In Situ Study of Catalytic Processes: Neutron Diffraction of a Methanol Synthesis Catalyst at Industrially Relevant Pressure

Design Principles of Catalytic Materials for CO2 Hydrogenation to Methanol

Heterogeneous catalysts are essential for thermocatalytic CO2 hydrogenation to methanol, a key route for sustainable production of this vital platform chemical and energy carrier. The primary catalyst families studied include copper-based, indium oxide-based, and mixed zinc-zirconium oxides-based materials. Despite significant progress in their design, research is often compartmentalized, lacking a holistic overview needed to surpass current performance limits. This perspective introduces generalized design principles for catalytic materials in CO2-to-methanol conversion, illustrating how complex architectures with improved functionality can be assembled from simple components (e.g., active phases, supports, and promoters). After reviewing basic concepts in CO2-based methanol synthesis, engineering principles are explored, building in complexity from single to binary and ternary systems. As active nanostructures are complex and strongly depend on their reaction environment, recent progress in operando characterization techniques and machine learning approaches is examined. Finally, common design rules centered around symbiotic interfaces integrating acid-base and redox functions and their role in performance optimization are identified, pinpointing important future directions in catalyst design for CO2 hydrogenation to methanol.

The Enigma of Methanol Synthesis by Cu/ZnO/Al2O3-Based Catalysts

The activity and durability of the Cu/ZnO/Al2O3 (CZA) catalyst formulation for methanol synthesis from CO/CO2/H2 feeds far exceed the sum of its individual components. As such, this ternary catalytic system is a prime example of synergy in catalysis, one that has been employed for the large scale commercial production of methanol since its inception in the mid 1960s with precious little alteration to its original formulation. Methanol is a key building block of the chemical industry. It is also an attractive energy storage molecule, which can also be produced from CO2 and H2 alone, making efficient use of sequestered CO2. As such, this somewhat unusual catalyst formulation has an enormous role to play in the modern chemical industry and the world of global economics, to which the correspondingly voluminous and ongoing research, which began in the 1920s, attests. Yet, despite this commercial success, and while research aimed at understanding how this formulation functions has continued throughout the decades, a comprehensive and universally agreed upon understanding of how this material achieves what it does has yet to be realized. After nigh on a century of research into CZA catalysts, the purpose of this Review is to appraise what has been achieved to date, and to show how, and how far, the field has evolved. To do so, this Review evaluates the research regarding this catalyst formulation in a chronological order and critically assesses the validity and novelty of various hypotheses and claims that have been made over the years. Ultimately, the Review attempts to derive a holistic summary of what the current body of literature tells us about the fundamental sources of the synergies at work within the CZA catalyst and, from this, suggest ways in which the field may yet be further advanced.

Neutron Scattering Studies of Heterogeneous Catalysis

Understanding the structural dynamics/evolution of catalysts and the related surface chemistry is essential for establishing structure-catalysis relationships, where spectroscopic and scattering tools play a crucial role. Among many such tools, neutron scattering, though less-known, has a unique power for investigating catalytic phenomena. Since neutrons interact with the nuclei of matter, the neutron-nucleon interaction provides unique information on light elements (mainly hydrogen), neighboring elements, and isotopes, which are complementary to X-ray and photon-based techniques. Neutron vibrational spectroscopy has been the most utilized neutron scattering approach for heterogeneous catalysis research by providing chemical information on surface/bulk species (mostly H-containing) and reaction chemistry. Neutron diffraction and quasielastic neutron scattering can also supply important information on catalyst structures and dynamics of surface species. Other neutron approaches, such as small angle neutron scattering and neutron imaging, have been much less used but still give distinctive catalytic information. This review provides a comprehensive overview of recent advances in neutron scattering investigations of heterogeneous catalysis, focusing on surface adsorbates, reaction mechanisms, and catalyst structural changes revealed by neutron spectroscopy, diffraction, quasielastic neutron scattering, and other neutron techniques. Perspectives are also provided on the challenges and future opportunities in neutron scattering studies of heterogeneous catalysis.

