Attrition studies with precipitated iron Fischer-Tropsch catalysts under reaction conditions

Fischer-Tropsch (F-T) synthesis in a slurry bubble column reactor (SBCR) is an attractive route for converting coal- or natural gas-derived synthesis gas into transportation fuels and valuable chemicals. The attrition properties of three precipitated Fe catalysts (100 Fe/3-5 Cu/4-6 K/16-25 SiO ₂) during F-T synthesis in a stirred tank slurry reactor (STSR) were studied. After 295-497 hr of F-T synthesis with these three catalysts in the STSR, the particle size reduction by fracture was moderate, whereas erosion (generation of particles smaller than 10 μm) was small (2.3-2.7%). Precipitated silica, which was used as a binder, provided strong interlocking forces between the primary particles. The silica content of these three catalysts was ∼ 9.5-13.9 wt % of the total catalyst weight. The three precipitated catalysts might be suitable for use in slurry bubble column reactor.