Synthesis and Characterisation of a Highly Active Cu/ZnO:Al Catalyst

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.

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.

Substitution of Copper by Magnesium in Malachite: Insights into the Synthesis and Structural Effects

The phase width of the copper hydroxycarbonate malachite, Cu₂CO₃(OH)₂, upon substitution with magnesium has been studied in detail. In extension of a previous study on amorphous precursors, the introduction of a hydrothermal aging step allowed the retrieval of crystalline hydroxycarbonate samples with up to 37 atom % Mg (metal content) that are suitable candidates as precursors to Cu/MgO catalysts for CO hydrogenation. Simultaneous refinements of X-ray powder diffraction and pair distribution function (PDF) data as well as complementary spectroscopic insight (X-ray absorption and infrared spectroscopy) revealed that samples with up to 18 atom % Mg are phase-pure magnesian malachites but the magnesium content can be increased beyond this threshold when mcguinnessite (CuMgCO₃(OH)₂) is accepted as a side phase. In a complementary study, a continuous increase of the magnesium fraction was found during aging and the corresponding structural evolution was studied by means of PDF. These findings add significant insight into the aging chemistry of crystalline Cu,Mg hydroxycarbonates. Furthermore, both phase-pure magnesian malachite and mcguinnessite-containing samples with up to 37 atom % Mg have been examined by thermogravimetry, X-ray powder diffraction, and N₂ physisorption and were found to be promising candidates for use as precursors for the preparation of Cu/MgO catalysts.

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.

New black indium oxide—tandem photothermal CO2-H2 methanol selective catalyst

It has long been known that the thermal catalyst Cu/ZnO/Al₂O₃(CZA) can enable remarkable catalytic performance towards CO₂ hydrogenation for the reverse water-gas shift (RWGS) and methanol synthesis reactions. However, owing to the direct competition between these reactions, high pressure and high hydrogen concentration (≥75%) are required to shift the thermodynamic equilibrium towards methanol synthesis. Herein, a new black indium oxide with photothermal catalytic activity is successfully prepared, and it facilitates a tandem synthesis of methanol at a low hydrogen concentration (50%) and ambient pressure by directly using by-product CO as feedstock. The methanol selectivities achieve 33.24% and 49.23% at low and high hydrogen concentrations, respectively.

Harsh reaction conditions are generally required for CO2 hydrogenation to shift the thermodynamic equilibrium towards methanol synthesis. Here, a new black indium oxide with two types of active sites, frustrated Lewis pairs and oxygen vacancies, is prepared, and facilitates a tandem synthesis of methanol at a low hydrogen concentration (50%) and ambient pressure.

Dependence of copper particle size and interface on methanol and CO formation in CO2 hydrogenation over Cu@ZnO catalysts

The copper particle size and the interface of Cu and ZnO showed strong impacts on the formation of methanol and CO in CO2 hydrogenation over Cu@ZnO catalysts.

Prospects and challenges for autonomous catalyst discovery viewed from an experimental perspective

Autonomous catalysis research requires elaborate integration of operando experiments into automated workflows. Suitable experimental data for analysis by artificial intelligence can be measured more readily according to standard operating procedures.

Continuous synthesis of Cu/ZnO/Al2O3 nanoparticles in a co-precipitation reaction using a silicon based microfluidic reactor

A microfluidic reactor enabled continuous co-precipitation synthesis of CuO/ZnO/Al2O3 catalysts for methanol production.

Greener and facile synthesis of Cu/ZnO catalysts for CO2 hydrogenation to methanol by urea hydrolysis of acetates

Cu/ZnO-based catalysts for methanol synthesis by CO_x hydrogenation are widely prepared via co-precipitation of sodium carbonates and nitrate salts, which eventually produces a large amount of wastewater from the washing step to remove sodium (Na⁺) and/or nitrate (NO₃⁻) residues. The step is inevitable since the remaining Na⁺ acts as a catalyst poison whereas leftover NO₃⁻ induces metal agglomeration during the calcination. In this study, sodium- and nitrate-free hydroxy-carbonate precursors were prepared via urea hydrolysis co-precipitation of acetate salt and compared with the case using nitrate salts. The Cu/ZnO catalysts derived from calcination of the washed and unwashed precursors show catalytic performance comparable to the commercial Cu/ZnO/Al₂O₃ catalyst in CO₂ hydrogenation at 240–280 °C and 331 bar. By the combination of urea hydrolysis and the nitrate-free precipitants, the catalyst preparation is simpler with fewer steps, even without the need for a washing step and pH control, rendering the synthesis more sustainable.

