Tuning Zeolite Properties towards CO 2 Methanation: An Overview

Fundamental properties and sustainable applications of the natural zeolite clinoptilolite

This review explores a set of sustainable applications of clinoptilolite, a natural zeolite abundant around the world in different localities. Thanks to its physico-chemical properties this material is extremely versatile for several applications, ranging from environmental catalysis and CO2 removal to industrial and agricultural wastewater purification, aquaculture, animal feeding, and food industry but also medical applications and energy storage systems. Due to the presence of cations in its framework, it is possible to tune the material's features making it suitable for adsorbing specific compounds. Thus, this review aims to provide insight into developing new technologies based on the use of this material that is sustainable, not harmful for humans and animals, naturally abundant, and above all cost-effective. Furthermore, it is intended to promote the use of natural materials in various areas with a view to sustainability and to reduce as far as possible the use of chemicals or other materials whose synthesis process can have a polluting effect on the environment.

Zinc-Catalyzed Hydroboration of Carbon Dioxide Amplified by Borane-Tethered Heteroscorpionate Bis(Pyrazolyl)methane Ligands

The borane-functionalized (BR2) bis(3,5-dimethylpyrazolyl)methane (LH) ligands 1a (BR2: 9-borabicyclo[3.3.1]nonane or 9-BBN), 1b (BR2: BCy2), and 1c (BR2: B(C6F5)2) were synthesized by the allylation-hydroboration of LH. Metalation of 1a,b with ZnCl2 yielded the heteroscorpionate dichloride complexes [(1a,b)ZnCl2] 3a,b. The reaction of 1a with ZnEt2 led to the formation of the zwitterionic complex [Et(1a)ZnEt(THF)] 5. The reaction of complex 3a with two equivalents of KHBEt3 under a carbon dioxide (CO2) atmosphere gave rise to the formation of the dimeric bis(formate) complex [(1a)Zn(OCHO)2]2 8, in which its borane moieties intermolecularly stabilize the formate ligands of opposite metal centers. The allylated precursor Lallyl and its zinc dichloride, diethyl and bis(formate) complexes [(Lallyl)ZnCl2] 2, [(Lallyl)ZnEt2] 4, and [(Lallyl)Zn(OCHO)2] 7 were also isolated. The catalyst systems composed of 1 mol % of 3a or 3b and two equivalents of KHBEt3 hydroborated CO2 at 1 bar with pinacolborane (HBPin) to the methanol-level product H3COBPin (and PinBOBPin) in yields of 42 or 86%, respectively. The catalyst systems using the unfunctionalized complex [(LH)ZnCl2] 6 and KHBEt3 or KHBEt3/nOctBR2 (BR2: 9-BBN or BCy2) hydroborated CO2 to H3COBPin but in 2.5- to 6-fold lower activities than those exhibited by 3a,b/KHBEt3. The hydroboration of CO2 using 8 as a catalyst led to yields of 39-43%, comparable to those obtained with 3a/KHBEt3. The results confirmed that the catalytic intermediates benefit from the incorporated boranes' intra- or intermolecular stabilizations.

Thermal and Plasma-Assisted CO2 Methanation over Ru/Zeolite: A Mechanistic Study Using In-Situ Operando FTIR

CO2 methanation is an attractive reaction to convert CO2 into a widespread fuel such as methane, being the combination of catalysts and a dielectric barrier discharge (DBD) plasma responsible for synergistic effects on the catalyst’s performances. In this work, a Ru-based zeolite catalyst, 3Ru/CsUSY, was synthesized by incipient wetness impregnation and characterized by TGA, XRD, H2-TPR, N2 sorption and CO2-TPD. Catalysts were tested under thermal and plasma-assisted CO2 methanation conditions using in-situ operando FTIR, with the aim of comparing the mechanism under both types of catalysis. The incorporation of Ru over the CsUSY zeolite used as support induced a decrease of the textural properties and an increase of the basicity and hydrophobicity, while no zeolite structural damage was observed. Under thermal conditions, a maximum CO2 conversion of 72% and CH4 selectivity above 95% were registered. These promising results were ascribed to the presence of small Ru0 nanoparticles over the support (16 nm), catalyst surface hydrophobicity and the presence of medium-strength basic sites in the catalyst. Under plasma-catalytic conditions, barely studied in similar setups in literature, CO2 was found to be excited by the plasma, facilitating its adsorption on the surface of 3Ru/CsUSY in the form of oxidized carbon species such as formates, aldehydes, carbonates, or carbonyls, which are afterwards progressively hydrogenated to methane. Adsorption and surface reaction of key intermediates, namely formate and aldehydic groups, was observed even on the support alone, an occurrence not reported before for thermal catalysis. Overall, similar reaction mechanisms were proposed for both thermal and plasma-catalysis conditions.

