The Mechanism of CO and CO 2 Hydrogenation to Methanol over Cu‐Based Catalysts

Breaking the Conversion-Selectivity Trade-Off in Methanol Synthesis from CO2 Using Dual Intimate Oxide/Metal Interfaces

The selective hydrogenation of carbon dioxide (CO2) to value-added chemicals, e.g., methanol, using green hydrogen retrieved from renewable resources is a promising approach for CO2 emission reduction and carbon resource utilization. However, this process suffers from the competing side reaction of reverse water-gas shift (RWGS) and methanol decomposition, which often leads to a strong conversion-selectivity trade-off and thus a poor methanol yield. Here, we report that InOx coating of PdCu bimetallic nanoparticles (NPs) to construct intimate InOx/Cu and InOx/PdIn dual interfaces enables the break of conversion-selectivity trade-off by achieving ∼80% methanol selectivity at ∼20% CO2 conversion close to the thermodynamic limit, far superior to that of conventional metal catalysts with a single active metal/oxide interface. Comprehensive microscopic and spectroscopic characterization revealed that the InOx/PdIn interface favors the activation of CO2 to formate, while the adjacent InOx/Cu interface readily converts formate intermediates to methoxy species in tandem, which thus cooperatively boosts methanol production. These findings of dual-interface synergies via oxide coating of bimetallic NPs open a new avenue to the design of active and selective catalysts for advanced catalysis.

CO2 activation by copper oxide clusters: size, composition, and charge state dependence

The interaction of CO2 with copper oxide clusters of different size, composition, and charge is investigated via infrared multiple-photon dissociation (IR-MPD) spectroscopy and density functional theory (DFT) calculations. Laser ablation of a copper target in the presence of an O2/He mixture leads to the preferred formation of oxygen-rich copper oxide cluster cations, CuxOy+ (y > x; x ≤ 8), while the anionic cluster distribution is dominated by stoichiometric (x = y) and oxygen-deficient (y < x; x ≤ 8) species. Subsequent reaction of the clusters with CO2 in a flow tube reactor results in the preferred formation of near-stoichiometric CuxOy(CO2)+/- complexes. IR-MPD spectroscopy of the formed complexes reveals the non-activated binding of CO2 to all cations while CO2 is activated by all anions. The great resemblance of spectra for all sizes investigated demonstrates that CO2 activation is largely independent of cluster size and Cu/O ratio but mainly determined by the cluster charge state. Comparison of the IR-MPD spectra with DFT calculations of the model systems Cu2O4(CO2)- and Cu3O4(CO2)- shows that CO2 activation exclusively results in the formation of a CO3 unit. Subsequent CO2 dissociation to CO appears to be unfavorable due to the instability of CO on the copper oxide clusters indicating that potential hydrogenation reactions will most likely proceed via formate or bicarbonate intermediates.

Mechanistic insights into CO2 hydrogenation to methanol on Cu(110): unveiling energy linear relationships and enhancing performance strategies

The study of energy correlations in catalytic reactions plays a pivotal role in guiding catalyst development. This paper focuses on the investigation of energy linear relationships in methanol synthesis from CO2 hydrogenation on copper surfaces, systematically exploring energy parameters including activation energy, reaction energy and adsorption energy. A comparative analysis of the adsorption characteristics and reaction parameters in the formate, formic acid and reverse water-gas shift pathways is conducted, laying the data foundation for subsequent linear studies. Then, descriptors are extracted from electronic, energetic and structural information and further integrated using the sure independence screening and sparsifying operator (SISSO) method to establish an energy description paradigm characterized by interpretability and accuracy. Additionally, reactions are further categorized based on hydrogenation types to mitigate the adverse effects of redundant data points. Finally, the summarized reaction descriptors are extended to Cu-based alloy systems to highlight the rationality and transferability of the developed descriptors.

Sustainable methanol production from carbon dioxide: advances, challenges, and future prospects

The urgent need to address global carbon emissions and promote sustainable energy solutions has led to a growing interest in carbon dioxide (CO2) conversion technologies. Among these, the transformation of CO2 into methanol (MeOH) has gained prominence as an effective mitigation strategy. This review paper provides a comprehensive exploration of recent advances and applications in the direct utilization of CO2 for the synthesis of MeOH, encompassing various aspects from catalysts to market analysis, environmental impact, and future prospects. We begin by introducing the current state of CO2 mitigation strategies, highlighting the significance of carbon recycling through MeOH production. The paper delves into the chemistry and technology behind the conversion of CO2 into MeOH, encompassing key themes such as feedstock selection, material and energy supply, and the various conversion processes, including chemical, electrochemical, photochemical, and photoelectrochemical pathways. An in-depth analysis of heterogeneous and homogeneous catalysts for MeOH synthesis is provided, shedding light on the advantages and drawbacks of each. Furthermore, we explore diverse routes for CO2 hydrogenation into MeOH, emphasizing the technological advances and production processes associated with this sustainable transformation. As MeOH holds a pivotal role in a wide range of chemical applications and emerges as a promising transportation fuel, the paper explores its various chemical uses, transportation, storage, and distribution, as well as the evolving MeOH market. The environmental and energy implications of CO2 conversion to MeOH are discussed, including a thermodynamic analysis of the process and cost and energy evaluations for large-scale catalytic hydrogenation.