Sodium- and nitrate-free hydroxy-carbonate precursors were prepared via urea hydrolysis co-precipitation of acetate salt, which is simpler with fewer steps, even without the need for a washing and pH control, rendering the synthesis more sustainable.

Unravelling the Structural Modification (Meso-Nano-) of Cu/ZnO-Al2O3 Catalysts for Methanol Synthesis by the Residual NaNO3 in Hydroxycarbonate Precursors

The effects of residual NaNO3 on the modification of Cu/ZnO-Al2O3 catalysts have been extensively documented, but the modification mechanism is so far unclear. This work studies in detail the influence of the residual sodium nitrate present in the hydroxycarbonate precursors on their decomposition during calcination and how it affects to the formation and configuration of the final active sites of the Cu/ZnO-Al2O3 catalysts. Different samples with varying sodium content after washing (from 0.01 to 7.3 wt%) were prepared and studied in detail after calcination and reduction steps. The results of this work demonstrated that NaNO3 affects the decomposition mechanism of the hydroxycarbonate precursors during calcination and produces its decarbonation at low temperature. The enhancement of the decarbonation by NaNO3 leads to segregation and crystallization of CuO and ZnO with loss of mesostructure and surface area in the calcined catalysts. The loss of mesostructure in calcined catalysts affects the subsequent reduction step, decreasing the reducibility and damaging the nanostructure of the reduced catalysts forming large Cu particles in poor contact with ZnOx that results in a significant decrease in the intrinsic activity of the copper active sites for methanol synthesis.

Direct Synthesis of Dimethyl Ether from Syngas on Bifunctional Hybrid Catalysts Based on Supported H3PW12O40 and Cu-ZnO(Al): Effect of Heteropolyacid Loading on Hybrid Structure and Catalytic Activity

The performance of bifunctional hybrid catalysts based on phosphotungstic acid (H3PW12O40, HPW) supported on TiO2 combined with Cu-ZnO(Al) catalyst in the direct synthesis of dimethyl ether (DME) from syngas has been investigated. We studied the effect of the HPW loading on TiO2 (from 1.4 to 2.7 monolayers) on the dispersion and acid characteristics of the HPW clusters. When the concentration of the heteropoliacid is slightly higher than the monolayer (1.4 monolayers) the acidity of the clusters is perturbed by the surface of titania, while for concentration higher than 1.7 monolayers results in the formation of three-dimensional HPW nanocrystals with acidity similar to the bulk heteropolyacid. Physical hybridization of supported heteropolyacids with the Cu-ZnO(Al) catalyst modifies both the acid characteristics of the supported heteropolyacids and the copper surface area of the Cu-ZnO(Al) catalyst. Hybridization gives rise to a decrease in the copper surface area and the disappearance of the strong acidic sites typical of HPW nanocrystals, showing all hybrids similar acid sites of weak or medium strength. The activity of the hybrids was tested for direct DME synthesis from syngas at 30 bar and 250 °C; only the hybrids with HPW loading higher than 1.4 monolayers showed activity for the direct synthesis of DME, showing that the sample loaded with 2.7 monolayers of heteropolyacid had higher activity than the reference hybrid representative of the most widely applied catalysts based on the combination of Cu-ZnO(Al) with HZSM-5. In spite of the high activity of the hybrids, they show a moderate loss in the DME production with TOS that denotes some kind of deactivation of the acidity function under reaction conditions.

