2) In addition, CoO oxide interaction with the doped support was enhanced, avoiding the particle mobility that can lead to catalyst deactivation by sintering A bimodal ZrO2-SiO2 support was selected for jet fuel direct synthesis via FTS reaction with different 1-olefins as additives (Li et al., 2016a) Olefins cofeeding effectively shifted the product distribution toward jet fuel range, markedly suppressing CH4, CO2, and light hydrocarbons (C2–C4) formation The large pores of the bimodal support, in fact, provided efficient pathways for reactants conversion and products diffusion, while the newly formed small pores assured high metal dispersion Rare-earth oxides, able to remarkably enhance catalyst reducibility, were shown to be beneficial for improving long-chain hydrocarbons selectivity (Spadaro et al., 2005) CeO2 addition (5 and 10 wt%) to Co/ZrO2 catalysts promoted the formation of larger cobalt particles, inhibiting water reoxidation and Co particles aggregation during the reaction and resulting in a better resistance toward deactivation (Zhang et al., 2016a) Fig 7.3 displays CO conversion with time onstream for doped and undoped catalysts: CeO2-modified samples assured a good stability during 100 h of reaction However, the deactivation rate was affected by the amount of ceria added However, a rapid deactivation was observed in the initial stage of the reaction over the 10 wt% catalysts, caused by the initial smaller pores that were filled by the liquid waxes produced during the FTS synthesis Carbon materials, including activated carbon, carbon nanotubes and nanofibers, carbon spheres, and mesoporous carbon, are also reported as catalytic support for Co, due to their several benefits with respect to the conventional oxides supports: these materials display high purity, high mechanical strength and thermal stability, and large surface area (Fu and Li, 2015) Moreover, having a hardly reducible surface, Co particle reducibility can be improved Carbon porous structure can also be properly controlled in order to promote the cobalt dispersion (Ha et al., 2013) Dı´az et al (2013) carried out FT reaction over Co catalysts supported on carbon nanofibers prepared at three different calcination temperatures (750°C, 600°C, and 450°C, denoted as Samples 1, 2, and 3, respectively) At 250°C, 20 bar, and H2/CO ratio of 2, the Samples and 2, having a medium pore radius, displayed high catalytic activity without Catalysts for conversion of synthesis gas 225 Fig 7.3 CO conversion with time onstream over Co/ZrO2 (dotted line), Co/(5)CeO2-ZrO2 (dash-dotted line), and Co/(10) CeO2-ZrO2 (dashed line); 220°C, 20 bar, and H2/CO ¼ CO conversion (%) 100 80 60 40 20 0 10 20 30 40 50 60 70 Time-on-stream (h) 80 90 100 deactivation; however, the promotion of WGS and methanation reaction led to significant CO2 and CH4 production The Sample 3, which was less active and suffered from deactivation, showed an improvement in C5 + selectivity Metal sintering was observed over all the catalysts and, especially, over the Sample 3, due to its lower structural order with respect to the other two catalysts The performances of Co-based catalysts supported on carbon nanotubes (CNT) and graphene nanosheets (GNS) for FT reaction at 220°C, 18 atm, and H2/CO ¼ were compared in order to evaluate the effect of morphology and structure on catalyst stability (Karimi et al., 2015) The difference, in terms of SSA (Table 7.2), between the bare GNS and CNT can be attributed to the nature and textural properties of graphene nanosheets Higher porosity was also observed over the GNS samples, which can be related to the interlayer spacing of them After 480 h of reaction, a specific area reduction of 20% and 3%, respectively, for the CNT and GNS catalysts, was observed Moreover, the extent of pore blockage for the CNT catalyst is higher than that of the GNS sample, as a consequence of its higher rates of sintering and clusters growth During stability tests, dCo Specific surface areas (SSA), porous volume (Vp), and cobalt average crystallite sizes (dCO) for Co/CNT and Co/GNS catalysts (Karimi et al., 2015) Table 7.2 Sample SSA (m2/g) Vp (cm3/g) dCo (nm) CNT Fresh Co/CNT Used Co/CNT GNS Fresh Co/GNS Used Co/GNS 497 372 298 848 602 586 1.034 0.765 0.428 2.2 1.46 1.23 — 8.6 10.08 — 7.8 8.8 226 