Researchers have recently devised a new approach to creating certain widely-used industrial chemicals. The approach utilizes the simple, commonly-used Fischer-Tropsch process in a novel way to produce alcohols and aldehydes, used in industry as fuel additives and feedstock for plasticizers, detergents, lubricants, and cosmetics.
The Fischer-Tropsch Process
The Fischer-Tropsch process is a long-studied chemical reaction that uses catalysts to convert carbon monoxide and hydrogen gas into liquid hydrocarbons. The process is simple, consisting of only one step, and has been used for almost a century to obtain liquid fuel.
The researchers demonstrated that this same process can instead be used to produce long-chain n-aldehydes, 1-alcohols and olefins and n-paraffins. These useful industrial chemicals are currently produced with a multi-step process that converts complex olefin molecules into the desired liquids, meaning the new approach offers an efficiency advantage.
To adapt the Fischer-Tropsch process, the researchers used a catalyst made of cobalt, manganese and potassium (potassium-promoted CoMn). The desired liquid chemicals form when the two gases react at the surface of the solid catalyst.
"The catalyst preparation is really important," said researcher Norbert Kruse. "And the chemistry aspect is wonderful: Starting with only two gases, we end up with a technically useful liquid that you usually obtain only after a number of steps in petrochemical refining. I think there is a good chance for industrial implementation."
More Efficient and Less Expensive
Using the new Fischer-Tropsch approach to mass-produce alcohols and aldehydes could be a huge boon to the relevant industries. The process could potentially lower the cost of producing the chemicals, as well as the amount of energy required to do so. This would mean cleaner, more environmentally friendly manufacturing.
The research team has applied for a patent on the process and are currently working with industrial partners to commercialize it. But beyond the economic benefits, the new approach could offer scientific insight into the Fischer-Tropsch process, still not understood at the molecular level even after a hundred years of use.
"We are making progress and are working very hard on that," said Kruse. "Possibly we can crack that nut."
You can read the team’s paper in Nature Communications.
For another example of improving well-known chemical process, learn how engineers found a better way to boil water.