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Fischer-Tropsch synthesis

This process transforms synthesis gas, a mixture of carbon monoxide and hydrogen, into a mixture of liquid hydrocarbons, also known as syncrude. It is the key-step in the so called BTL, CTL and GTL technologies, aimed at converting biomasses, coal and natural gas into high performance fuels and chemicals.The Fischer-Tropsch synthesis usually comes downstream a gasification process, aiming at converting the carbon-source into syngas, and may be followed by a series of hydrotreating processes for upgrading the syncrude.
Cobalt and iron based catalysts can be used for the Fischer-Tropsch synthesis. Cobalt is particularly suitable for the conversion of the H2-rich syngas usually obtained from natural gas. Iron is usually selected for the conversion of the H2-deficient mixtures obtained from the gasification of coal and biomasses.
Research activities on this topic have been performed in cooperation with Eni and ENEA.
The activities carried out with Eni (since 1998) have been focused mainly on cobalt based catalysts for GTL applications. From a fundamental point of view, the research has allowed to clarify the mechanism and the detailed molecular kinetics of the complex reaction network, which involves more than 100 different species. Examples of the results can be found in the following papers: Chemical Engineering Science 62 (2007) 5338; Topics in Catalysis 54 (2011) 786. The detailed kinetics obtained within this project has been used by Eni for the development and the operations of the pilot-scale Slurry Bubble Column Reactor for the Fischer-Tropsch synthesis installed at the Sannazzaro de Burgundi refinery (Italy).
From a more applied standpoint, the research has allowed to contribute to the development of the "FTMR-technology", a new reactor configuration for the Fischer-Tropsch synthesis which is at the heart of the Small-Scale GTL technology developed by Eni. Such a technology, claimed in a series of patents applications including WO/2010/130399 and WO/2014/102350, is based on the adoption of externally cooled multitubular reactors loaded with highly conductive honeycomb monoliths. More details on this subject can be found in our paper Chemical Engineering Journal 171 (2011) 1294, which is featured article by the journal "Advances in Engineering" and has been awarded as "Chemical Engineering Journal Top Cited Paper for 2011 and 2012".
Also, the research has been focused on the development of innovative catalysts, with an increased activity and tailored geometries.
The activities carried out with ENEA (since 2011) have been focused mainly on iron based catalysts for CTL applications. The research has allowed to clarify the reactivity of CO2 contained in the synthesis gas. The role of potassium as catalyst promoter has been also investigated, in view of its ability to boost the reactivity of CO2.

Faculties involved in the project are: Pio Forzatti, Luca Lietti, Enrico Tronconi, Carlo Giorgio Visconti