ACS Catalysis
Research Article
iron has been replaced by nickel or cobalt or, in the tri-metallic
case, 20% by Ni and Co.
conversion levels and markedly changed product distributions
during FTS.
The FTS activity of the catalysts increased in the order Fe ≪
CoFe < NiFe < CoNiFe. Several factors contribute to this
trend. In addition to the larger particle size of the unpromoted
iron catalyst, the degree of carburization is significantly lower
than in the promoted catalysts, as the iron catalyst forms iron
oxide during FTS. In contrast to this, the bi- and tri-metallic
catalysts are almost fully reduced and carbided (Table 3).
Furthermore, Co and Ni exhibit higher intrinsic activity than
iron for CO hydrogenation.96,111
Addition of Co and/or Ni into the ferrite structure via a co-
precipitation method yielded substituted ferrites with crystal-
lite sizes ranging between 4 and 7 nm. The inclusion of the
substituents in the ferrite lattice alters the position (i.e., d-
spacing) of the (3 1 1) reflection, which is the most intense
one. The XRD analysis (Figure 1) shows a slight increase in
the d-spacing upon the introduction of the substitutes: from
2.51 Å for Fe3O4, to 2.52 Å for Co0.3Fe2.7O4 and Ni0.3Fe2.7O4,
and 2.53 Å for the tri-metallic Co0.3Ni0.3Fe2.4O4. The change in
d-spacings is small, in line with the comparable ionic radii of
Fe2+ (0.83 Å), Co2+ (0.82 Å), and Ni2+ (0.78 Å).110
Also, the magnetic measurements in Table 2 indicate that
the incorporation of Ni and Co in the ferrite lattice did occur,
as the measured values for the saturation magnetization of the
ferrite and Co-substituted ferrites were comparable, and both
higher than those of the Ni-containing ferrites, in agreement
with literature values. Fe3O4 and CoFe2O4 are reported to have
similar measured magnetic moments of 4 μB,110 while the
NiFe2O4 measured magnetic moment is 2.3 μB.110 These
values explain the comparable saturation magnetization for
ferrite and the Co-substituted ferrite, and both being higher
than those of the Ni-containing ferrites (bi- and tri-metallic
ferrite). The same effect is observed in the reduced alloys.
Hence, the characterization results are consistent with the
notion that the substituting elements have indeed been
incorporated in the ferrite structure. This is also reflected in
the thermal evolution of the reduction process, as is clearly
revealed by the in situ XRD experiments of Figure 4, and the in
situ magnetization measurements of Figure 5. While the effects
of cobalt incorporation in the ferrite for reduction are subtle
(but noticeable, Figure 4), nickel clearly facilitates the
reduction of the iron significantly and reduces the temperature
needed for complete reduction by more than 50 °C.
As the Fe metal and the bi- and tri-metallic alloys exhibit
higher saturation magnetization than the corresponding ferrites
(Table 2), reduction can be monitored by following the
magnetization in situ. One should be aware that, for
superparamagnetic particles, an increase in crystallite size
during the reduction process also contributes to an increase in
saturation magnetization of the metallic phase. Figure 5
confirms the trend revealed by the in situ XRD that
incorporation of Ni in the ferrites enhances their reducibility
significantly, while Co has little effect. Reduction of oxides
proceeds via the dissociation of H2 on metallic nuclei formed
at the surface of the oxide, a process that occurs more easily on
nickel oxide than on iron oxide. Once such metallic nuclei have
been established, H2 molecules can dissociate readily and H-
atoms can diffuse over the surface and effectuate reduction of
the iron oxide. This process is often referred to as intraparticle
hydrogen spillover in the literature.79
The product selectivity of the CoFe system resembles that of
iron, but incorporation of Ni has a significant effect on the
distribution of products. The NiFe and CoNiFe catalysts show
higher hydrogenation activity, as evident in the higher
selectivity for CH4, a lower chain-growth probability, lower
olefin/paraffin ratios in the C2−4 and C5+ fraction, and a
doubling in the selectivity toward oxygenates, notably C2+
alcohols. It is well-known that the primary FTS product is rich
in olefins, while subsequent secondary readsorption and
hydrogenation enhances the overall paraffin content.112 The
olefin to paraffin ratio in the product fraction with carbon
numbers of 2−4 drops from 4.3 to 2.9 when Co is
incorporated into the catalyst and to 1 in the presence of Ni.
The same qualitative trend is observed for the longer carbon
chain numbers at an overall lower olefin content, a well-
documented observation associated to a longer residence time
of the primary olefin and, therefore, a higher probability of
secondary hydrogenation.112−114 The increases in the paraffin
content, methane selectivity, and decreased chain growth
probability upon incorporation of nickel in the catalyst can be
attributed to the relatively high hydrogenation activity of
nickel, and is in fact also reflected in the enhanced reducibility
of the Ni-containing catalysts, as discussed above.
The oxygenate selectivities over Fe, CoFe, NiFe, and
CoNiFe were 10.4, 11.7, 17.0, and 15.9 C%, respectively
(Table 4 and Figure 10), the dominant oxygenates being
alcohols, followed by aldehydes. Ethanol is the predominant
product, representing 40−50% of all oxygenates. Within the C2
oxygenates, the ethanol content increases from 56% on pure
Fe, to 76% on CoFe and 82−84% for the Ni-containing alloys.
The selectivity of valuable C2+ alcohols plus aldehydes
increased from 8.5 to 15 C% which translates to a relative
increase of 76%. This effect is even more substantial when
expressing the C2+ oxygenates formation in terms of yields
(1.40, 2.45, 3.71, 3.78 C% over Fe, CoFe, NiFe, and CoNiFe,
respectively) as increases of 75, 165, and 170% were obtained
via Co, Ni, and Co+Ni modification, respectively. The findings
are considered to be of key importance for further develop-
ment of active and selective catalysts for specific classes of
compounds. It is likely that additional promotion (e.g., with
alkali metals) can greatly enhance performance in terms of this
type of catalysts and bring them on par with state-of-the-art
catalysts for the production of oxygenates from synthesis
gas.115,116
The iron metal and the corresponding alloys form the
precursor of the catalytically active phases, which form in situ
during the FTS reaction. All active samples contain the Fe5C2
There are different proposed formation mechanisms for
oxygenates reported in literature.2 Aldehydes and alcohols
form in the “enol” mechanism via a chain termination step,
while acids may form via the Cannizzaro reaction (i.e.,
secondary reaction of aldehydes).2 Johnston and Joyner117
proposed that alcohol formation takes place via the coupling
reaction of alkyl and surface hydroxyl groups. However, the
most considered mechanism of oxygenate formation in FTS is
̈
or Hagg carbide, while it is not possible to ascertain whether
these carbides contain the Co and Ni as substituents on the Fe
positions or as segregated metal or carbide. Nevertheless, the
effect of the substituents is obvious, in the (1) crystallite sizes
of the carbide phases, which are smaller (Table 3), (2) smaller
amount and different nature of the carbon accrued by the
catalysts during FTS (Figures 8 and 9) and, (3) higher CO
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ACS Catal. 2020, 10, 14661−14677