CO2 Hydrogenation to CH3OH on Metal-Doped TiO2(110): Mechanisms, Strain Effect and a New Thermodynamic-Kinetic Relation

Surface strain and linear thermodynamic-kinetic relation are interesting topics in catalysis. Development of low temperature methanol catalysts of high activity and selectivity is of particularly importance for conversion of CO2 to methanol. In the present paper CO2 hydrogenation to methanol on Znx@TiO2(110) (x=0-2) was explored using density functional calculations and microkinetic simulations. The reaction mechanisms on the three model systems were determined and it is shown that Zn2@TiO2(110) is the most active. The most favorable pathway on Zn2@TiO2(110) is identified and CO2+H to HCOO is found to be the rate-controlling step. It is demonstrated that there is a linear relation (named AEB relation) between the adsorption energies of the initial states and the barriers for the controlling step on the 18 systems studied. Calculations on strained surfaces show that the AEB relation exists within ±1 % strain. Sr2@TiO2(110) and -1 % strained CaZn and ZnCu doped TiO2(110) are potential good low temperature catalysts and deserve experimental testing.

Improving Molecule-Metal Surface Reaction Networks Using the Meta-Generalized Gradient Approximation: CO2 Hydrogenation

Density functional theory is widely used to gain insights into molecule-metal surface reaction networks, which is important for a better understanding of catalysis. However, it is well-known that generalized gradient approximation (GGA) density functionals (DFs), most often used for the study of reaction networks, struggle to correctly describe both gas-phase molecules and metal surfaces. Also, GGA DFs typically underestimate reaction barriers due to an underestimation of the self-interaction energy. Screened hybrid GGA DFs have been shown to reduce this problem but are currently intractable for wide usage. In this work, we use a more affordable meta-GGA (mGGA) DF in combination with a nonlocal correlation DF for the first time to study and gain new insights into a catalytically important surface reaction network, namely, CO2 hydrogenation on Cu. We show that the mGGA DF used, namely, rMS-RPBEl-rVV10, outperforms typical GGA DFs by providing similar or better predictions for metals and molecules, as well as molecule-metal surface adsorption and activation energies. Hence, it is a better choice for constructing molecule-metal surface reaction networks.

Visualizing the gas-sensitive structure of the CuZn surface in methanol synthesis catalysis

Methanol formation over Cu/ZnO catalysts is linked with a catalytically active phase created by contact between Cu nanoparticles and Zn species whose chemical and structural state depends on reaction conditions. Herein, we use variable-temperature scanning tunneling microscopy at elevated pressure conditions combined with X-ray photoelectron spectroscopy measurements to investigate the surface structures and chemical states that evolve when a CuZn/Cu(111) surface alloy is exposed to reaction gas mixtures. In CO2 hydrogenation conditions, Zn stays embedded in the CuZn surface, but once CO gas is added to the mixture, the Zn segregates onto the Cu surface. The Zn segregation is CO-induced, and establishes a new dynamic state of the catalyst surface where Zn is continually exchanged at the Cu surface. Candidates for the migrating few-atom Zn clusters are further identified in time-resolved imaging series. The findings point to a significant role of CO affecting the distribution of Zn in the multiphasic ZnO/CuZn/Cu catalysts.

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.

Multiscale Investigation of the Mechanism and Selectivity of CO2 Hydrogenation over Rh(111)

CO2 hydrogenation over Rh catalysts comprises multiple reaction pathways, presenting a wide range of possible intermediates and end products, with selectivity toward either CO or methane being of particular interest. We investigate in detail the reaction mechanism of CO2 hydrogenation to the single-carbon (C1) products on the Rh(111) facet by performing periodic density functional theory (DFT) calculations and kinetic Monte Carlo (kMC) simulations, which account for the adsorbate interactions through a cluster expansion approach. We observe that Rh readily facilitates the dissociation of hydrogen, thus contributing to the subsequent hydrogenation processes. The reverse water-gas shift (RWGS) reaction occurs via three different reaction pathways, with CO hydrogenation to the COH intermediate being a key step for CO2 methanation. The effects of temperature, pressure, and the composition ratio of the gas reactant feed are considered. Temperature plays a pivotal role in determining the surface coverage and adsorbate composition, with competitive adsorption between CO and H species influencing the product distribution. The observed adlayer configurations indicate that the adsorbed CO species are separated by adsorbed H atoms, with a high ratio of H to CO coverage on the Rh(111) surface being essential to promote CO2 methanation.

