The paper presents a review of modern industrial and competitive experimental approaches to gas-to-liquid (GTL) and polyalphaolefin (PAO) oil technologies for the production of synthetic base oils. The key aspects of the synthesis of environmentally friendly isoparaffin and PAO base oils are discussed: the feedstocks, process designs, and catalysts. Based on an analysis of relevant scientific and engineering advances reported to date, the current trends of synthetic base oil technologies are shown, including the creation of novel high-performance homogeneous and heterogeneous catalysts, as well as the prospects for the Fischer-Tropsch process and the GTL technology in general for the production of isoparaffin oils (including those with improved low-temperature properties) and of synthetic PAO oil components.

Hydrocarbon synthesis from CO and H₂ over a cobalt catalyst has been carried out, and the dependence of the selectivity and productivity of the process on process parameters, namely, temperature, pressure, GHSV, and synthesis gas composition has been investigated. Raising the temperature by 17°C decreases the high-molecular-weight hydrocarbon (C₃₅₊) selectivity of the process by 24% at GHSV = 60 h⁻¹ and by 69% at GHSV = 100 h⁻¹. Raising the pressure from 0.1 to 2.0 MPa improves these characteristics of the process, and increasing the GHSV from 60 to 300 h⁻¹ diminishes them. Concentrated synthesis gas mixtures should be used to obtain C₃₅₊ hydrocarbons (ceresin). The actual composition of the resulting hydrocarbon mixture differs from the theoretical composition calculated using the Anderson-Schulz-Flory molar mass distribution equation, suggesting that, under real synthesis conditions, the molar mass distribution is described by more complicated relationships. This study is an applied one, and its results are planned to be used in the design of a pilot plant for ceresin (brand 100) production.

The study investigates the effects of nickel introduction methods on the properties of a hybrid cobalt catalyst in a combination of Fischer–Tropsch synthesis and the hydroprocessing of the synthesized products. At 240°C, 2 MPa, and syngas WHSV 1000 h ^–1 , the catalytic performances were compared, the products were analyzed for the hydrocarbon and fractional compositions, and the characteristics of the synthesized fuels were determined. Among the catalysts differing in nickel introduction method, the sample with a nickel-containing zeolite component prepared by ion exchange was found to have the highest hydrogenation activity, while the sample with a metal component generated by joint cobalt/nickel introduction [Co/SiO ₂ + Ni(i)/HZSM-5 + Al ₂ O ₃ ] exhibited the highest isomerization activity.

This study investigates the production of diesel fuels by integrated Fischer–Tropsch synthesis over a bifunctional cobalt catalyst consisting of a cobalt component (Co–Al ₂ O ₃ /SiO ₂ ) and a zeolite-containing component (ZSM-5). The catalytic properties were tested in a continuous-flow reactor with a stationary catalyst bed at 240–250°C, 2 MPa, and gas WHSV 1000 h ^–1 . The effects of the SiO ₂ /Al ₂ O ₃ ratio in a HZSM-5 zeolite on the catalytic performance, catalyst deactivation rate, and hydrocarbon and fractional compositions of the synthetic product were identified. The low-temperature properties of the synthesized diesel fuel satisfy the current requirements for winter fuels.

A review of modern approaches to the development of cobalt catalyst technology used in most known ways of synthesizing hydrocarbons from CO and H₂ using the Fischer–Tropsch is presented. The development of efficient catalysts solves the problem of replacing fossil fuels with ultra-clean alternative fuels and reduces their negative impact on the environment. An analysis of results from scientific and technological research, including ones obtained recently by the authors, shows current lines in developing the technology of high-performance catalysts for the Fischer–Tropsch synthesis of hydrocarbons using classical and integrated GTL technology, including the creation of new types of polyfunctional systems. The review mainly describes the catalytic characteristics of supported cobalt catalysts synthesized via impregnation and polyfunctional hybrid catalysts obtained on their basis for the selective synthesis of fuel fraction hydrocarbons. Problems of controlling selectivity, productivity, and changes in the activity and physicochemical properties of catalysts during long-term operation are considered.

New bifunctional cobalt catalysts for combined Fischer–Tropsch synthesis and hydroprocessing of hydrocarbons containing Pt were developed. To prepare catalysts in the form of a composite mixture, the FT synthesis catalyst Co-Al₂O₃/SiO₂ and ZSM-5 zeolite in the H-form were used as metal and acid components, respectively, with boehmite as a binder. The catalysts were characterized by various methods, such as XRD using synchrotron radiation, SEM, EDS, TEM and TPR. The effect of the Pt introduction method on the particle size and conditions for cobalt reduction was studied. The testing of catalysts in Fischer–Tropsch synthesis was carried out at a pressure of 2.0 MPa, a temperature of 240 and 250 °C, an H₂/CO ratio of 2 and a synthesis gas volumetric velocity of 1000 h⁻¹. It is shown that the method of introducing a hydrogenating metal by adjusting the nano-sized spatial structure of the catalyst determined the activity in the synthesis and group and fractional composition of the resulting products. It is established that the presence of Pt intensified the processes of synthesis and hydrogenation, including isomeric products, and reduced the content of unsaturated hydrocarbons. The application of Pt by impregnation onto the surface of the metal component of the catalysts provided the highest productivity for C₅₊ hydrocarbons, and for the acidic component, it enabled maximum cracking and isomerizing abilities.