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In order to develop an iron-based catalyst with high attrition resistance and stability for Fischer–Tropsch synthesis (FTS), a series of experiments were carried out to investigate the effects of SiO2 and its hydroxyl content and a boron promoter on the attrition resistance and catalytic behavior of spray-dried precipitated Fe/Cu/K/SiO2 catalysts. The catalysts were characterized by means of N2 physisorption, nuclear magnetic resonance (NMR), X-ray diffraction (XRD), Raman spectrum, X-ray photoelectron spectroscopy (XPS), H2-thermogravimetric analysis (H2-TGA), temperature-programmed reduction and hydrogenation (TPR and TPH), and scanning and transmission electron microscopy (SEM and TEM). The FTS performance of the catalysts was tested in a slurry-phase continuously stirred tank reactor (CSTR), while the attrition resistance study included a physical test with the standard method and a chemical attrition test under simulated reaction conditions. The results indicated that the increase in SiO2 content enhances catalysts’ attrition resistance and FTS stability, but decreases activity due to the suppression of further reduction of the catalysts. Moreover, the attrition resistance of the catalysts with the same silica content was greatly improved with an increase in hydroxyl number within silica sources, as well as the FTS activity and stability to some degree. Furthermore, the boron element was found to show remarkable promotion of FTS stability, and the promotion mechanism was discussed with regard to probable interactions between Fe and B, K and B, and SiO2 and B, etc. An optimized catalyst based on the results of this study was finalized, scaled up, and successfully applied in a megaton industrial slurry bubble FTS unit, exhibiting excellent FTS performance.

Precipitated iron Fischer–Tropsch synthesis catalysts impregnated with chlorine were prepared and their Fischer–Tropsch synthesis performances were tested in a 1 L stirred tank reactor. The results showed that the chlorine modification had a significant influence on the Fischer–Tropsch synthesis performance of the precipitated iron catalyst. Compared with the catalyst without the chlorine modification, the catalyst containing about 0.1 wt% chlorine was deactivated by about 40% and the catalyst containing about 1 wt% chlorine was deactivated by about 65%. The textural properties, phase, reduction properties, and chlorine adsorption state of the catalysts before and after the Fischer–Tropsch synthesis were characterized. The strong interaction between chlorine and iron in the catalyst hindered the reduction and carbonization of the catalyst, which was the reason for the deactivation of the catalyst caused by the chlorine modification.