Quantification of Zinc Atoms in a Surface Alloy on Copper in an Industrial-Type Methanol Synthesis Catalyst

Methanol Synthesis from CO2/CO Mixture on Cu-Zn Catalysts from Microkinetics-Guided Machine Learning Pathway Search

Methanol synthesis on industrial Cu/ZnO/Al₂O₃ catalysts via the hydrogenation of CO and CO₂ mixture, despite several decades of research, is still puzzling due to the nature of the active site and the role of CO₂ in the feed gas. Herein, with the large-scale machine learning atomic simulation, we develop a microkinetics-guided machine learning pathway search to explore thousands of reaction pathways for CO₂ and CO hydrogenations on thermodynamically favorable Cu-Zn surface structures, including Cu(111), Cu(211), and Zn-alloyed Cu(211) surfaces, from which the lowest energy pathways are identified. We find that Zn decorates at the step-edge at Cu(211) up to 0.22 ML under reaction conditions with the Zn-Zn dimeric sites being avoided. CO₂ and CO hydrogenations occur exclusively at the step-edge of the (211) surface with up to 0.11 ML Zn coverage, where the low coverage of Zn (0.11 ML) does not much affect the reaction kinetics, but the higher coverages of Zn (0.22 ML) poison the catalyst. It is CO₂ hydrogenation instead of CO hydrogenation that dominates methanol synthesis, agreeing with previous isotope experiments. While metallic steps are identified as the major active site, we show that the [-Zn-OH-Zn-] chains (cationic Zn) can grow on Cu(111) surfaces under reaction conditions, which suggests the critical role of CO in the mixed gas for reducing the cationic Zn and exposing metal sites for methanol synthesis. Our results provide a comprehensive picture on the dynamic coupling of the feed gas composition, the catalyst active site, and the reaction activity in this complex heterogeneous catalytic system.

In Situ Spectroscopic Characterization and Theoretical Calculations Identify Partially Reduced ZnO1-x /Cu Interfaces for Methanol Synthesis from CO2

The active site of the industrial Cu/ZnO/Al₂ O₃ catalyst used in CO₂ hydrogenation to methanol has been debated for decades. Grand challenges remain in the characterization of structure, composition, and chemical state, both microscopically and spectroscopically, and complete theoretical calculations are limited when it comes to describing the intrinsic activity of the catalyst over the diverse range of structures that emerge under realistic conditions. Here a series of inverse model catalysts of ZnO on copper hydroxide were prepared where the size of ZnO was precisely tuned from atomically dispersed species to nanoparticles using atomic layer deposition. ZnO decoration boosted methanol formation to a rate of 877 g_MeOH  kg_cat ^-1  h^-1 with ≈80 % selectivity at 493 K. High pressure in situ X-ray absorption spectroscopy demonstrated that the atomically dispersed ZnO species are prone to aggregate at oxygen-deficient ZnO ensembles instead of forming CuZn metal alloys. By modeling various potential active structures, density functional theory calculations and microkinetic simulations revealed that ZnO/Cu interfaces with oxygen vacancies, rather than stoichiometric interfaces, Cu and CuZn alloys were essential to catalytic activation.

Chemical Batteries with CO2

Efforts to obtain raw materials from CO2 by catalytic reduction as a means of combating greenhouse gas emissions are pushing the boundaries of the chemical industry. The dimensions of modern energy regimes, on the one hand, and the necessary transport and trade of globally produced renewable energy, on the other, will require the use of chemical batteries in conjunction with the local production of renewable electricity. The synthesis of methanol is an important option for chemical batteries and will, for that reason, be described here in detail. It is also shown that the necessary, robust, and fundamental understanding of processes and the material science of catalysts for the hydrogenation of CO2 does not yet exist.

Identifying the nature of the active sites in methanol synthesis over Cu/ZnO/Al2O3 catalysts

The heterogeneously catalysed reaction of hydrogen with carbon monoxide and carbon dioxide (syngas) to methanol is nearly 100 years old, and the standard methanol catalyst Cu/ZnO/Al2O3 has been applied for more than 50 years. Still, the nature of the Zn species on the metallic Cu0 particles (interface sites) is heavily debated. Here, we show that these Zn species are not metallic, but have a positively charged nature under industrial methanol synthesis conditions. Our kinetic results are based on a self-built high-pressure pulse unit, which allows us to inject selective reversible poisons into the syngas feed passing through a fixed-bed reactor containing an industrial Cu/ZnO/Al2O3 catalyst under high-pressure conditions. This method allows us to perform surface-sensitive operando investigations as a function of the reaction conditions, demonstrating that the rate of methanol formation is only decreased in CO2-containing syngas mixtures when pulsing NH3 or methylamines as basic probe molecules.

