From laboratory to demo: A novel activation technology for iron-based Fischer-Tropsch synthesis catalysts

• A new technology for activating FT catalysts using gas–solid fluidized bed. • The activated catalysts achieved long-term storage for the first time. • It was first discovered that high pressure is beneficial to reactions. Novel activation methods for iron-based Fischer-Tropsch (FT) synthesis catalysts using a gas–solid fluidized bed reactor (FBR) were studied to address the shortcomings of the existing activation technologies using slurry bubble column reactor (SBCR). A pilot unit and an industrial demonstration unit were constructed to investigate the influences of process parameters. The pilot test results indicated that increasing pressure and superficial gas velocity (SGV) were beneficial to improving the activation performance. The optimal range for the H 2 /CO molar ratio of the syngas at the inlet was found between 50 and 70. Compared to the short-lived catalysts activated using SBCR, the catalysts activated using the FBR can be stored under nitrogen protection for nearly 1000 h. The experimental results of the industrial demonstration unit indicate that, given the same output and performance of activated catalysts, FBR has the competitive advantages of higher temperature stability, smaller reactor size, and shorter reaction cycle in comparison with SBCR.