Enhanced Methanol Synthesis from CO2 Hydrogenation Achieved by Tuning the Cu-ZnO Interaction in ZnO/Cu2O Nanocube Catalysts Supported on ZrO2 and SiO2

The nature of the Cu-Zn interaction and especially the role of Zn in Cu/ZnO catalysts used for methanol synthesis from CO2 hydrogenation are still debated. Migration of Zn onto the Cu surface during reaction results in a Cu-ZnO interface, which is crucial for the catalytic activity. However, whether a Cu-Zn alloy or a Cu-ZnO structure is formed and the transformation of this interface under working conditions demand further investigation. Here, ZnO/Cu2O core-shell cubic nanoparticles with various ZnO shell thicknesses, supported on SiO2 or ZrO2 were prepared to create an intimate contact between Cu and ZnO. The evolution of the catalyst's structure and composition during and after the CO2 hydrogenation reaction were investigated by means of operando spectroscopy, diffraction, and ex situ microscopy methods. The Zn loading has a direct effect on the oxidation state of Zn, which, in turn, affects the catalytic performance. High Zn loadings, resulting in a stable ZnO catalyst shell, lead to increased methanol production when compared to Zn-free particles. Low Zn loadings, in contrast, leading to the presence of metallic Zn species during reaction, showed no significant improvement over the bare Cu particles. Therefore, our work highlights that there is a minimum content of Zn (or optimum ZnO shell thickness) needed to activate the Cu catalyst. Furthermore, in order to minimize catalyst deactivation, the Zn species must be present as ZnOx and not metallic Zn or Cu-Zn alloy, which is undesirably formed during the reaction when the precatalyst ZnO overlayer is too thin.

2D Metal/Graphene and 2D Metal/Graphene/Metal Systems for Electrocatalytic Conversion of CO2 to Formic Acid

Efficiently transforming CO2 into renewable energy sources is crucial for decarbonization efforts. Formic acid (HCOOH) holds great promise as a hydrogen storage compound due to its high hydrogen density, non-toxicity, and stability under ambient conditions. However, the electrochemical reduction of CO2 (CO2 RR) on conventional carbon black-supported metal catalysts faces challenges such as low stability through dissolution and agglomeration, as well as suffering from high overpotentials and the necessity to overcome the competitive hydrogen evolution reaction (HER). In this study, we modify the physical/chemical properties of metal surfaces by depositing metal monolayers on graphene (M/G) to create highly active and stable electrocatalysts. Strong covalent bonding between graphene and metal is induced by the hybridization of sp and d orbitals, especially the sharpd z 2 ${{d}_{{z}^{2}}}$ ,d y z ${{d}_{yz}}$ , andd x z ${{d}_{xz}}$ orbitals of metals near the Fermi level, playing a decisive role. Moreover, charge polarization on graphene in M/G enables the deposition of another thin metallic film, forming metal/graphene/metal (M/G/M) structures. Finally, evaluating overpotentials required for CO2 reduction to HCOOH, CO, and HER, we find that Pd/G, Pt/G/Ag, and Pt/G/Au exhibit excellent activity and selectivity toward HCOOH production. Our novel 2D hybrid catalyst design methodology may offer insights into enhanced electrochemical reactions through the electronic mixing of metal and other p-block elements.

Mn-promoted MoS2 catalysts for CO2 hydrogenation: enhanced methanol selectivity due to MoS2/MnOx interfaces

Considering the alarming scenario of climate change, CO2 hydrogenation to methanol is considered a key process for phasing out fossil fuels by means of CO2 utilization. In this context, MoS2 catalysts have recently shown to be promising catalysts for this reaction, especially in the presence of abundant basal-plane sulfur vacancies and due to synergistic mechanisms with other phases. In this work, Mn-promoted MoS2 prepared by a hydrothermal method presents considerable selectivity for CO2 hydrogenation to methanol in comparison with pure MoS2 and other promoters such as K and Co. Interestingly, if CO is used as a carbon source for the reaction, methanol production is remarkably lower, which suggests the absence of a CO intermediate during CO2 hydrogenation to methanol. After optimization of synthesis parameters, a methanol selectivity of 64% is achieved at a CO2 conversion of 2.8% under 180 °C. According to material characterization by X-ray Diffraction and X-ray Absorption, the Mn promoter is present mainly in the form of MnO and MnCO3 phases, with the latter undergoing convertion to MnO upon H2 pretreatment. However, following exposure to reaction conditions, X-ray photoelectron spectroscopy suggests that higher oxidation states of Mn may be present at the surface, suggesting that the improved catalytic activity for CO2 hydrogenation to methanol arises from a synergy between MoS2 and MnOx at the catalyst surface.

Nature of Zirconia on a Copper Inverse Catalyst Under CO2 Hydrogenation Conditions

The growing concern over the escalating levels of anthropogenic CO2 emissions necessitates effective strategies for its conversion to valuable chemicals and fuels. In this research, we embark on a comprehensive investigation of the nature of zirconia on a copper inverse catalyst under the conditions of CO2 hydrogenation to methanol. We employ density functional theory calculations in combination with the Grand Canonical Basin Hopping method, enabling an exploration of the free energy surface including a variable amount of adsorbates within the relevant reaction conditions. Our focus centers on a model three-atom Zr cluster on a Cu(111) surface decorated with various OH, O, and formate ligands, noted Zr3Ox (OH)y (HCOO)z/Cu(111), revealing major changes in the active site induced by various reaction parameters such as the gas pressure, temperature, conversion levels, and CO2/H2 feed ratios. Through our analysis, we have unveiled insights into the dynamic behavior of the catalyst. Specifically, under reaction conditions, we observe a large number of composition and structures with similar free energy for the catalyst, with respect to changing the type, number, and binding sites of adsorbates, suggesting that the active site should be regarded as a statistical ensemble of diverse structures that interconvert.