Shape-Dependent CO2 Hydrogenation to Methanol over Cu2O Nanocubes Supported on ZnO

The hydrogenation of CO₂ to methanol over Cu/ZnO-based catalysts is highly sensitive to the surface composition and catalyst structure. Thus, its optimization requires a deep understanding of the influence of the pre-catalyst structure on its evolution under realistic reaction conditions, including the formation and stabilization of the most active sites. Here, the role of the pre-catalyst shape (cubic vs spherical) in the activity and selectivity of ZnO-supported Cu nanoparticles was investigated during methanol synthesis. A combination of ex situ, in situ, and operando microscopy, spectroscopy, and diffraction methods revealed drastic changes in the morphology and composition of the shaped pre-catalysts under reaction conditions. In particular, the rounding of the cubes and partial loss of the (100) facets were observed, although such motifs remained in smaller domains. Nonetheless, the initial pre-catalyst structure was found to strongly affect its subsequent transformation in the course of the CO₂ hydrogenation reaction and activity/selectivity trends. In particular, the cubic Cu particles displayed an increased activity for methanol production, although at the cost of a slightly reduced selectivity when compared to similarly sized spherical particles. These findings were rationalized with the help of density functional theory calculations.

Chemical Electron Microscopy (CEM) for Heterogeneous Catalysis at Nano: Recent Progress and Challenges

Chemical electron microscopy (CEM), a toolbox that comprises imaging and spectroscopy techniques, provides dynamic morphological, structural, chemical, and electronic information about an object in chemical environment under conditions of observable performance. CEM has experienced a revolutionary improvement in the past years and is becoming an effective characterization method for revealing the mechanism of chemical reactions, such as catalysis. Here, we mainly address the concept of CEM for heterogeneous catalysis in the gas phase and what CEM could uniquely contribute to catalysis, and illustrate what we can know better with CEM and the challenges and future development of CEM.

Dynamic interplay between metal nanoparticles and oxide support under redox conditions

The dynamic interactions between noble metal particles and reducible metal-oxide supports can depend on redox reactions with ambient gases. Transmission electron microscopy revealed that the strong metal-support interaction (SMSI)-induced encapsulation of platinum particles on titania observed under reducing conditions is lost once the system is exposed to a redox-reactive environment containing oxygen and hydrogen at a total pressure of ~1 bar. Destabilization of the metal-oxide interface and redox-mediated reconstructions of titania lead to particle dynamics and directed particle migration that depend on nanoparticle orientation. A static encapsulated SMSI state was reestablished when switching back to purely oxidizing conditions. This work highlights the difference between reactive and nonreactive states and demonstrates that manifestations of the metal-support interaction strongly depend on the chemical environment.

Drastic Events and Gradual Change Define the Structure of an Active Copper-Zinc-Alumina Catalyst for Methanol Synthesis

The copper-zinc-alumina (CZA) catalyst is one of the most important catalysts. Nevertheless, understanding of the complex CZA structure is still limited and hampers further optimization. Critical to the production of a highly active and stable catalyst are optimal start-up procedures in hydrogen. Here, by employing operando X-ray absorption spectroscopy and X-ray diffraction, we follow how the industrial CZA precursor evolves into the working catalyst. Two major events in the activation drastically alter the copper- and zinc-containing components in the CZA catalyst and define the final working catalyst structure: the reduction of the starting copper(II) oxide, and the ripening and re-oxidation of zinc oxide upon the switch to catalytic conditions. These drastic events are also accompanied by other gradual, structural changes. Understanding what happens during these events is key to develop tailored start-up protocols that are aimed at maximal longevity and activity of the catalysts.

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.

Operando high-pressure investigation of size-controlled CuZn catalysts for the methanol synthesis reaction

Although Cu/ZnO-based catalysts have been long used for the hydrogenation of CO₂ to methanol, open questions still remain regarding the role and the dynamic nature of the active sites formed at the metal-oxide interface. Here, we apply high-pressure operando spectroscopy methods to well-defined Cu and Cu_0.7Zn_0.3 nanoparticles supported on ZnO/Al₂O₃, γ-Al₂O₃ and SiO₂ to correlate their structure, composition and catalytic performance. We obtain similar activity and methanol selectivity for Cu/ZnO/Al₂O₃ and CuZn/SiO₂, but the methanol yield decreases with time on stream for the latter sample. Operando X-ray absorption spectroscopy data reveal the formation of reduced Zn species coexisting with ZnO on CuZn/SiO₂. Near-ambient pressure X-ray photoelectron spectroscopy shows Zn surface segregation and the formation of a ZnO-rich shell on CuZn/SiO₂. In this work we demonstrate the beneficial effect of Zn, even in diluted form, and highlight the influence of the oxide support and the Cu-Zn interface in the reactivity.

