Unveiling the Influence of Activation Protocols on Cobalt Catalysts for Sustainable Fuel Synthesis

The Fischer–Tropsch Synthesis process is projected to have a significant impact in the near future due to its potential for synthesizing sustainable fuels from biomass, carbon dioxide and organic wastes. In this catalytic process, catalyst activation plays a major role in the overall performance of Fischer–Tropsch Synthesis. Catalyst activation temperatures are considerably higher than the typical operating conditions of industrial reactors. Consequently, ex situ activation is often required for industrial Fischer–Tropsch Synthesis processes. This study evaluated the influence of different activation approaches (in situ, ex situ, passivation and low-temperature activation). Catalytic experiments were conducted in a fixed-bed reactor at 230 °C and 20 bar·g using a reference supported Co/γ-Al2O3 catalyst. Experimental results demonstrate that catalysts can be effectively reduced ex situ. This work reveals that re-activation of the catalyst after ex situ reduction is unnecessary, as the reaction conditions themselves re-reduce any superficial oxides formed, owing to the reducing nature of the reactant mixture. This approach could simplify reactor design by enabling temperature requirements to match operating conditions (e.g., 230 °C), thereby reducing both investment and operational costs and eliminating additional catalyst preparation steps.