Capsule-Structured Copper-Zinc Catalyst for Highly Efficient Hydrogenation of Carbon Dioxide to Methanol

To develop a new and efficient CO₂ -to-methanol catalyst is of extreme significance but still remains a challenge. Herein, an innovative indirect two-step strategy is reported to synthesize a highly efficient capsule-structured copper-based CO₂ -to-methanol catalyst (CZA-r@CZM). It consists of a structurally reconstructed millimeter-sized Cu/ZnO/Al₂ O₃ core (CZA-r) with intensified Cu-ZnO interactions, which is made by a facile hydrothermal treatment in an alkaline aqueous solution, and a Cu/ZnO/MgO (CZM) shell prepared by an ethylene glycol-assisted physical coating method. The CZA-r core displays 2.7 times higher CO₂ hydrogenation activity with 2.0 times higher CO selectivity than the previously reported Cu/ZnO/Al₂ O₃ (CZA-p), whereas the CZM shell can efficiently catalyze hydrogenation of the as-formed CO from the CZA-r core to methanol as it passes through the shell. As a result, the developed capsule-structured CZA-r@CZM catalyst exhibits 2.4 times higher CO₂ conversion with 1.8 times higher turnover frequency and 2.3-fold higher methanol space-time yield than the CZA-p catalyst (729.8 vs. 312.6 g_MeOH  kg_cat ^-1  h^-1 ). In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTs) experiments reveal that the CO₂ hydrogenation reaction proceeds through a reverse water-gas shift reaction followed by a CO hydrogenation pathway via an *H₃ CO intermediate. This work not only produces an efficient CO₂ -to-methanol catalyst, but also opens a new avenue for designing superior catalysts for other consecutive transformations.

Negative Charging of Au Nanoparticles during Methanol Synthesis from CO2 /H2 on a Au/ZnO Catalyst: Insights from Operando IR and Near-Ambient-Pressure XPS and XAS Measurements

The electronic and structural properties of Au/ZnO under industrial and idealized methanol synthesis conditions have been investigated. This was achieved by kinetic measurements in combination with time-resolved operando infrared (DRIFTS) as well as in situ near-ambient pressure X-ray photoelectron spectroscopy (NAP-XPS) and X-ray absorption near-edge spectroscopy (XANES) measurements at the O K-edge together with high-resolution electron microscopy. The adsorption of CO during the reaction revealed the presence of negatively charged Au nanoparticles/Au sites during the initial phase of the reaction. Near-ambient-pressure XPS and XANES demonstrate the build-up of O vacancies during the reaction, which goes along with a substantial increase in the rate of methanol formation. The results are discussed in comparison with previous findings for Cu/ZnO and Au/ZnO catalysts.

Selective photocatalytic conversion of methane into carbon monoxide over zinc-heteropolyacid-titania nanocomposites

Chemical utilization of vast fossil and renewable feedstocks of methane remains one of the most important challenges of modern chemistry. Herein, we report direct and selective methane photocatalytic oxidation at ambient conditions into carbon monoxide, which is an important chemical intermediate and a platform molecule. The composite catalysts on the basis of zinc, tungstophosphoric acid and titania exhibit exceptional performance in this reaction, high carbon monoxide selectivity and quantum efficiency of 7.1% at 362 nm. In-situ Fourier transform infrared and X-ray photoelectron spectroscopy suggest that the catalytic performance can be attributed to zinc species highly dispersed on tungstophosphoric acid /titania, which undergo reduction and oxidation cycles during the reaction according to the Mars-van Krevelen sequence. The reaction proceeds via intermediate formation of surface methyl carbonates.

Revealing the Role of Gold in the Growth of Two-Dimensional Molybdenum Disulfide by Surface Alloy Formation

The formation of Mo/Au surface alloy during Au-assisted chemical vapor deposition (CVD) of MoS₂ is confirmed by a series of control experiments. A metal-organic chemical vapor deposition (MOCVD) system is adapted to conduct two-dimensional MoS₂ growth in a controlled environment. Sequential injection of Mo and S precursors, which does not yield any MoS₂ on SiO₂ /Si, grows atomically thin MoS₂ on Au, indicating the formation of an alloy phase. Transmission electron microscopy of a cross-section of the specimen confirms the confinement of the alloy phase near the surface only. These results show that the reaction intermediate is the surface alloy, and that the role of Au in the Au-assisted CVD is the formation of an atomically thin reservoir of Mo near the surface. This mechanism is clearly distinguished from that of MOCVD, which does not involve the formation of any alloy phases.

Highly active Cu/ZnO–Al catalyst for methanol synthesis: effect of aging on its structure and activity

The influence of aging of precipitates on the physical and catalytic properties of a copper/zinc oxide-aluminium (Cu/ZnO–Al) catalyst with an optimized composition (low Al concentration, Cu/Zn/Al = 68/29/3) prepared using co-precipitation has been investigated in detail. The change in the structure of precipitates with aging (from amorphous zincian georgeite to crystalline zincian malachite) strongly influences the micro- and nano-structure (Cu and ZnO crystallite size, exposed copper surface area, Cu–ZnO interactions and stability of ZnO) of the final Cu/ZnO–Al catalysts obtained after calcination and reduction of the precipitates. The results of catalytic activity in methanol synthesis from syngas show the higher intrinsic activity of the catalysts derived from aged zincian malachite precipitates as consequence of the increase in the exposed copper surface area and the Cu–ZnO contacts. The stability of catalysts under the reaction conditions was also improved in the catalysts derived from precipitates aged after crystallization of malachite. The catalyst derived from the precipitate removed close to the point of crystallization of malachite shows very poor activity in the methanol synthesis as consequence of its segregated large Cu crystallites in low contact with ZnO derived from the absence of carbonate retention after calcination of the precipitate and the presence of sodium species after conventional washing which favour the strong sintering and crystallization of Cu during reduction.

The catalysts derived from precipitates aged after crystallization of zincian malachite show higher activity and stability

Heterogeneous catalysis

A heterogeneous catalyst is a functional material that continually creates active sites with its reactants under reaction conditions. These sites change the rates of chemical reactions of the reactants localized on them without changing the thermodynamic equilibrium between the materials.