Growth and Termination Dynamics of Multiwalled Carbon Nanotubes at Near Ambient Pressure: An in Situ Transmission Electron Microscopy Study

Understanding the growth mechanism of carbon nanotubes (CNTs) has been long pursued since its discovery. With recent integration of in situ techniques into the study of CNT growth, important insights about the growth mechanism of CNT have been generated, which have improved our understanding significantly. However, previous in situ experiments were mainly conducted at low pressures which were far from the practical conditions. Direct information about the growth dynamics under relevant conditions is still absent and thus is highly desirable. In this work, we report atomic-scale observations of multiwalled CNT (MWCNT) growth and termination at near ambient pressure by in situ transmission electron microscopy. On the basis of the real-time imaging, we are able to reveal that the working catalyst is constantly reshaping at its apex during catalyzing CNT growth, whereas at the base the catalyst remains faceted and barely shows any morphological change. The active catalyst is identified as crystalline Fe₃C, based on lattice fringes that can be imaged during growth. However, the oscillatory growth behavior of the CNT and the structural dynamics of the apex area strongly indicate that the carbon concentration in the catalyst particle is fluctuating during the course of CNT growth. Extended observations further reveal that the catalyst splitting can occur: whereas the majority of the catalyst stays at the base and continues catalyzing CNT growth, a small portion of it gets trapped inside of the growing nanotube. The catalyst splitting can take place multiple times, leading to shrinkage of both, catalyst size and diameter of CNT, and finally the growth termination of CNT due to the full coverage of the catalyst by carbon layers. Additionally, in situ observations show two more scenarios for the growth termination, that is, out-migration of the catalyst from the growing nanotube induced by (i) Oswald ripening and (ii) weakened adhesion strength between the catalyst and CNT.

Moving Frontiers in Transition Metal Catalysis: Synthesis, Characterization and Modeling

Nanosized transition metal particles are important materials in catalysis with a key role not only in academic research but also in many processes with industrial and societal relevance. Although small improvements in catalytic properties can lead to significant economic and environmental impacts, it is only now that knowledge-based design of such materials is emerging, partly because the understanding of catalytic mechanisms on nanoparticle surfaces is increasingly improving. A knowledge-based design requires bottom-up synthesis of well-defined model catalysts, an understanding of the catalytic nanomaterials "at work" (operando), and both a detailed understanding and a prediction by theoretical methods. This article reports on progress in colloidal synthesis of transition metal nanoparticles for preparation of model catalysts to close the materials gap between the discoveries of fundamental surface science and industrial application. The transition metal particles, however, often undergo extensive transformations when applied to the catalytic process and much progress has recently been achieved operando characterization techniques under relevant reaction conditions. They allow better understanding of size/structure-activity correlations in these systems. Moreover, the growth of computing power and the improvement of theoretical methods uncover mechanisms on nanoparticles and have recently predicted highly active particles for CO/CO₂ hydrogenation or direct H₂ O₂ synthesis.

Neutron Scattering Investigations of Hydride Species in Heterogeneous Catalysis

In heterogeneous catalysis, hydrides on the surface or in the bulk play a critical role as either active components or reaction intermediates in many hydrogen-involving reactions, but characterization of the nature and structure of these hydride species remains challenging. Neutron scattering, which is extremely sensitive to light elements, such as hydrogen, has shown great potential in meeting this challenge. In this Minireview, recent advances in neutron studies of hydride species, mainly over the two most typical classes of catalysts-metals and oxides-are surveyed. Findings on catalysts outside these categories are raised if they are considered to be relevant for contextualization in the present Minireview. The adsorption, dissociation, spillover, and reactivity of hydrogen, especially hydride species over supported metal and oxide catalysts, have been successfully investigated, mostly by means of neutron vibrational spectroscopy. Insights from these neutron studies, which are otherwise not possible with other techniques, shed light on the interaction mechanism of hydrogen with solid surfaces and reaction mechanisms in which hydrogen is involved. Future research challenges on neutron scattering studies of hydrides, as well as catalysis in general, are also highlighted, and more operando-type neutron studies need be conducted to advance the field.