Bioenergy Systems for the Future increased for both the catalysts; however, a more significant crystal growth was recorded over the Co/CNT catalyst The latter sample displayed a drop of activity of 15.8% in the first 120 h of reaction, while in the remaining period, it only drops of 4.9% Conversely, due to the lower extent of sintering phenomena and GNS hydrophilic properties that limit water deposition and cobalt reoxidation, only a conversion reduction of about 2.7% in the first period and 1.2% between 120 and 480 h was observed over the Co/CNT catalyst The relationship between C5 + selectivity and metal particle sizes for Co catalysts supported on carbon nanotubes and spheres was also studied (Xiong et al., 2011) In order to limit water effect, measurements were carried out at a low CO conversion (4%) The change in C5 + selectivity with particle sizes (Fig 7.4) can be explained considering that large Co particles promote the formation of bridge-type adsorbed CO, more active and more easily dissociated, which enhanced the chain growth and C5 + selectivity Co supported over spheres, however, displayed slightly higher C5 + selectivity for a similar sized particle In fact, over nonporous carbon spheres, all cobalt particles are dispersed on the outer surface of the support Therefore, the hydrogen concentration around the active cobalt particles is the same as that in the reactor, thus leading to less light hydrocarbon production Chernyak et al (2016) investigated the effect of oxidation time (1–15 h) selected during Co supported over carbon nanotubes preparation on their performances for FT synthesis at 190°C, atmospheric pressure, and H2/CO ¼ The sample oxidized for h displayed the highest CO conversion and yield to C5+ products Selectivity to heavy hydrocarbons is almost the same over the catalyst treated for 3, 9, and 15 h while increased over the sample oxidized for h Syngas mixture, especially when produced from coal or biomass, can be CO2rich, and carbon dioxide can significantly affect FT activity Dı´az et al (2014) studied the effect of CO2 cofeeding on the catalytic performances of a Co catalyst supported over carbon nanofibers at 220–250°C, 20 bar, and H2/CO ¼ Increasing temperatures assure higher catalytic activity and the rate of undesired reactions (WGS and methanation) However, once reaction temperature was fixed at 250°C, 100 99 C5+ selectivity (%) Fig 7.4 Influence on Co particle size on C5 + selectivity over Co/ carbon nanotubes (square) and spheres (triangle); 225°C, bar, and CO/H2 ratio of 0.5 98 97 96 95 94 93 92 10 15 20 25 30 35 40 Cobalt particle size (nm) 45 50 Catalysts for conversion of synthesis gas 263 nonnoble-based catalysts used for WGS application, Cu/ZnO/Al2O3 is still considered the best formulation The two-stage process configuration is extremely profitable, because it allows to reach the 99.5% and over of CO conversion; however, it has major drawbacks that result in excessive operative and plants costs; the realization of a single-stage process would therefore be a notable process intensification In this context, the development of highly active catalysts in a temperature range intermediate with respect the conventional two stages is highly wanted The best candidate for these purposes are the noble metal-based catalysts (Grenoble et al., 1981), that show high conversion in a wide range of temperature, even in low concentration, and are compatible with fuel processor systems Gold catalysts (Yang et al., 2013) are really highly active but suffer of rapid deactivation, due to the sintering phenomena, and the preparative methods are extremely complex Similar consideration makes the use of rhodium (Cornaglia et al., 2012) not adequate for WGS applications; much more stable are the platinum-based catalysts (Palma et al., 2014), supported ceria, or ceria-/zirconiamixed oxide (Palma et al., 2015) Despite the excellent performance of the noble-metal-based catalysts, none of the described formulations is able to support a real single-stage process; recently, the development of highly thermal conductive structured catalysts, coupled with highly active catalytic systems, seems to be the best alternative to realize a single-stage WGS process (van Dijk et al., 2010) The use of highly thermal conductive carriers