Combining Atomic Layer Deposition with Surface Organometallic Chemistry to Enhance Atomic-Scale Interactions and Improve the Activity and Selectivity of Cu-Zn/SiO2 Catalysts for the Hydrogenation of CO2 to Methanol

The direct synthesis of methanol via the hydrogenation of CO2, if performed efficiently and selectively, is potentially a powerful technology for CO2 mitigation. Here, we develop an active and selective Cu-Zn/SiO2 catalyst for the hydrogenation of CO2 by introducing copper and zinc onto dehydroxylated silica via surface organometallic chemistry and atomic layer deposition, respectively. At 230 °C and 25 bar, the optimized catalyst shows an intrinsic methanol formation rate of 4.3 g h-1 gCu-1 and selectivity to methanol of 83%, with a space-time yield of 0.073 g h-1 gcat-1 at a contact time of 0.06 s g mL-1. X-ray absorption spectroscopy at the Cu and Zn K-edges and X-ray photoelectron spectroscopy studies reveal that the CuZn alloy displays reactive metal support interactions; that is, it is stable under H2 atmosphere and unstable under conditions of CO2 hydrogenation, indicating that the dealloyed structure contains the sites promoting methanol synthesis. While solid-state nuclear magnetic resonance studies identify methoxy species as the main stable surface adsorbate, transient operando diffuse reflectance infrared Fourier transform spectroscopy indicates that μ-HCOO*(ZnOx) species that form on the Cu-Zn/SiO2 catalyst are hydrogenated to methanol faster than the μ-HCOO*(Cu) species that are found in the Zn-free Cu/SiO2 catalyst, supporting the role of Zn in providing a higher activity in the Cu-Zn system.

Strained few-layer MoS2 with atomic copper and selectively exposed in-plane sulfur vacancies for CO2 hydrogenation to methanol

In-plane sulfur vacancies (Sv) in molybdenum disulfide (MoS2) were newly unveiled for CO2 hydrogenation to methanol, whereas edge Sv were found to facilitate methane formation. Thus, selective exposure and activation of basal plane is crucial for methanol synthesis. Here, we report a mesoporous silica-encapsulated MoS2 catalysts with fullerene-like structure and atomic copper (Cu/MoS2@SiO2). The main approach is based on a physically constrained topologic conversion of molybdenum dioxide (MoO2) to MoS2 within silica. The spherical curvature enables the generation of strain and Sv in inert basal plane. More importantly, fullerene-like structure of few-layer MoS2 can selectively expose in-plane Sv and reduce the exposure of edge Sv. After promotion by atomic copper, the resultant Cu/MoS2@SiO2 exhibits stable specific methanol yield of 6.11 molMeOH molMo-1 h-1 with methanol selectivity of 72.5% at 260 °C, much superior to its counterparts lacking the fullerene-like structure and copper decoration. The reaction mechanism and promoting role of copper are investigated by in-situ DRIFTS and in-situ XAS. Theoretical calculations demonstrate that the compressive strain facilitates Sv formation and CO2 hydrogenation, while tensile strain accelerates the regeneration of active sites, rationalizing the critical role of strain.

Nitrogen recovery from low-value biogenic feedstocks via steam gasification to methylotrophic yeast biomass

Carbon and nitrogen are crucial elements for life and must be efficiently regenerated in a circular economy. Biomass streams at the end of their useful life, such as sewage sludge, are difficult to recycle even though they contain organic carbon and nitrogen components. Gasification is an emerging technology to utilize such challenging waste streams and produce syngas that can be further processed into, e.g., Fischer-Tropsch fuels, methane, or methanol. Here, the objective is to investigate if nitrogen can be recovered from product gas cleaning in a dual fluidized bed (DFB) after gasification of softwood pellets to form yeast biomass. Yeast biomass is a protein-rich product, which can be used for food and feed applications. An aqueous solution containing ammonium at a concentration of 66 mM was obtained and by adding other nutrients it enables the growth of the methylotrophic yeast Komagataella phaffii to form 6.2 g.L^-1 dry yeast biomass in 3 days. To further integrate the process, it is discussed how methanol can be obtained from syngas by chemical catalysis, which is used as a carbon source for the yeast culture. Furthermore, different gas compositions derived from the gasification of biogenic feedstocks including sewage sludge, bark, and chicken manure are evaluated for their ability to yield methanol and yeast biomass. The different feedstocks are compared based on their potential to yield methanol and ammonia, which are required for the generation of yeast biomass. It was found that the gasification of bark and chicken manure yields a balanced carbon and nitrogen source for the formation of yeast biomass. Overall, a novel integrated process concept based on renewable, biogenic feedstocks is proposed connecting gasification with methanol synthesis to enable the formation of protein-rich yeast biomass.