The high pressure gas capabilities at Oak Ridge National Laboratory's neutron facilities

The study of samples subjected to high pressure gas is an important asset in materials research and has consequently been a priority of the sample environment development at the Oak Ridge National Laboratory's (ORNL) neutron program. Such effort has resulted in the availability of an extensive combination of pressure cells and gas intensifiers (both commercially available and custom made). These resources are available across both neutron facilities at ORNL: the Spallation Neutron Source and the High Flux Isotope Reactor. Current capabilities include, for example, in situ measurements up to 6 kbar and a 3 kbar hydrogen-capable intensifier with a gas recovery feature. In this communication, we will review the existing suite of high pressure gas capabilities, with special emphasis on recent in-house developments. A number of examples will be presented to illustrate how such capabilities are being deployed on neutron beamlines to enable frontier science.

Determination of toluene hydrogenation kinetics with neutron diffraction

Total neutron scattering has been used to follow the hydrogenation of toluene-d₈ to methylcyclohexane-d₁₄ over 3 wt% platinum supported on highly ordered mesoporous silica (MCM-41) at 298 K and under 150–250 mbar D₂ pressure.

A highly effective and stable CuZn0.3MgxAlOycatalyst for the manufacture of chirall-phenylalaninol: the role of Mg and its hydrotalcite-like precursor

A highly effective and stable CuZn_0.3Mg_0.1AlO_ycatalyst derived from a Cu-rich hydrotalcite-like precursor was prepared for the catalytic hydrogenation ofl-phenylalanine methyl ester tol-phenylalaninol with ~100% ee selectivity.

Different routes to methanol: inelastic neutron scattering spectroscopy of adsorbates on supported copper catalysts

Inelastic neutron scattering of Cu-based methanol synthesis catalysts revealed that the surface coverage after reaction depends on the support oxide.

Direct observation of graphene growth and associated copper substrate dynamics by in situ scanning electron microscopy

This work highlights the importance of in situ experiments for an improved understanding of graphene growth on copper via metal-catalyzed chemical vapor deposition (CVD). Graphene growth inside the chamber of a modified environmental scanning electron microscope under relevant low-pressure CVD conditions allows visualizing structural dynamics of the active catalyst simultaneously with graphene nucleation and growth in an unparalleled way. It enables the observation of a complete CVD process from substrate annealing through graphene nucleation and growth and, finally, substrate cooling in real time and nanometer-scale resolution without the need of sample transfer. A strong dependence of surface dynamics such as sublimation and surface premelting on grain orientation is demonstrated, and the influence of substrate dynamics on graphene nucleation and growth is presented. Insights on the growth mechanism are provided by a simultaneous observation of the growth front propagation and nucleation rate. Furthermore, the role of trace amounts of oxygen during growth is discussed and related to graphene-induced surface reconstructions during cooling. Above all, this work demonstrates the potential of the method for in situ studies of surface dynamics on active metal catalysts.

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.

Catalyst characterisation techniques and reaction cells operating at realistic conditions; towards acquisition of kinetically relevant information

Catalyst characterisation techniques and reaction cells operating at realistic conditions; towards acquisition of kinetically relevant information.

Quantification of zinc atoms in a surface alloy on copper in an industrial-type methanol synthesis catalyst

Methanol has recently attracted renewed interest because of its potential importance as a solar fuel. Methanol is also an important bulk chemical that is most efficiently formed over the industrial Cu/ZnO/Al2O3 catalyst. The identity of the active site and, in particular, the role of ZnO as a promoter for this type of catalyst is still under intense debate. Structural changes that are strongly dependent on the pretreatment method have now been observed for an industrial-type methanol synthesis catalyst. A combination of chemisorption, reaction, and spectroscopic techniques provides a consistent picture of surface alloying between copper and zinc. This analysis enables a reinterpretation of the methods that have been used for the determination of the Cu surface area and provides an opportunity to independently quantify the specific Cu and Zn areas. This method may also be applied to other systems where metal-support interactions are important, and this work generally addresses the role of the carrier and the nature of the interactions between carrier and metal in heterogeneous catalysts.

Cu/ZnO nanocatalysts in response to environmental conditions: surface morphology, electronic structure, redox state and CO2 activation

Methanol synthesis is one of the landmarks of heterogeneous catalysis due to the great industrial significance of methanol as a clean liquid fuel and as a raw material for industry.