Pathways of Methane Transformation over Copper‐Exchanged Mordenite as Revealed by In Situ NMR and IR Spectroscopy

Unraveling the catalytic performance of RuO2(1 1 0) for highly-selective ethylene production from methane at low temperature: Insights from first-principles and microkinetic simulations

Despite significant progress in low-temperature methane (CH4) activation, commercial viability, specifically obtaining high yields of C1/C2 products, remains a challenge. High desorption energy (>2 eV) and overoxidation of the target products are key limitations in CH4 utilization. Herein, we employ first-principles density functional theory (DFT) and microkinetics simulations to investigate the CH4 activation and the feasibility of its conversion to ethylene (C2H4) on the RuO2 (1 1 0) surface. The CH activation and CH4 dehydrogenation processes are thoroughly investigated, with a particular focus on the diffusion of surface intermediates. The results show that the RuO2 (1 1 0) surface exhibits high reactivity in CH4 activation (Ea = 0.60 eV), with CH3 and CH2 are the predominant species, and CH2 being the most mobile intermediate on the surface. Consequently, self-coupling of CH2* species via CC coupling occurs more readily, yielding C2H4, a potential raw material for the chemical industry. More importantly, we demonstrate that the produced C2H4 can easily desorb under mild conditions due to its low desorption energy of 0.97 eV. Microkinetic simulations based on the DFT energetics indicate that CH4 activation can occur at temperatures below 200 K, and C2H4 can be desorbed at room temperature. Further, the selectivity analysis predicts that C2H4 is the major product at low temperatures (300-450 K) with 100 % selectivity, then competes with formaldehyde at intermediate temperatures in the CH4 conversion over RuO2 (1 1 0) surface. The present findings suggest that the RuO2 (1 1 0) surface is a potential catalyst for facilitating ethylene production under mild conditions.

Redox and Kinetic Properties of Composition-Dependent Active Sites in Copper-Exchanged Chabazite for Direct Methane-to-Methanol Oxidation

The CH4 oxidation performance of Cu-chabazite zeolites characterized by distinct Si/Al ratios and Cu loadings has been studied and the observed variations in reactivity have been correlated to the differences in the nature of the formed active centers. Plug flow reactor tests, in situ Fourier-transform infrared, and X-ray absorption spectroscopy demonstrate that a decrease in Cu loading shifts the reactivity/redox profile to higher temperatures and increases the CH3OH selectivity and Cu-efficiency. In situ electron paramagnetic resonance, Raman, ultraviolet-visible, Fourier-transform infrared, and photoluminescence spectroscopies reveal that this behavior is associated with the presence of monomeric Cu active sites, including bare Cu2+ and [CuOH]+ present at low Si/Al ratio and Cu loading. Formation of two distinct [Cu2(μ-O)]2+ moieties at higher Si/Al ratio or Cu loading forces these trends into the opposite direction. Operando electron paramagnetic resonance and ultraviolet-visible spectroscopy show that the apparent activation energy of monomeric Cu active species decreases with increasing Si/Al ratio, whereas the one of dimeric centers is unaffected.

Spectroscopic Investigation of the Role of Water in Copper Zeolite Methane Oxidation

Methane is one of the most potent greenhouse gases; developing technology for its abatement is essential for combating climate change. Copper zeolites can activate methane at low temperatures and pressures, demonstrating promise for this technology. However, a barrier to industrial implementation is the inability to recycle the Cu(II) active site. Anaerobic active site regeneration has been reported for copper-loaded mordenite, where it is proposed that water oxidizes Cu(I) formed from the methane reaction, producing H2 gas as a byproduct. However, this result has been met with skepticism given the overall reaction is thermodynamically unfavorable. In this study, we use X-ray absorption and electron paramagnetic resonance spectroscopies to study the role of water in copper zeolite methane oxidation. We find that water does not oxidize Cu(I) to Cu(II) in CH4-reacted Cu-MOR. Further, using isotope label mass spectrometry, we detail an alternate source of the hydrogen byproduct. We uncover that, although water does not oxidize Cu(I), it has the potential to facilitate low temperature methane abatement through promotion of product decomposition to carbon dioxide and H2.