Nanomaterials as catalysts for CO2 transformation into value-added products: A review

Carbon dioxide (CO₂₎ is the most important greenhouse gas (GHG), accounting for 76% of all GHG emissions. The atmospheric CO₂ concentration has increased from 280 ppm in the pre-industrial era to about 418 ppm, and is projected to reach 570 ppm by the end of the 21^st century. In addition to reducing CO₂ emissions from anthropogenic activities, strategies to adequately address climate change must include CO₂ capture. To promote circular economy, captured CO₂ should be converted to value-added materials such as fuels and other chemical feedstock. Due to their tunable chemistry (which allows them to be selective) and high surface area (which allows them to be efficient), engineered nanomaterials are promising for CO₂ capturing and/or transformation. This work critically reviewed the application of nanomaterials for the transformation of CO₂ into various fuels, like formic acid, carbon monoxide, methanol, and ethanol. We discussed the literature on the use of metal-based nanomaterials, inorganic/organic nanocomposites, as well as other routes suitable for CO₂ conversion such as the electrochemical, non-thermal plasma, and hydrogenation routes. The characteristics, steps, mechanisms, and challenges associated with the different transformation technologies were also discussed. Finally, we presented a section on the outlook of the field, which includes recommendations for how to continue to advance the use of nanotechnology for conversion of CO₂ to fuels.

2D carbon nitride as a support with single Cu, Ag, and Au atoms for carbon dioxide reduction reaction

The electrochemical conversion of CO2 into value-added chemicals is an important approach to recycling CO2. In this work, we have combined the most efficient metal catalysts for this reaction, namely Cu, Ag, and Au, as single-atom particles dispersed on a two-dimensional carbon nitride support, with the aim of exploring their performance in the CO2 reduction reaction. Here, we report density functional theory computations showing the effect of single metal-atom particles on the support. We found that bare carbon nitride needed a high overpotential to overcome the energy barrier for the first proton-electron transfer, while the second transfer was exergonic. The deposition of single metal atoms enhances the catalytic activity of the system as the first proton-electron transfer is favored in terms of energy, although strong binding energies were found for CO adsorption on Cu and Au single atoms. Our theoretical interpretations are consistent with the experimental evidence that the competitive H2 generation is favored due to the strong CO binding energies. Our computational study paves the road to finding suitable metals that catalyze the first proton-electron transfer in the carbon dioxide reduction reaction and produce reaction intermediates with moderate binding energies, promoting a spillover to the carbon nitride support and thereby serving as bifunctional electrocatalysts.

Gas-Dependent Active Sites on Cu/ZnO Clusters for CH3OH Synthesis

This study describes an instantaneously gas-induced dynamic transition of an industrial Cu/ZnO/Al₂O₃ catalyst. Cu/ZnO clusters become "alive" and lead to a promotion in reaction rate by almost one magnitude, in response to the variation of the reactant components. The promotional changes are functions of either CO₂-to-CO or H₂O-to-H₂ ratio which determines the oxygen chemical potential thus drives Cu/ZnO clusters to undergo reconstruction and allows the maximum formation of Cu-Zn²⁺ sites for CH₃OH synthesis.

Accurate descriptions of molecule-surface interactions in electrocatalytic CO2 reduction on the copper surfaces

Copper-based catalysts play a pivotal role in many industrial processes and hold a great promise for electrocatalytic CO₂ reduction reaction into valuable chemicals and fuels. Towards the rational design of catalysts, the growing demand on theoretical study is seriously at odds with the low accuracy of the most widely used functionals of generalized gradient approximation. Here, we present results using a hybrid scheme that combines the doubly hybrid XYG3 functional and the periodic generalized gradient approximation, whose accuracy is validated against an experimental set on copper surfaces. A near chemical accuracy is established for this set, which, in turn, leads to a substantial improvement for the calculated equilibrium and onset potentials as against the experimental values for CO₂ reduction to CO on Cu(111) and Cu(100) electrodes. We anticipate that the easy use of the hybrid scheme will boost the predictive power for accurate descriptions of molecule-surface interactions in 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.

Optimal Icosahedral Copper-Based Bimetallic Clusters for the Selective Electrocatalytic CO2 Conversion to One Carbon Products

Electrochemical CO2 reduction reactions can lead to high value-added chemical and materials production while helping decrease anthropogenic CO2 emissions. Copper metal clusters can reduce CO2 to more than thirty different hydrocarbons and oxygenates yet they lack the required selectivity. We present a computational characterization of the role of nano-structuring and alloying in Cu-based catalysts on the activity and selectivity of CO2 reduction to generate the following one-carbon products: carbon monoxide (CO), formic acid (HCOOH), formaldehyde (H2C=O), methanol (CH3OH) and methane (CH4). The structures and energetics were determined for the adsorption, activation, and conversion of CO2 on monometallic and bimetallic (decorated and core@shell) 55-atom Cu-based clusters. The dopant metals considered were Ag, Cd, Pd, Pt, and Zn, located at different coordination sites. The relative binding strength of the intermediates were used to identify the optimal catalyst for the selective CO2 conversion to one-carbon products. It was discovered that single atom Cd or Zn doping is optimal for the conversion of CO2 to CO. The core@shell models with Ag, Pd and Pt provided higher selectivity for formic acid and formaldehyde. The Cu-Pt and Cu-Pd showed lowest overpotential for methane formation.

