Cobalt metal foam catalyst, method of making same, thermal-medium-circulating heat-exchange reactor using same, and method of producing a liquid fuel by means of a Fischer-Tropsch synthesis reaction using thermal-medium-circulating heat-exchange reactor

Patent metadata

Field	Value
Publication number	US-10160917-B2
Application number	US-201615075743-A
Country	US
Kind code	B2
Filing date	Mar 21, 2016
Priority date	Feb 16, 2010
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

A method of producing liquid fuel by a Fischer-Tropsch synthesis reaction using a thermal medium-circulated heat exchanger type reactor is provided. The thermal medium-circulated heat exchanger type reactor uses the cobalt metal foam catalyst including a metal foam coated with cobalt catalyst powder is used. Exothermic reaction heat generated by the Fischer-Tropsch synthesis reaction occurring in the cobalt metal foam catalyst layer of the tube unit is controlled by thermal medium oil circulating in the shell unit at a reaction temperature of 190˜250° C. and a reaction pressure of 20˜25 atm, and simultaneously the reaction is conducted, thus producing liquid fuel.

First claim

The invention claimed is:

1. A method of producing liquid fuel by a Fischer-Tropsch synthesis reaction using a thermal medium-circulated heat exchanger type reactor, comprising:
preparing a tube unit comprising an outer heat exchange surface having a circumference and a shell unit that fully surrounds the circumference of the outer heat exchange surface of the tube unit to form a space between the tube unit and the shell unit;
disposing a cobalt metal-foam catalyst layer inside the tube unit;
supplying a synthesis gas into an upper portion of the tube unit through a synthesis gas supply line;
heating the cobalt metal-foam catalyst layer to bring about a Fischer-Tropsch synthesis reaction inside the tube unit, using an electric heater provided at the circumference of the shell unit, to thereby produce a liquid fuel product from the synthesis gas;
supplying a thermal medium oil having a predetermined temperature into a lower portion of the space through a thermal medium oil supply line;
recovering the thermal medium oil from an upper portion of the space through a thermal medium oil recovery line;
heat-exchanging between the tube unit and the thermal medium oil using a heat exchange pin protruding from an outer surface of the tube unit, thereby controlling heat generated by the Fischer-Tropsch synthesis reaction;
recovering the liquid fuel product through a lower portion of the tube unit,
wherein the metal-foam of the cobalt metal-foam catalyst layer comprises any one of iron-chromium-aluminum alloy, nickel-chromium alloy, copper-nickel alloy, aluminum-copper alloy, zinc-copper alloy, or silver-copper alloy, and
the metal-foam was pre-treated by atomic layer deposition to form an Al 2 O 3 thin film on the surface of the metal-foam.

2. The method of producing liquid fuel according to claim 1 , further comprising: controlling the predetermined temperature using a heat exchanger provided on the thermal medium oil supply line.

3. The method of producing liquid fuel according to claim 2 , wherein the predetermined temperature is adjusted to 190˜250° C.

4. The method of producing liquid fuel according to claim 1 , wherein the cobalt metal-foam catalyst layer is heated to 300˜500° C.

5. A method of producing liquid fuel by a Fischer-Tropsch synthesis reaction using a thermal medium-circulated heat exchanger type reactor, comprising:
preparing a tube unit comprising an outer heat exchange surface having a circumference and a shell unit that fully surrounds the circumference of the outer heat exchange surface of the tube unit to form a space between the tube unit and the shell unit;
disposing a cobalt metal-foam catalyst layer inside the tube unit, wherein the cobalt metal-foam catalyst layer is heated to 300˜500° C.;
supplying a synthesis gas into an upper portion of the tube unit through a synthesis gas supply line;
heating the cobalt metal-foam catalyst layer to bring about a Fischer-Tropsch synthesis reaction inside the tube unit, using an electric heater provided at the circumference of the shell unit, to thereby produce a liquid fuel product from the synthesis gas;
supplying a thermal medium oil having a predetermined temperature into a lower portion of the space through a thermal medium oil supply line;
controlling the predetermined temperature using a heat exchanger provided on the thermal medium oil supply line, wherein the predetermined temperature is adjusted to 190˜250° C.;
recovering the thermal medium oil from an upper portion of the space through a thermal medium oil recovery line;
heat-exchanging between the tube unit and the thermal medium oil using a heat exchange pin protruding from an outer surface of the tube unit, thereby controlling heat generated by the Fischer-Tropsch synthesis reaction;
recovering the liquid fuel product through a lower portion of the tube unit, and
wherein the metal-foam comprises a copper-nickel alloy that was pre-treated by atomic layer deposition to form and Al 2 O 3 thin film on the surface of the metal-foam.

6. The method of producing liquid fuel according to claim 1 , wherein the metal-foam of the cobalt metal-foam catalyst layer comprises aluminum, iron, iron-chromium-aluminum alloy, nickel-chromium alloy, copper-nickel alloy, aluminum-copper alloy, zinc-copper alloy, or silver-copper alloy.

7. The method of producing liquid fuel according to claim 6 , wherein the metal-foam comprises a copper-nickel alloy that was pre-treated by atomic layer deposition to form an Al 2 O 3 thin film on the surface of the metal-foam.

Assignees

• Korea Inst Energy Res

Inventors

• Yang Jung-Il
• Jung Heon
• Chun Dong-Hyun
• Park Ji-Chan

Classifications

• B01J37/0225

  of metal substrates · CPC title

• C10G2300/70

  Catalyst aspects · CPC title

• B01J2208/00212

  Plates; Jackets; Cylinders · CPC title

• B01J37/0219

  the coating containing organic compounds · CPC title

• B01J37/0217

  Pretreatment of the substrate before coating · CPC title