allows to flatten the thermal profile by back diffusion over the bed (Fig 7.15), increasing the temperature at the inlet and decreasing the temperature at the outlet, with a consequent increase of the CO conversion (Palma et al., 2016) 100% 95% Co conversion 90% 85% 80% 75% ΔT-HTS ΔT-LTS ΔT-single stage Equilibrium 70% T [K] Fig 7.15 Schematic representation of two-stage and single-stage WGS processes 264 Bioenergy Systems for the Future The total CO conversion in WGS process is, to the best, the 99.8%; unfortunately, for the most applications, the maximum CO content permitted in hydrogen is in the order of few parts per million (ppm), for example, in polymer electrolyte membrane fuel cell (PEMFC) applications (Garcia et al., 2008), so the purity obtained with the WGS process is totally unsatisfactory; a further purification step is required 7.5.2 Preferential oxidation (PROX) Preferential oxidation is one of the catalytic processes that allow to remove small amounts of CO to reach parts per million (ppm) levels form hydrogen-rich streams (Liu et al., 2012b), by selective oxidation of carbon monoxide It is normally performed in temperature range intermediate between the LTS and the maximum operative temperature of the PEM-FC (80–180°C): CO + 1=2O2 ! CO2 Δo298K ¼ À283 kJ=mol (7.13) Hydrogen combustion may also occur as side reaction, so a highly selective catalyst is therefore required The first selective PROX catalysts were patented in the 1960s and were based on rhodium or ruthenium supported on alumina (Cohn Johann, 1965), however, all the platinum group metals are active A comparative study between the noble metals (Pt, Pd, Rh, and Ru) and base metals (Co/Cu, Ni/Co/Fe, Ag, Cr, Fe, and Mn) has identified both Ru/Al2O3 and Rh/Al2O3 as the most active catalysts in selective CO oxidation, with hydrogen-rich fuel cell feedstreams, providing almost complete conversion from 100°C up (Oh and Sinkevitch, 1993) Interesting results were obtained with bimetallic systems, the Pt-Ru/mordenite catalysts showed superior performance with respect the corresponding monometallic counterparts at 150°C (Hiroshi et al., 2000); however, at higher temperature and with silica as support, the ruthenium derivate provided the best activity (Chin et al., 2006) A promotion effect was obtained also with iron; the Pt-Fe/mordenite system showed an extremely superior performance with respect to the Pt/mordenite catalyst, at various experimental conditions (Watanabe et al., 2003) 7.5.3 Methanation The alternative to PROX, in reducing to ppm the CO content in hydrogen, is the methanation; this reaction consumes three moles of hydrogen for each mole of carbon monoxide, so it is effectively usable only when the carbon monoxide to be removed is really exiguous: CO + 3H2 >CH4 + H2 O Δo298K ¼ + 206 kJ=mol (7.14) Comparative studies between various metals (Fe, Co, Ni, Pd, Pt, and Ru) and various supports (ZrO2, TiO2, SiO2, Al2O3, and MgO) have showed that the Ni/ZrO2 and Ru/TiO2 are effective catalysts for the complete removal of carbon monoxide in hydrogen-rich gas stream, in the presence of 25 vol% of CO2 (Takenaka et al., 2004), identifying the nickel as the most cost effective choice Catalysts for conversion of synthesis gas 7.5.4 265 Reverse water gas shift (rWGS) The reverse water-gas shift reaction is the inverse reaction of WGS, it produces carbon monoxide and water by reacting carbon dioxide and hydrogen, while the equilibrium conversion increases with temperature (Daza and Kuhn, 2016) The RWGS is used to regulate the H2/CO ratio in the syngas, to produce pure carbon monoxide and is involved in the methanol synthesis To obtain a good conversion, the operative temperatures are high, however, to shift the equilibrium toward the products, it is possible to recycle the CO2 excess, increase the concentration of the reactant, or remove the vapor by desiccant bed or by permselective membrane to water (Centi and Perathoner, 2009) Except for the Fe-Cr-based catalysts that are active above 400°C, the most studied catalytic systems are Cu, Pt, and Rh, supported on various oxides; the Cu/Zn/Al2O3 catalysts showed the best performance in the temperature range 200–350°C (Tanaka et al., 2003b); the Pt/CeO2 catalysts are active for 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