Ga and Zn increase the oxygen affinity of Cu-based catalysts for the CO x hydrogenation according to ab initio atomistic thermodynamics

The direct hydrogenation of CO or CO2 to methanol, a highly vivid research area in the context of sustainable development, is typically carried out with Cu-based catalysts. Specific elements (so-called promoters) improve the catalytic performance of these systems under a broad range of reaction conditions (from pure CO to pure CO2). Some of these promoters, such as Ga and Zn, can alloy with Cu and their role remains a matter of debate. In that context, we used periodic DFT calculations on slab models and ab initio thermodynamics to evaluate both metal alloying and surface formation by considering multiple surface facets, different promoter concentrations and spatial distributions as well as adsorption of several species (O*, H*, CO* and ) for different gas phase compositions. Both Ga and Zn form an fcc-alloy with Cu due to the stronger interaction of the promoters with Cu than with themselves. While the Cu-Ga-alloy is more stable than the Cu-Zn-alloy at low promoter concentrations (<25%), further increasing the promoter concentration reverses this trend, due to the unfavoured Ga-Ga-interactions. Under CO2 hydrogenation conditions, a substantial amount of O* can adsorb onto the alloy surfaces, resulting in partial dealloying and oxidation of the promoters. Therefore, the CO2 hydrogenation conditions are actually rather oxidising for both Ga and Zn despite the large amount of H2 present in the feedstock. Thus, the growth of a GaO x /ZnO x overlayer is thermodynamically preferred under reaction conditions, enhancing CO2 adsorption, and this effect is more pronounced for the Cu-Ga-system than for the Cu-Zn-system. In contrast, under CO hydrogenation conditions, fully reduced and alloyed surfaces partially covered with H* and CO* are expected, with mixed CO/CO2 hydrogenation conditions resulting in a mixture of reduced and oxidised states. This shows that the active atmosphere tunes the preferred state of the catalyst, influencing the catalytic activity and stability, indicating that the still widespread image of a static catalyst under reaction conditions is insufficient to understand the complex interplay of processes taking place on a catalyst surface under reaction conditions, and that dynamic effects must be considered.

Physico-Chemical Modifications Affecting the Activity and Stability of Cu-Based Hybrid Catalysts during the Direct Hydrogenation of Carbon Dioxide into Dimethyl-Ether

The direct hydrogenation of CO₂ into dimethyl-ether (DME) has been studied in the presence of ferrierite-based CuZnZr hybrid catalysts. The samples were synthetized with three different techniques and two oxides/zeolite mass ratios. All the samples (calcined and spent) were properly characterized with different physico-chemical techniques for determining the textural and morphological nature of the catalytic surface. The experimental campaign was carried out in a fixed bed reactor at 2.5 MPa and stoichiometric H₂/CO₂ molar ratio, by varying both the reaction temperature (200-300 °C) and the spatial velocity (6.7-20.0 NL∙g_cat^-1∙h^-1). Activity tests evidenced a superior activity of catalysts at a higher oxides/zeolite weight ratio, with a maximum DME yield as high as 4.5% (58.9 mg_DME∙g_cat^-1∙h^-1) exhibited by the sample prepared by gel-oxalate coprecipitation. At lower oxide/zeolite mass ratios, the catalysts prepared by impregnation and coprecipitation exhibited comparable DME productivity, whereas the physically mixed sample showed a high activity in CO₂ hydrogenation but a low selectivity toward methanol and DME, ascribed to a minor synergy between the metal-oxide sites and the acid sites of the zeolite. Durability tests highlighted a progressive loss in activity with time on stream, mainly associated to the detrimental modifications under the adopted experimental conditions.

Manganese Oxide as a Promoter for Copper Catalysts in CO2 and CO Hydrogenation

In this work, we discuss the role of manganese oxide as a promoter in Cu catalysts supported on graphitic carbon during hydrogenation of CO2 and CO. MnOx is a selectivity modifier in an H2/CO2 feed and is a highly effective activity promoter in an H2/CO feed. Interestingly, the presence of MnOx suppresses the methanol formation from CO2 (TOF of 0.7 ⋅ 10-3 s-1 at 533 K and 40 bar) and enhances the low-temperature reverse water-gas shift reaction (TOF of 5.7 ⋅ 10-3 s-1) with a selectivity to CO of 87 %C. Using time-resolved XAS at high temperatures and pressures, we find significant absorption of CO2 to the MnO, which is reversed if CO2 is removed from the feed. This work reveals fundamental differences in the promoting effect of MnOx and ZnOx and contributes to a better understanding of the role of reducible oxide promoters in Cu-based hydrogenation catalysts.

Competition between reverse water gas shift reaction and methanol synthesis from CO2: influence of copper particle size

Converting CO₂ into value-added chemicals and fuels, such as methanol, is a promising approach to limit the environmental impact of human activities. Conventional methanol synthesis catalysts have shown limited efficiency and poor stability in a CO₂/H₂ mixture. To design improved catalysts, crucial for the effective utilization of CO₂, an in-depth understanding of the active sites and reaction mechanism is desired. The catalytic performance of a series of carbon-supported Cu catalysts, with Cu particle sizes in the range of 5 to 20 nm, was evaluated under industrially relevant temperature and pressure, i.e. 260 °C and 40 bar(g). The CO₂ hydrogenation reaction exhibited clear particle size effects up to 13 nm particles, with small nanoparticles having the lower activity, but higher methanol selectivity. MeOH and CO formation showed a different size-dependence. The TOF_CO increased from 1.9 × 10^-3 s^-1 to 9.4 × 10^-3 s^-1 with Cu size increasing from 5 nm to 20 nm, while the TOF_MeOH was size-independent (8.4 × 10^-4 s^-1 on average). The apparent activation energies for MeOH and CO formation were size-independent with values of 63 ± 7 kJ mol^-1 and 118 ± 6 kJ mol^-1, respectively. Hence the size dependence was ascribed to a decrease in the fraction of active sites suitable for CO formation with decreasing particle size. Theoretical models and DFT calculations showed that the origin of the particle size effect is most likely related to the differences in formate coverage for different Cu facets whose abundancy depends on particle size. Hence, the CO₂ hydrogenation reaction is intrinsically sensitive to the Cu particle size.

