Optimizing preparations of Co Fischer-Tropsch catalysts for stability against sintering

[Display omitted] •Optimized support physical and chemical properties, and addition of a support stabilizer are crucial in development of a sinter-resistant catalyst.•Impregnation, precipitation, and solution combustion are the three chief industrially relevant methods for catalyst precursor deposition.•The drying stage plays a critical role in determining the spatial distribution of NCs over the support.•Calcination should be designed to control the decomposition of the metal precursor, produce an optimal Co3O4 NC size with a sharp size distribution and a uniform spatial distribution on the support, and remove almost all of the precursor.•Reduction method and noble metal promoters play a critical role in determining the extent of reduction, metal NC size, and metal NC phase. Catalyst deactivation is of a major concern in industrial applications. Catalyst deactivation in any process can be minimized through: (i) appropriate catalyst design, and (ii) careful process control. In the present review we focus on the design of a Co catalyst to significantly hinder catalyst deactivation via sintering during FT reaction while enhancing catalytic activity and selectivity. First, it is shown how support and promoter physical and chemical properties can affect Co catalyst design. Support physical and chemical properties essential for preparing an optimally active, selective, and stable, commercial Co FT catalysts are recommended. Secondly, it is explained how carefully-controlled deposition of a Co salt via industrially-realistic methods is critical in controlling catalyst precursor-support interactions, nanocrystal size, and spatial distributions vital to sintering resistance. Three catalyst precursor deposition methods are discussed: impregnation, precipitation, and solution combustion; advantages and disadvantages of each method are detailed. Finally, effects of drying, calcination, and reduction on catalyst properties important to activity, selectivity and resistance to sintering are explained, and best practices for conducting each step are recommended.