The overarching goal of our research group is to design and synthesize core-shell nanocatalysts to be used for Fischer Tropsch Synthesis (FTS) using CO2 enriched syngas in stainless steel 3D printed microchannel microreactors. We have prepared three different core-shell catalysts Fe3O4@SiO2, Fe2O3@SiO2 and FeCo@SiO2Al2O3 for F-T studies. These catalysts were characterized by a series of techniques including N2 physio-sorption, XRD, SEM, TEM and H2-TPR. In the case of Fe based core-shell catalyst, the surface area of Fe2O3@SiO2, 617m2/g, is greater than that of Fe3O4@SiO2, 106 m2/g. The surface area decreases with the addition of Al2O3 in the shell part of FeCo@SiO2Al2O3 catalyst. The XRD analysis of Fe3O4@SiO2 shows peaks for Fe3O4. The XRD of Fe2O3@SiO2 exhibits the peaks for iron, indicating the successful synthesis of desired phases. The TEM and SEM images show some agglomerations in the case of Fe2O3 and Fe3O4 based catalysts. The mesoporous hexagonal structure ensures the improvement of diffusion of reactants and products as well as enhanced heat transfer, which is significant for exothermic FTS reactions. We have evaluated the novel material’s feasibility as the catalyst for FTS in 3D printed stainless steel microchannel reactors in the temperature range of 200-350°C at 20 atm with H2/CO molar ratio of 1:2. Preliminary results show that the Fe2O3@SiO2 yields higher conversion % than Fe3O4@SiO2 and Fe2O3@SiO2 is higher C4+, C2-C4 selectivity % than Fe3O4@SiO2.

Iron based core-shell catalyst for Fischer-Tropsch synthesis in 3D printed stainless steel microchannel microreactor

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