Elucidation of Cu-Zn Surface Alloying on Cu(997) by Machine-Learning Molecular Dynamics

The Cu-Zn surface alloy has been extensively involved in the investigation of the true active site of Cu/ZnO/Al2O3, the industrial catalyst for methanol synthesis which remains under controversy. The challenge lies in capturing the interplay between the surface and reaction under operating conditions, which can be overcome given that the explicit dynamics of the system is known. To provide a better understanding of the dynamic of Cu-Zn surface at the atomic level, the structure and the formation process of the Cu-Zn surface alloy on Cu(997) were investigated by machine-learning molecular dynamics (MD). Gaussian process regression aided with on-the-fly learning was employed to build the force field used in the MD. The simulation reveals atomistic details of the alloying process, that is, the incorporation of deposited Zn adatoms to the Cu substrate. The surface alloying is found to start at upper and lower terraces near the step edge, which emphasize the role of steps and kinks in the alloying. The incorporation of Zn at the middle terrace was found at the later stage of the simulation. The rationalization of alloying behavior was performed based on statistics and barriers of various elementary events that occur during the simulation. It was observed that the alloying scheme at the upper terrace is dominated by the confinement of Zn step adatoms by other adatoms, highlighting the importance of step fluctuations in the alloying process. On the other hand, the alloying scheme at the lower terrace is dominated by direct exchange between the Zn step adatom and the Cu atom underneath. The alloying at the middle terrace is dominated by the wave deposition mechanism and deep confinement of Zn adatoms. The short propagation of alloyed Zn in the middle terrace was observed to proceed by means of indirect exchange instead of local exchange as proposed in the previous scanning tunneling microscopy (STM) observation. The comparison of migration rate and activation energies to the result of STM observation is also made. We have found that at a certain distance from the surface, the STM tip significantly affects the elementary events such as vacancy formation and direct exchange.

A Detailed Process and Techno-Economic Analysis of Methanol Synthesis from H2 and CO2 with Intermediate Condensation Steps

In order to increase the typically low equilibrium CO2 conversion to methanol using commercially proven technology, the addition of two intermediate condensation units between reaction steps is evaluated in this work. Detailed process simulations with heat integration and techno-economic analyses of methanol synthesis from green H2 and captured CO2 are presented here, comparing the proposed process with condensation steps with the conventional approach. In the new process, a CO2 single-pass conversion of 53.9% was achieved, which is significantly higher than the conversion of the conventional process (28.5%) and its equilibrium conversion (30.4%). Consequently, the total recycle stream flow was halved, which reduced reactant losses in the purge stream and the compression work of the recycle streams, lowering operating costs by 4.8% (61.2 M€·a−1). In spite of the additional number of heat exchangers and flash drums related to the intermediate condensation units, the fixed investment costs of the improved process decreased by 22.7% (94.5 M€). This was a consequence of the increased reaction rates and lower recycle flows, reducing the required size of the main equipment. Therefore, intermediate condensation steps are beneficial for methanol synthesis from H2/CO2, significantly boosting CO2 single-pass conversion, which consequently reduces both the investment and operating costs.

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.

Hydrogenation of Formate Species Using Atomic Hydrogen on a Cu(111) Model Catalyst

The reaction mechanism of the CH₃OH synthesis by the hydrogenation of CO₂ on Cu catalysts is unclear because of the challenge in experimentally detecting reaction intermediates formed by the hydrogenation of adsorbed formate (HCOO_a). Thus, the objective of this study is to clarify the reaction mechanism of the CH₃OH synthesis by establishing the kinetic natures of intermediates formed by the hydrogenation of adsorbed HCOO_a on Cu(111). We exposed HCOO_a on Cu(111) to atomic hydrogen at low temperatures of 200-250 K and observed the species using infrared reflection absorption (IRA) spectroscopy and temperature-programmed desorption (TPD) studies. In the IRA spectra, a new peak was observed upon the exposure of HCOO_a on Cu(111) to atomic hydrogen at 200 K and was assigned to the adsorbed dioxymethylene (H₂COO_a) species. The intensity of the new peak gradually decreased with heating from 200 to 290 K, whereas the IR peaks representing HCOO_a species increased correspondingly. In addition, small amounts of formaldehyde (HCHO), which were formed by the exposure of HCOO_a species to atomic hydrogen, were detected in the TPD studies. Therefore, H₂COO_a is formed via hydrogenation by atomic hydrogen, which thermally decomposes at ∼250 K on Cu(111). We propose a potential diagram of the CH₃OH synthesis via H₂COO_a from CO₂ on Cu surfaces, with the aid of density functional theory calculations and literature data, in which the hydrogenation of bidentate HCOO_a to H₂COO_a is potentially the rate-determining step and accounts for the apparent activation energy of the methanol synthesis from CO₂ on Cu surfaces.

