Active Fischer-Tropsch synthesis Fe-Cu-K/SiO₂ catalysts prepared by autocombustion method without a reduction step

The purpose of this study was to prepare iron-based catalysts supported on silica by autocombustion method for directly using for Fischer–Tropsch synthesis (FTS) without a reduction step. The effect of different citric acid (CA):iron nitrate (N) molar ratios and acid types on the FTS performance of catalysts were investigated. The CA:N molar ratios had an important influence on the formation of iron active phases and FTS activity. The iron carbide (Fe_xC), which is known to be one of the iron active phases, was demonstrated by the X-ray diffraction and X-ray photoelectron spectroscopy. Increasing the CA:N molar ratios up to 0.1 increased CO conversion of catalyst to 86.5%, which was then decreased markedly at higher CA:N molar ratios. An excess of CA resulted in carbon residues covering the catalyst surface and declined FTS activity. The optimal catalyst (CA:N molar ratio = 0.1) achieved the highest CO conversion when compared with other autocombustion catalysts as well as reference catalyst prepared by impregnation method, followed by a reduction step. The autocombustion method had the advantage to synthesize more efficient catalysts without a reduction step. More interestingly, iron-based FTS catalysts need induction duration at the initial stage of FTS reaction even after reduction, because metallic iron species need time to be transformed to Fe_xC. But here, even if without reduction, Fe_xC was formed directly by autocombustion and induction period was eliminated during FTS reaction.