Gas phase methanol synthesis with Raman spectroscopy for gas composition monitoring

Applicability of Raman spectroscopy for time-resolved gas composition monitoring during direct methanol synthesis via carbon dioxide hydrogenation was investigated. A series of methanol synthesis experiments with varied reactor conditions was conducted and the reactor outlet stream was analyzed with in-line gas Raman spectroscopy. Concentrations of H₂, CO₂ and CO were determined directly from the acquired spectral data. For evaluation of methanol and water content a data reconciliation algorithm was developed. The algorithm involves estimation of the occurring chemical reactions' extents by iterative minimization of the difference between concentration values acquired from the experimental data and concentration values computed based on the mass conservation principle. The obtained experimental concentrations were compared and validated against the results of the reactor mathematical modeling, which is based upon a well-established kinetic interpretation of the process. The findings indicate good repeatability and accuracy of the developed gas analysis system, which together with the advantageous temporal resolution of the method, make Raman spectroscopy a promising technique for fast response monitoring of the process.

Applicability of Raman spectroscopy for time-resolved gas composition monitoring during direct methanol synthesis via carbon dioxide hydrogenation is investigated.

F-doping of nanostructured ZnO: a way to modify structural, electronic, and surface properties

Polycrystalline ZnO is a material often used in heterogeneous catalysis. Its properties can be altered by the addition of dopants. We used gaseous fluorine (F_2(g)) as direct way to incorporate fluoride in ZnO as anionic dopants. Here, the consequences of this treatment on the structural and electronic properties, as well as on the acidic/basic sites of the surface, are investigated. It is shown that the amount of F incorporation into the structure can be controlled by the synthesis parameters (t, T, p). While the surface of ZnO was altered as shown by, e.g., IR spectroscopy, XPS, and STEM/EDX measurements, the F₂ treatment also influenced the electronic properties (optical band gap, conductivity) of ZnO. Furthermore, the Lewis acidity/basicity of the surface was affected which is evidenced by using, e.g., different probe molecules (CO₂, NH₃). In situ investigations of the fluorination process offer valuable insights on the fluorination process itself.

Multi-Scale Analysis of Integrated C1 (CH4 and CO2) Utilization Catalytic Processes: Impacts of Catalysts Characteristics up to Industrial-Scale Process Flowsheeting, Part I: Experimental Analysis of Catalytic Low-Pressure CO2 to Methanol Conversion

A multi-aspect analysis of low-pressure catalytic hydrogenation of CO2 for methanol production is reported in the first part (part I) of this paper. This includes an extensive review of distinguished low-pressure catalytic CO2-hydrogenation systems. Specifically, the results of the conducted systematic experimental investigation on the impacts of synthesis and micro-scale characteristics of the selected Cu/ZnO/Al2O3 model-catalysts on their activity and stability are discussed. The performance of the investigated Cu/ZnO/Al2O3 catalysts, synthesized via different methods, were tested under a targeted range of operating conditions in this research. Specifically, the performances of these tested Cu/ZnO/Al2O3 catalysts with regard to the impacts of the main operating parameters, namely H2/CO2 ratio (at stoichiometric -3-, average -6- and high -9- ratios), temperature (in the range of 160–260 °C) and the lower and upper values of physically achievable gas hourly space velocity (GHSV) (corresponding to 200 h−1 and 684 h−1, respectively), were analyzed. It was found that the catalyst prepared by the hydrolysis co-precipitation method, with a homogenously distributed copper content over its entire surface, provides a promising methanol yield of 21% at a reaction temperature of 200 °C, lowest tested GHSV, highest tested H2/CO2 ratio (9) and operating pressure (10 bar). This is in line with other promising results so far reported for this catalytic system even in pilot-plant scale, highlighting its potential for large-scale methanol production. To analyze the findings in more details, the thermal-reaction performance of the system, specifically with regard to the impact of GHSV on the CO2-conversion and methanol selectivity, and yield were experimentally investigated. Moreover, the stability of the selected catalysts, as another crucial factor for potential industrial operation of this system, was tested under continual long-term operation for 150 h, the reaction-reductive shifting-atmospheres and also even after introducing oxygen to the catalyst surface followed by hydrogen reduction-reaction tests. Only the latter state was found to affect the stable performance of the screened catalysts in this research. In addition, the reported experimental reactor performances have been analyzed in the light of equilibrium-based calculated achievable performance of this reaction system. In the performed multi-scale analysis in this research, the requirements for establishing a selective-stable catalytic performance based on the catalyst- and reactor-scale analyses have been identified. This will be combined with the techno–economic performance analysis of the industrial-scale novel integrated process, utilizing the selected catalyst in this research, in the form of an add-on catalytic system under 10 bar pressure and H2/CO2 ratio (3), for efficiently reducing the overall CO2-emission from oxidative coupling of methane reactors, as reported in the second part (part II) of this paper.