CO2 Hydrogenation to Renewable Methane on Ni/Ru Modified ZSM-5 Zeolites: The Role of the Preparation Procedure

Mono- and bimetallic Ni- and Ru-modified micro-mesoporous ZSM-5 catalysts were prepared by wet impregnation. The influence of the Ni content, the addition of Ru and the sequence of the modification by two metals on the physicochemical properties of the catalysts were studied. They were characterized by X-ray powder diffraction (XRD), N2 physisorption, temperature-programmed reduction (TPR-TGA), TEM and XPS spectroscopy. Formation of finely dispersed nickel and/or ruthenium oxide species was observed on the external surface and in the pores of zeolite support. It was found that the peculiarity of the used zeolite structure and the modification procedure determine the type of formed metal oxides, their dispersion and reducibility. XPS study revealed that the surface became rich in nickel and poorer in ruthenium for bimetallic catalysts. Ni had higher dispersion in the presence of ruthenium, and TPR investigations also confirmed its facilitated reducibility. The studied catalysts were tested in CO2 hydrogenation to methane. 10Ni5RuZSM-5 material showed the highest activity and high selectivity for methane formation, reaching the equilibrium conversion and 100% selectivity at 400 °C. Stability and reusability of the latter catalyst show that it is appropriate for practical application.

Structured clay minerals-based nanomaterials for sustainable photo/thermal carbon dioxide conversion to cleaner fuels: A critical review

In efforts to achieve a sustainable development goal, the utilization of CO₂ to generate renewable fuels is promising, as it is a sustainable technology that provides affordable and clean energy. To realize the production of renewable green fuels, a proficient and low-cost technology is required. Using photo/thermal catalytic process, the goal of sustainable CO₂ hydrogenation can be achieved. There have been several types of catalysts under exploration, however, they are expensive with limited availability. In the current development, green materials such as mineral clays are emerging as cocatalyst/supports for CO₂ hydrogenation. Clays are bestowed with various beneficial properties such as a large surface area, high porosity, abundant basic sites, excellent thermal stability and chemical corrosion resistance. Clays are promising materials that can drastically reduce the cost in catalyst preparation, partially fulfil the energy demand and reduce greenhouse gas emission. This review aims to focus on the various types of clays and their applications in the field of photo/thermal CO₂ hydrogenation to renewable fuels. Firstly, the classifications of clays are provided, whereby they can be differentiated based on their silicate layers, namely 1:1 and 2:1 type clay and their properties are thoroughly discussed to provide advantages and applications. The applications of various clays such as kaolinite, halloysite, montmorillonite, attapulgite, saponite and volkonskoite for CO₂ hydrogenation reactions are systematically discoursed. In addition, various approaches to improve the capability of raw clays as catalyst support are critically discussed, which include thermal treatment, exfoliation, acid-leaching and pillaring approaches. A critical discussion regarding the engineering aspects to further enhance clay-based catalyst for CO₂ hydrogenation are further disclosed. In short, clays are freely available materials that can be found in abundance. However, there are many more different types of natural green clays that have not been studied and explored in various energy applications.

