Ceria-Zirconia/Zeolite Bifunctional Catalyst for Highly Selective Conversion of Syngas into Aromatics

Dual-engine-driven realizing high-yield synthesis of Para-Xylene directly from CO2-containing syngas

The direct synthesis of light aromatics, especially para-xylene (p-X), from syngas/CO2 is drawing strong interest, but improving the space-time yield (STY) of p-X is a significant challenge. Here, a dynamic "dual-engine-driven" (DED) catalytic system is designed by combining two partners of ZnCr and FeMn (named "dual-engine") with Z5@SiO2 capsule zeolite. The DED catalyst of 1.0%FeMn&[ZnCr&Z5@SiO2] shows an extremely higher p-X STY of 36.1 gp-x·kgcat-1·h-1, about eight times higher than that of [ZnCr&Z5]. DED manipulates ZnCr engine for methanol formation and drives FeMn engine for light olefins generation together, and then the formed methanol and light olefins are coordinately converted in situ into p-X-rich aromatics over Z5@SiO2. The DED model boosts the driving force for syngas/CO2 conversion, simultaneously concerting the cooperation of "dual-engine" for p-X generation, resulting in extremely high STY of p-X. This study achieves non-petroleum p-X production at industrial-relevant level and advances knowledge in designing innovative heterogeneous catalysts.

Recent advances in bifunctional synthesis gas conversion to chemicals and fuels with a comparison to monofunctional processes

In order to meet the climate goals of the Paris Agreement and limit the potentially catastrophic consequences of climate change, we must move away from the use of fossil feedstocks for the production of chemicals and fuels. The conversion of synthesis gas (a mixture of hydrogen, carbon monoxide and/or carbon dioxide) can contribute to this. Several reactions allow to convert synthesis gas to oxygenates (such as methanol), olefins or waxes. In a consecutive step, these products can be further converted into chemicals, such as dimethyl ether, short olefins, or aromatics. Alternatively, fuels like gasoline, diesel, or kerosene can be produced. These two different steps can be combined using bifunctional catalysis for direct conversion of synthesis gas to chemicals and fuels. The synergistic effects of combining two different catalysts are discussed in terms of activity and selectivity and compared to processes based on consecutive reaction with single conversion steps. We found that bifunctional catalysis can be a strong tool for the highly selective production of dimethyl ether and gasoline with high octane numbers. In terms of selectivity bifunctional catalysis for short olefins or aromatics struggles to compete with processes consisting of single catalytic conversion steps.

Direct and stable hydrogenation of CO2 to aromatics over a tandem catalyst Zn0.1Ti0.9Ox/HZSM-5

Direct and stable conversion of CO2 to aromatics (CTA) is an attractive route for reducing CO2 emissions. However, due to the chemical inertness of CO2, direct CTA reaction with high aromatics selectivity is still challenging. In this work, a tandem catalyst Zn0.1Ti0.9Ox/HZSM-5 with appropriate density and strength of acid sites exhibits a high aromatics selectivity of 67.2% and long-term stability over 100 h. Furthermore, the total selectivity of benzene, toluene, and xylene achieves 24.1% over Zn0.1Ti0.9Ox/HZSM-5 with a modified hydrophilic surface. In addition, the CTA via the formate route has been determined in this reaction system.

Fabricating Uniform TiO2-CeO2 Solid Solution Supported Pd Catalysts by an In Situ Capture Strategy for Low-Temperature CO Oxidation

Support properties regulation has been a feasible method for the improvement of noble metal catalytic performance. For Pd-based catalysts, TiO₂-CeO₂ material has been widely used as an important support. However, due to the considerable discrepancy in the solubility product constant between titanium and cerium hydroxides, it is still challenging to synthesize a uniform TiO₂-CeO₂ solid solution in the catalysts. Herein, an in situ capture strategy was constructed to fabricate a uniform TiO₂-CeO₂ solid solution as supports for an enhanced Pd-based catalyst. The obtained Pd/TiO₂-CeO₂-iC catalyst possessed enriched reactive oxygen species and optimized CO adsorption capability, manifesting a superior CO oxidation activity (T₁₀₀ = 70 °C) and stability (over 170 h). We believe this work provides a viable strategy for precise characteristic modulation of composite oxide supports during the fabrication of advanced noble metal-based catalysts.