Silver and Copper Dual Single Atoms Boosting Direct Oxidation of Methane to Methanol via Synergistic Catalysis

Rationally constructing atom-precise active sites is highly important to promote their catalytic performance but still challenging. Herein, this work designs and constructs ZSM-5 supported Cu and Ag dual single atoms as a proof-of-concept catalyst (Ag1 -Cu1 /ZSM-5 hetero-SAC (single-atom catalyst)) to boost direct oxidation of methane (DOM) by H2 O2 . The Ag1 -Cu1 /ZSM-5 hetero-SAC synthesized via a modified co-adsorption strategy yields a methanol productivity of 20,115 µmol gcat -1 with 81% selectivity at 70 °C within 30 min, which surpasses most of the state-of-the-art noble metal catalysts. The characterization results prove that the synergistic interaction between silver and copper facilitates the formation of highly reactive surface hydroxyl species to activate the C-H bond as well as the activity, selectivity, and stability of DOM compared with SACs, which is the key to the enhanced catalytic performance. This work believes the atomic-level design strategy on dual-single-atom active sites should pave the way to designing advanced catalysts for methane conversion.

Methane Oxidation to Methanol

The direct transformation of methane to methanol remains a significant challenge for operation at a larger scale. Central to this challenge is the low reactivity of methane at conditions that can facilitate product recovery. This review discusses the issue through examination of several promising routes to methanol and an evaluation of performance targets that are required to develop the process at scale. We explore the methods currently used, the emergence of active heterogeneous catalysts and their design and reaction mechanisms and provide a critical perspective on future operation. Initial experiments are discussed where identification of gas phase radical chemistry limited further development by this approach. Subsequently, a new class of catalytic materials based on natural systems such as iron or copper containing zeolites were explored at milder conditions. The key issues of these technologies are low methane conversion and often significant overoxidation of products. Despite this, interest remains high in this reaction and the wider appeal of an effective route to key products from C-H activation, particularly with the need to transition to net carbon zero with new routes from renewable methane sources is exciting.

Single Atom Catalysts for Selective Methane Oxidation to Oxygenates

Direct conversion of methane (CH₄) to C_1-2 liquid oxygenates is a captivating approach to lock carbons in transportable value-added chemicals, while reducing global warming. Existing approaches utilizing the transformation of CH₄ to liquid fuel via tandemized steam methane reforming and the Fischer-Tropsch synthesis are energy and capital intensive. Chemocatalytic partial oxidation of methane remains challenging due to the negligible electron affinity, poor C-H bond polarizability, and high activation energy barrier. Transition-metal and stoichiometric catalysts utilizing harsh oxidants and reaction conditions perform poorly with randomized product distribution. Paradoxically, the catalysts which are active enough to break C-H also promote overoxidation, resulting in CO₂ generation and reduced carbon balance. Developing catalysts which can break C-H bonds of methane to selectively make useful chemicals at mild conditions is vital to commercialization. Single atom catalysts (SACs) with specifically coordinated metal centers on active support have displayed intrigued reactivity and selectivity for methane oxidation. SACs can significantly reduce the activation energy due to induced electrostatic polarization of the C-H bond to facilitate the accelerated reaction rate at the low reaction temperature. The distinct metal-support interaction can stabilize the intermediate and prevent the overoxidation of the reaction products. The present review accounts for recent progress in the field of SACs for the selective oxidation of CH₄ to C_1-2 oxygenates. The chemical nature of catalytic sites, effects of metal-support interaction, and stabilization of intermediate species on catalysts to minimize overoxidation are thoroughly discussed with a forward-looking perspective to improve the catalytic performance.

DFT Analysis of Methane C-H Activation and Over-Oxidation by [Cu2 O]2+ and [Cu2 O2 ]2+ Sites in Zeolite Mordenite: Intra- versus Inter-site Over-Oxidation