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.

Insight into the Nature of the ZnO x Promoter during Methanol Synthesis

Despite the great commercial relevance of zinc-promoted copper catalysts for methanol synthesis, the nature of the Cu-ZnO x synergy and the nature of the active Zn-based promoter species under industrially relevant conditions are still a topic of vivid debate. Detailed characterization of the chemical speciation of any promoter under high-pressure working conditions is challenging but specifically hampered by the large fraction of Zn spectator species bound to the oxidic catalyst support. We present the use of weakly interacting graphitic carbon supports as a tool to study the active speciation of the Zn promoter phase that is in close contact with the Cu nanoparticles using time-resolved X-ray absorption spectroscopy under working conditions. Without an oxidic support, much fewer Zn species need to be added for maximum catalyst activity. A 5-15 min exposure to 1 bar H2 at 543 K only slightly reduces the Zn(II), but exposure for several hours to 20 bar H2/CO and/or H2/CO/CO2 leads to an average Zn oxidation number of +(0.5-0.6), only slightly increasing to +0.8 in a 20 bar H2/CO2 feed. This means that most of the added Zn is in a zerovalent oxidation state during methanol synthesis conditions. The Zn average coordination number is 8, showing that this phase is not at the surface but surrounded by other metal atoms (whether Zn or Cu), and indicating that the Zn diffuses into the Cu nanoparticles under reaction conditions. The time scale of this process corresponds to that of the generally observed activation period for these catalysts. These results reveal the speciation of the relevant Zn promoter species under methanol synthesis conditions and, more generally, present the use of weakly interacting graphitic supports as an important strategy to avoid excessive spectator species, thereby allowing us to study the nature of relevant promoter species.

Synthetic Routes to Crystalline Complex Metal Alkyl Carbonates and Hydroxycarbonates via Sol–Gel Chemistry—Perspectives for Advanced Materials in Catalysis

Metal alkoxides are easily available and versatile precursors for functional materials, such as solid catalysts. However, the poor solubility of metal alkoxides in organic solvents usually hinders their facile application in sol–gel processes and complicates access to complex carbonate or oxidic compounds after hydrolysis of the precursors. In our contribution we have therefore shown three different solubilization strategies for metal alkoxides, namely the derivatization, the hetero-metallization and CO2 insertion. The latter strategy leads to a stoichiometric insertion of CO2 into the metal–oxygen bond of the alkoxide and the subsequent formation of metal alkyl carbonates. These precursors can then be employed advantageously in sol–gel chemistry and, after controlled hydrolysis, result in chemically defined crystalline carbonates and hydroxycarbonates. Cu- and Zn-containing carbonates and hydroxycarbonates were used in an exemplary study for the synthesis of Cu/Zn-based bulk catalysts for methanol synthesis with a final comparable catalytic activity to commercial standard reference catalysts.

The state of zinc in methanol synthesis over a Zn/ZnO/Cu(211) model catalyst

The active chemical state of zinc (Zn) in a zinc-copper (Zn-Cu) catalyst during carbon dioxide/carbon monoxide (CO₂/CO) hydrogenation has been debated to be Zn oxide (ZnO) nanoparticles, metallic Zn, or a Zn-Cu surface alloy. We used x-ray photoelectron spectroscopy at 180 to 500 millibar to probe the nature of Zn and reaction intermediates during CO₂/CO hydrogenation over Zn/ZnO/Cu(211), where the temperature is sufficiently high for the reaction to rapidly turn over, thus creating an almost adsorbate-free surface. Tuning of the grazing incidence angle makes it possible to achieve either surface or bulk sensitivity. Hydrogenation of CO₂ gives preference to ZnO in the form of clusters or nanoparticles, whereas in pure CO a surface Zn-Cu alloy becomes more prominent. The results reveal a specific role of CO in the formation of the Zn-Cu surface alloy as an active phase that facilitates efficient CO₂ methanol synthesis.

Conversion of Carbon Dioxide into Methanol Using Cu-Zn Nanostructured Materials as Catalysts

Nowadays, there is a growing awareness of the great environmental impact caused by the enormous amounts of carbon dioxide emitted. Several alternatives exist to solve this problem, and one of them is the hydrogenation of carbon dioxide into methanol by using nanomaterials as catalysts. The aim of this alternative is to produce a value-added chemical, such as methanol, which is a cheaply available feedstock. The development of improved materials for this conversion reaction and a deeper study of the existing ones are important for obtaining higher efficiencies in terms of yield, conversion, and methanol selectivity, in addition to allowing milder reaction conditions in terms of pressure and temperature. In this work, the performance of copper, zinc, and zinc oxide nanoparticles in supported and unsupported bimetallic systems is evaluated in order to establish a comparison among the different materials according to their efficiency. For that, a packed bed reactor operating with a continuous gas flow is used. The obtained results indicate that the use of bimetallic systems combined with porous supports, such as zeolite and activated carbon, is beneficial, thus improving the performance of unsupported materials by four times.