Influence of the ZnCrAl Oxide Composition on the Formation of Hydrocarbons from Syngas

The conversion of syngas into value-added hydrocarbons gains increasing attention due to its potential to produce sustainable platform chemicals from simple starting materials. Along this line, the "OX-ZEO" process that combines a methanol synthesis catalyst with a zeolite, capable of catalyzing the methanol-to-hydrocarbon reaction, was found to be a suitable alternative to the classical Fischer-Tropsch synthesis. Hitherto, understanding the mechanism of the OX-ZEO process and simultaneously optimizing the CO conversion and the selectivity toward a specific hydrocarbon remains challenging. Herein, we present a comparison of a variety of ZnCrAl oxides with different metal ratios combined with a H-ZSM-5 zeolite for the conversion of syngas to hydrocarbons. The effect of aluminum on the catalytic activity was investigated for ZnCrAl oxides with a Zn/Cr ratio of 4:1, 1:1, and 1:2. The product distribution and CO conversion were found to be strongly influenced by the Zn/Cr/Al ratio. Although a ratio of Zn/Cr of 1:2 was best to produce lower olefins and aromatics, with aromatic selectivities of up to 37%, catalysts with a 4:1 ratio revealed high paraffin selectivity up to 52%. Notably, a distinct effect of aluminum in the oxide lattice on the catalytic activity and product selectivity was observed, as a higher Al content leads to a lower CO conversion and a changed product spectrum. We provide additional understanding of the influence of different compositions of ZnCrAl oxides on their surface properties and the catalytic activity in the OX-ZEO process. Furthermore, the variation of the zeolite component supports the important role of the channel topology of the porous support material for the hydrocarbon production. In addition, variation of the gas hourly space velocity showed a correlation of contact time, CO conversion, and hydrocarbon selectivity. At a gas hourly space velocity of 4200 mL/g_cat h, CO conversion as high as 44% along with a CO₂ selectivity of 42% and a lower paraffin (C₂ ⁰-C₄ ⁰) selectivity of 41% was observed.

OUP accepted manuscript

The rational design synthesis of zeolite catalysts with effective, environmentally benign and atom-economic routes is a major topic in the field of microporous materials, as it would avoid the high labor cost and inefficiency of traditional trial-and-error methods in developing new structures and dispel environmental concerns regarding the industrial mass production of zeolites. Catalytic applications of zeolite materials have expanded from conventional single functionalities, such as solid acids or selective oxidation catalysts to bi/multifunctionalities through combination with metals or metal oxides. This is a response to new requirements from petrochemical and fine chemical industries, such as precise control of product distribution, conversion of low-carbon resources for chemical production, and solutions to increasingly severe environmental problems related to CO₂ and NO_x. Thus, based on the systematic knowledge of zeolite chemistry and science that researchers have acquired in the past half-century and the development requirements, remarkable progress has been made in zeolite synthesis and catalysis in the past 10 years. This includes the manipulation of zeolitic monolayers derived from layered zeolites and germanosilicates to construct novel zeolite materials and effective and green zeolite syntheses as well as the synergistic interaction of zeolites and metal/metal oxides with different space distributions in the conversion of low-carbon resources. With many zeolite catalysts and catalytic processes being developed, our understanding of the close relationship between zeolite synthesis, structure and catalytic properties has deepened. Researchers are gradually approaching the goal of rationally designing zeolite catalysts with precisely controlled activity and selectivity for particular applications.

Advances in Catalytic Applications of Zeolite-Supported Metal Catalysts

Zeolites possessing large specific surface areas, ordered micropores, and adjustable acidity/basicity have emerged as ideal supports to immobilize metal species with small sizes and high dispersities. In recent years, the zeolite-supported metal catalysts have been widely used in diverse catalytic processes, showing excellent activity, superior thermal/hydrothermal stability, and unique shape-selectivity. In this review, a comprehensive summary of the state-of-the-art achievements in catalytic applications of zeolite-supported metal catalysts are presented for important heterogeneous catalytic processes in the last five years, mainly including 1) the hydrogenation reactions (e.g., CO/CO₂ hydrogenation, hydrogenation of unsaturated compounds, and hydrogenation of nitrogenous compounds); 2) dehydrogenation reactions (e.g., alkane dehydrogenation and dehydrogenation of chemical hydrogen storage materials); 3) oxidation reactions (e.g., CO oxidation, methane oxidation, and alkene epoxidation); and 4) other reactions (e.g., hydroisomerization reaction and selective catalytic reduction of NO_x with ammonia reaction). Finally, some current limitations and future perspectives on the challenge and opportunity for this subject are pointed out. It is believed that this review will inspire more innovative research on the synthesis and catalysis of zeolite-supported metal catalysts and promote their future developments to meet the emerging demands for practical applications.

