Preparation of a novel structured catalyst based on aligned carbon nanotube arrays for a microchannel Fischer-Tropsch synthesis reactor

A novel microstructured catalyst based on aligned multiwall carbon nanotube arrays was synthesized and tested for Fischer-Tropsch synthesis (FTS) reaction in a microchannel reactor. Fabrication of such a structured catalyst first involved metal organic chemical vapor deposition (MOCVD) of a dense Al2O3 thin film over FeCrAlY foam to enhance the adhesion between ceramic-based catalyst and metal substrate. Aligned multiwall carbon nanotubes were deposited uniformly over the substrate by controlled catalytic decomposition of ethylene. These nanotube bundles were directly attached to FeCrAlY foam through a submicron layer of oxide thin film. Coating the outer surfaces of these nanobundles with an active catalyst layer forms a unique hierarchical structure with fine interstitials between the carbon nanotube bundles. The microstuctural catalyst possessed superior thermal conductivity inherent from carbon nanotube, which allows efficient heat removal from catalytic active sites during exothermic FTS reaction. The concept was tested and demonstrated in a microchannel fixed bed FTS reactor. FTS turn-over activity was found to enhance by a factor of four owing to potential improvement in mass transfer in the unique microstructure. Furthermore, improved temperature control with the carbon nanotube arrays also allows the Fischer-Tropsch synthesis being operated at temperatures as high as 265 °C without reaction runaway.