Methane over-oxidation by copper-exchanged zeolites prevents realization of high-yield catalytic conversion. However, there has been little description of the mechanism for methane over-oxidation at the copper active sites of these zeolites. Using density functional theory (DFT) computations, we reported that tricopper [Cu₃ O₃ ]²⁺ active sites can over-oxidize methane. However, the role of [Cu₃ O₃ ]²⁺ sites in methane-to-methanol conversion remains under debate. Here, we examine methane over-oxidation by dicopper [Cu₂ O]²⁺ and [Cu₂ O₂ ]²⁺ sites using DFT in zeolite mordenite (MOR). For [Cu₂ O₂ ]²⁺ , we considered the μ-(η² :η² ) peroxo-, and bis(μ-oxo) motifs. These sites were considered in the eight-membered (8MR) ring of MOR. μ-(η² :η² ) peroxo sites are unstable relative to the bis(μ-oxo) motif with a small interconversion barrier. Unlike [Cu₂ O]²⁺ which is active for methane C-H activation, [Cu₂ O₂ ]²⁺ has a very large methane C-H activation barrier in the 8MR. Stabilization of methanol and methyl at unreacted dicopper sites however leads to over-oxidation via sequential hydrogen atom abstraction steps. For methanol, these are initiated by abstraction of the CH₃ group, followed by OH and can proceed near 200 °C. Thus, for [Cu₂ O]²⁺ and [Cu₂ O₂ ]²⁺ species, over-oxidation is an inter-site process. We discuss the implications of these findings for methanol selectivity, especially in comparison to the intra-site process for [Cu₃ O₃ ]²⁺ sites and the role of Brønsted acid sites.

H2 O-Built Proton Transfer Bridge Enhances Continuous Methane Oxidation to Methanol over Cu-BEA Zeolite

Direct oxidation of methane to methanol (DMTM) is a big challenge in C₁ chemistry. We present a continuous N₂ O-DMTM investigation by simultaneously introducing 10 vol % H₂ O into the reaction system over Cu-BEA zeolites. Combining a D₂ O isotopic tracer technique and ab initio molecular dynamics (AIMD) simulation, we for the first time demonstrate that the H₂ O molecules can participate in the reaction through a proton transfer route, wherein the H₂ O molecules can build a high-speed proton transfer bridge between the generated moieties of CH₃ ^- and OH^- over the evolved mono(μ-oxo) dicopper ([Cu-O-Cu]²⁺ ) active site, thereby pronouncedly boosting the CH₃ OH selectivity (3.1→71.6 %), productivity (16.8→242.9 μmol g_cat ^-1  h^-1 ) and long-term reaction stability (10→70 h) relative to the scenario of absence of H₂ O. Unravelling the proton transfer of H₂ O over the dicopper [Cu-O-Cu]²⁺ site would substantially contribute to highly efficient catalyst designs for the continuous DMTM.

Harnessing of Diluted Methane Emissions by Direct Partial Oxidation of Methane to Methanol over Cu/Mordenite

The upgrading of diluted methane emissions into valuable products can be accomplished at low temperatures (200 °C) by the direct partial oxidation of methanol over copper-exchanged zeolite catalysts. The reaction has been studied in a continuous fixed-bed reactor loaded with a Cu–mordenite catalyst, according to a three-step cyclic process: adsorption of methane, desorption of methanol, and reactivation of the catalyst. The purpose of the work is the use of methane emissions as feedstocks, which is challenging due to their low methane concentration and the presence of oxygen. Methane concentration had a marked influence on methane adsorption and methanol production (decreased from 164 μmol/g Cu for pure methane to 19 μmol/g Cu for 5% methane). The presence of oxygen, even in low concentrations (2.5%), reduced methane adsorption drastically. However, methanol production was only affected slightly (average decrease of 9%), concluding that methane adsorbed on the active centers yielding methanol is not influenced by oxygen.

Identification of Kinetic and Spectroscopic Signatures of Copper Sites for Direct Oxidation of Methane to Methanol

Copper-exchanged zeolites of different topologies possess high activity in the direct conversion of methane to methanol via the chemical looping approach. Despite a large number of studies, identification of the active sites, and especially their intrinsic kinetic characteristics remain incomplete and ambiguous. In the present work, we collate the kinetic behavior of different copper species with their spectroscopic identities and track the evolution of various copper motifs during the reaction. Using time-resolved UV/Vis and in situ EPR, XAS, and FTIR spectroscopies, two types of copper monomers were identified, one of which is active in the reaction with methane, in addition to a copper dimeric species with the mono-μ-oxo structure. Kinetic measurements showed that the reaction rate of the copper monomers is somewhat slower than that of the dicopper mono-μ-oxo species, while the activation energy is two times lower.