Na+-gated water-conducting nanochannels for boosting CO2 conversion to liquid fuels

Robust, gas-impeding water-conduction nanochannels that can sieve water from small gas molecules such as hydrogen (H₂), particularly at high temperature and pressure, are desirable for boosting many important reactions severely restricted by water (the major by-product) both thermodynamically and kinetically. Identifying and constructing such nanochannels into large-area separation membranes without introducing extra defects is challenging. We found that sodium ion (Na⁺)-gated water-conduction nanochannels could be created by assembling NaA zeolite crystals into a continuous, defect-free separation membrane through a rationally designed method. Highly efficient in situ water removal through water-conduction nanochannels led to a substantial increase in carbon dioxide (CO₂) conversion and methanol yield in CO₂ hydrogenation for methanol production.

Enhanced CH3OH selectivity in CO2 hydrogenation using Cu-based catalysts generated via SOMC from GaIII single-sites

Small and narrowly distributed nanoparticles of copper alloyed with gallium supported on silica containing residual Ga^III sites can be obtained via surface organometallic chemistry in a two-step process: (i) formation of isolated Ga^III surface sites on SiO₂ and (ii) subsequent grafting of a Cu^I precursor, [Cu(O ^t Bu)]₄, followed by a treatment under H₂ to generate CuGa _x alloys. This material is highly active and selective for CO₂ hydrogenation to CH₃OH. In situ X-ray absorption spectroscopy shows that gallium is oxidized under reaction conditions while copper remains as Cu⁰. This CuGa material only stabilizes methoxy surface species while no formate is detected according to ex situ infrared and solid-state nuclear magnetic resonance spectroscopy.

CO2 Hydrogenation to Methanol over Ce and Zr Containing UiO-66 and Cu/UiO-66

Direct hydrogenation of CO2 to methanol is an interesting method to recycle CO2 emitted e.g., during combustion of fossil fuels. However, it is a challenging process because both the selectivity to methanol and its production are low. The metal-organic frameworks are relatively new class of materials with a potential to be used as catalysts or catalysts supports, also in the reaction of MeOH production. Among many interesting structures, the UiO-66 draws significant attention owing to its chemical and thermal stability, developed surface area, and the possibility of tuning its properties e.g., by exchanging the zirconium in the nodes to other metal cations. In this work we discuss—for the first time—the performance of Cu supported on UiO-66(Ce/Zr) in CO2 hydrogenation to MeOH. We show the impact of the composition of UiO-66-based catalysts, and the character of Cu-Zr and Cu-Ce interactions on MeOH production and MeOH selectivity during test carried out for 25 h at T = 200 °C and p = 1.8 MPa. Significant increase of selectivity to MeOH was noticed after exchanging half of Zr4+ cations with Ce4+; however, no change in MeOH production occurred. It was found that the Cu-Ce coexistence in the UiO-66-based catalytic system reduced the selectivity to MeOH when compared to Cu/UiO-66(Zr), which was ascribed to lower concentration of Cu0 active sites in Cu/UiO-66(Ce/Zr), and this was caused by oxygen spill-over between Cu0 and Ce4+, and thus, the oxidation of the former. The impact of reaction conditions on the structure stability of tested catalyst was also determined.

Data on TGA of precursors and SEM of reduced Cu/ZnO catalysts co-modified with aluminium and gallium for methanol synthesis

The modification of Cu–Zn catalysts with low amount of Al and Ga (Al+Ga = 3%) was investigated and data corresponding to its influence on the decomposition of the calcined precursors and on the nanomorphology and surface concentration of reduced catalysts were presented in this contribution. The data presented here are supplementary material of the catalysts presented in the research article “Structure and activity of Cu/ZnO catalysts co-modified with aluminium and gallium for methanol synthesis” published in Catalysis Today [1].

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