Enhanced middle-distillate production through integrated non-noble metal catalysis on Fischer-Tropsch synthesis

Integrating hydrocracking with Fischer–Tropsch synthesis (FTS) offers a pathway to overcome the limitations imposed by the Anderson–Schulz–Flory (ASF) distribution and to enhance the yield of middle distillates. Here, we explore a single-pass, non-noble metal catalytic approach of dual bed configurations composed of a Co–CeO 2 FTS catalyst and a Ni/Y zeolite for primary synthesis and effluent post-treatment simultaneously. Three reactor configurations were tested—standalone, sequential bed, and physically mixed—under isoconversion conditions across a wide temperature range (235–280 °C and 2.0 MPa). The middle-distillate selectivity peaked at 78 mol% operating at high conversions (X CO > 60%), overcoming reported literature values. The sequential configuration exhibited enhanced isoparaffinic content and promoted olefin oligomerization, while the mixed configuration promoted methane reforming and hydrocracking. In situ DRIFTS, together with comprehensive product-distribution analysis, consistently indicated the presence of three configuration-dependent pathways: olefin oligomerization, hydrocracking of heavier hydrocarbons, and methane reforming, whose relative contributions vary according to the catalyst arrangement. In conclusion, the Ni/Y zeolite has shown activity processing FTS effluents in integrated dual bed configurations by tailoring product distribution and reducing undesired fractions.