Spray-Dried Iron Fischer−Tropsch Catalysts. 2. Effect of Carburization on Catalyst Attrition Resistance

Abstract

Spray drying has been recently used by this research team in the preparation of Fe Fischer−Tropsch catalysts with higher attrition resistance for use in slurry bubble column reactors. In the first paper in this series, the effects of the type, concentration, and network structure of SiO2 on the attrition resistance of two series of spray-dried Fe catalysts in their calcined state were explored and the dependence of catalyst attrition resistance on catalyst particle density was discussed. As a continuation of our previous effort, the effect of carburization on catalyst attrition resistance was studied and is presented in this paper. After carburization, the majority component of the catalysts, hematite (Fe2O3), was converted to iron carbides, mostly χ-carbide (Fe2C5). Breakage of individual catalyst particles and fines formation, which can be considered as evidence of chemical attrition, was only observed during carburization of the catalyst with low SiO2 concentration <9 wt %. With an increase in the tota...