Methane Over-Oxidation by Extra-Framework Copper-Oxo Active Sites of Copper-Exchanged Zeolites: Crucial Role of Traps for the Separated Methyl Group

Copper-exchanged zeolites are useful for stepwise conversion of methane to methanol at moderate temperatures. This process also generates some over-oxidation products like CO and CO₂ . However, mechanistic pathways for methane over-oxidation by copper-oxo active sites in these zeolites have not been previously described. Adequate understanding of methane over-oxidation is useful for developing systems with higher methanol yields and selectivities. Here, we use density functional theory (DFT) to examine methane over-oxidation by [Cu₃ O₃ ]²⁺ active sites in zeolite mordenite MOR. The methyl group formed after activation of a methane C-H bond can be stabilized at a μ-oxo atom of the active site. This μ-(O-CH₃ ) intermediate can undergo sequential hydrogen atom abstractions till eventual formation of a copper-monocarbonyl species. Adsorbed formaldehyde, water and formates are also formed during this process. The overall mechanistic path is exothermic, and all intermediate steps are facile at 200 °C. Release of CO from the copper-monocarbonyl costs only 3.4 kcal/mol. Thus, for high methanol selectivities, the methyl group from the first hydrogen atom abstraction step must be stabilized away from copper-oxo active sites. Indeed, it must be quickly trapped at an unreactive site (short diffusion lengths) while avoiding copper-oxo species (large paths between active sites). This stabilization of the methyl group away from the active sites is central to the high methanol selectivities obtained with stepwise methane-to-methanol conversion.

The accuracy challenge of the DFT-based molecular assignment of 13C MAS NMR characterization of surface intermediates in zeolite catalysis

The influence of the model and method choice on the DFT predicted ¹³C NMR chemical shifts of zeolite surface methoxide species has been systematically analyzed. Twelve ¹³C NMR chemical shift calculation protocols on full periodic and hybrid periodic-cluster DFT calculations with varied structural relaxation procedures are examined. The primary assessment of the accuracy of the computational protocols has been carried out for the Si-O(CH₃)-Al surface methoxide species in ZSM-5 zeolite with well-defined experimental NMR parameters (chemical shift, δ(¹³C) value) as a reference. Different configurations of these surface intermediates and their location inside the ZSM-5 pores are considered explicitly. The predicted δ value deviates by up to ±0.8 ppm from the experimental value of 59 ppm due to the varied confinement of the methoxide species at different zeolite sites (model accuracy). The choice of the exchange-correlation functional (method accuracy) introduces ±1.5 ppm uncertainty in the computed chemical shifts. The accuracy of the predicted ¹³C NMR chemical shifts for the computational assignment of spectral characteristics of zeolite intermediates has been further analyzed by considering the potential intermediate species formed upon methane activation by Cu/ZSM-5 zeolite. The presence of Cu species in the vicinity of surface methoxide increases the prediction uncertainty to ±2.5 ppm. The full geometry relaxation of the local environment of an active site at an appropriate level of theory is critical to ensure a good agreement between the experimental and computed NMR data. Chemical shifts (δ) calculated via full geometry relaxation of a cluster model of a relevant portion of the zeolite lattice site are in the best agreement with the experimental values. Our analysis indicates that the full geometry optimization of a cluster model at the PBE0-D3/6-311G(d,p) level of theory followed by GIAO/PBE0-D3/aug-cc-pVDZ calculations is the most suitable approach for the calculation of ¹³C chemical shifts of zeolite surface intermediates.

The Direct Partial Oxidation of Methane to Dimethyl Ether over Pt/Y2 O3 Catalysts Using an NO/O2 Shuttle

Using a mixture of NO + O₂ as the oxidant enabled the direct selective oxidation of methane to dimethyl ether (DME) over Pt/Y₂ O₃ . The reaction was carried out in a fixed bed reactor at 0.1 MPa over a temperature range of 275-375 °C. During the activity tests, the only carbon-containing products were DME and CO₂ . The DME productivity (μmol g_cat ^-1  h^-1 ) was comparable to oxygenate productivities reported in the literature for strong oxidants (N₂ O, H₂ O₂ , O₃ ). The NO + O₂ mixture formed NO₂ , which acted as the oxygen atom carrier for the ultimate oxidant O₂ . During the methane partial oxidation reaction, NO and NO₂ were not reduced to N₂ . In situ FTIR showed the formation of surface nitrate species, which are considered to be key intermediate species for the selective oxidation.