Boosting the synthesis of value-added aromatics directly from syngas via a Cr2O3 and Ga doped zeolite capsule catalyst

Even though the transformation of syngas into aromatics has been realized via a methanol-mediated tandem process, the low product yield is still the bottleneck, limiting the industrial application of this technology. Herein, a tailor-made zeolite capsule catalyst with Ga doping and SiO2 coating was combined with the methanol synthesis catalyst Cr2O3 to boost the synthesis of value-added aromatics, especially para-xylene, from syngas. Multiple characterization studies, control experiments, and density functional theory (DFT) calculation results clarified that Ga doped zeolites with strong CO adsorption capability facilitated the transformation of the reaction intermediate methanol by optimizing the first C-C coupling step under a high-pressure CO atmosphere, thereby driving the reaction forward for aromatics synthesis. This work not only reveals the synergistic catalytic network in the tandem process but also sheds new light on principles for the rational design of a catalyst in terms of oriented conversion of syngas.

Enhancing BTX selectivity of the syngas to aromatics reaction through silylation of CTAB pretreated ZSM-5

Silylation of CTAB pretreated ZSM-5 combined with ceria–zirconia solid solution (CZS) was performed and this was used as a bifunctional catalyst for syngas conversion into light aromatics.

Direct conversion of syngas into aromatics over a bifunctional catalyst: inhibiting net CO2 release

Tandem catalysis via methanol intermediate is a promising route for the direct conversion of syngas into aromatics. However, the simultaneous formation of CO2 is a serious problem. Here, we demonstrate that CO2 was formed by the water-gas shift (WGS) reaction (CO + H2O → CO2 + H2) over a ZnO-ZrO2/H-ZSM-5 catalyst, and the net CO2 formation could be inhibited without affecting the formation of aromatics by co-feeding CO2.

The Effects of the Crystalline Phase of Zirconia on C–O Activation and C–C Coupling in Converting Syngas into Aromatics

Zirconia has recently been used as an efficient catalyst in the conversion of syngas. The crystalline phases of ZrO2 in ZrO2/HZSM-5 bi-functional catalysts have important effects on C–O activation and C–C coupling in converting syngas into aromatics and been investigated in this work. Monoclinic ZrO2 (m-ZrO2) and tetragonal ZrO2 (t-ZrO2) were synthesized by hydrothermal and chemical precipitation methods, respectively. The results of in situ diffuse reflection infrared Fourier transform spectroscopy (DRIFTs) revealed that there were more active hydroxyl groups existing on the surface of m-ZrO2, and CO temperature programmed desorption (CO-TPD) results indicated that the CO adsorption capacity of m-ZrO2 was higher than that of t-ZrO2, which can facilitate the C–O activation of m-ZrO2 for syngas conversion compared to that of t-ZrO2. And the CO conversion on the m-ZrO2 catalyst was about 50% more than that on the t-ZrO2 catalyst. 31P and 13C magic angle spinning nuclear magnetic resonance (MAS NMR) analysis revealed a higher acid and base density of m-ZrO2 than that of t-ZrO2, which enhanced the C–C coupling. The selectivity to CH4 on the m-ZrO2 catalyst was about 1/5 of that on the t-ZrO2 catalyst in syngas conversion. The selectivity to C2+ hydrocarbons over m-ZrO2 or t-ZrO2 as well as the proximity of the ZrO2 sample and HZSM-5 greatly affected the further aromatization in converting syngas into aromatics.

Two-way desorption coupling to enhance the conversion of syngas into aromatics by MnO/H-ZSM-5

We herein report a composite catalyst containing partially reducible and highly active manganese oxide and nano-size H-ZSM-5 with short b-axis, prepared for the direct conversion of syngas into aromatics.

Direct conversion of syngas into light aromatics over Cu-promoted ZSM-5 with ceria–zirconia solid solution

Syngas conversion with 72.1% selectivity to aromatics and 40.8% CO conversion was achieved over a copper and silica-modified ZSM-5 and ceria–zirconia solid solution bifunctional catalyst.

New horizon in C1 chemistry: breaking the selectivity limitation in transformation of syngas and hydrogenation of CO2 into hydrocarbon chemicals and fuels

Recent advances in bifunctional catalysis for conversion of syngas and hydrogenation of CO₂ into chemicals and fuels have been highlighted.

Nano-sized ZrO2 derived from metal–organic frameworks and their catalytic performance for aromatic synthesis from syngas

Oxygen vacancies apparently improve the surface properties of nano-sized ZrO₂, inducing the promotion of the catalytic performance of nano-sized ZrO₂.