17O Labeling Reveals Paired Active Sites in Zeolite Catalysts

Current needs for extending zeolite catalysts beyond traditional gas-phase hydrocarbon chemistry demand detailed characterization of active site structures, distributions, and hydrothermal impacts. A broad suite of homonuclear and heteronuclear NMR correlation experiments on dehydrated H-ZSM-5 catalysts with isotopically enriched ¹⁷O frameworks reveals that at least two types of paired active sites exist, the amount of which depends on the population of fully framework-coordinated tetrahedral Al (Al(IV)-1) and partially framework-coordinated tetrahedral Al (Al(IV)-2) sites, both of which can be denoted as (SiO)_4-n-Al(OH)_n. The relative amounts of Al(IV)-1 and Al(IV)-2 sites, and subsequent pairing, cannot be inferred from the catalyst Si/Al ratio, but depend on synthetic and postsynthetic modifications. Correlation experiments demonstrate that, on average, acidic hydroxyl groups from Al(IV)-1/Al(IV)-2 pairs are closer to one another than those from Al(IV)-1/Al(IV)-1 pairs, as supported by computational DFT calculations. Through-bond and through-space polarization transfer experiments exploiting ¹⁷O nuclei reveal a number of different acidic hydroxyl groups in varying Si/Al catalysts, the relative amounts of which change following postsynthetic modifications. Using room-temperature isotopic exchange methods, it was determined that ¹⁷O was homogeneously incorporated into the zeolite framework, while ¹⁷O → ²⁷Al polarization transfer experiments demonstrated that ¹⁷O incorporation does not occur for extra-framework Al_nO_m species. Data from samples exposed to controlled hydrolysis indicates that nearest neighbor Al pairs in the framework are more susceptible to hydrolytic attack. The data reported here suggest that Al(IV)-1/Al(IV)-2 paired sites are synergistic sites leading to increased reactivity in both low- and high-temperature reactions. No evidence was found for paired framework/nonframework sites.

On the Optimization of Ni/A and Ni/X Synthesis Procedure toward Active and Selective Catalysts for the Production of CH4 from CO2

Herein, optimization of zeolite NaA/NaX synthesis conditions in order to obtain the final product with high surface area and pore volume was investigated. An optimal synthesis condition was 5 days aging time and crystallization time of 9 h with the co-addition of cetyltrimethylammonium bromide (CTAB) and heptane. All those optimal synthesis conditions provided mixed phase between zeolite NaA and NaX, and addition of those organic phases improved the surface area and pore volume of the final synthesized zeolite. The role of CTAB and heptane on increasing the surface area of zeolite was studied by in situ small-angle X-ray scattering (SAXS). The SAXS results evidenced that small nucleation precursor was formed upon the addition of organic phase, and this nucleation precursor can provide zeolite with high-characteristic XRD signals of mixed phase of zeolite A and X after the crystallization process. The synthesized zeolite obtained from optimal synthesis condition with high surface area was further used as a catalyst support by impregnating with 5, 10, 15, and 20wt%Ni for catalyzing CO2 methanation reaction. The results found that 15wt%Ni/zeolite expressed the highest catalytic activity with high CH4 selectivity and stability. This was due to high dispersion of Ni species on catalyst surface and high metal-support interaction between Ni and zeolite. These results indicated that the mixed phase zeolite support can be a potential catalyst support for this reaction.

Alkali and Alkali-Earth Metals Incorporation to Ni/USY Catalysts for CO2 Methanation: The Effect of the Metal Nature

CO2 methanation is typically carried out using Ni-supported catalysts containing promoters such as alkali or alkali-earth metals to improve their properties. In this work, bimetallic Ni-based USY zeolite catalysts containing alkali (Li, K and Cs) and alkali-earth (Mg, Ca) metal compounds were prepared using the same conditions (15 wt% of metals; co-impregnation), characterized by N2 sorption, XRD, TGA, CO2 adsorption–desorption, DRS UV-Vis and H2-TPR, and finally applied in CO2 methanation reaction (86,100 mL h−1 g−1, PCO2 = 0.16 bar, H2:CO2 = 4:1). For each group, the effects of the second metal nature on the properties and performances were assessed. Alkali metals incorporation induced considerably low catalytic performances (CH4 yields < 26%), attributed to their negative impact on zeolite structure preservation. On the contrary, alkali-earth metal-containing catalysts exhibited lower structural damage. However, the formation of Ni-Mg mixed oxides in Ni-Mg/USY catalyst and CaCO3 during the reaction in Ni-Ca/USY sample could explain their performances, similar or lower than those obtained for Ni/USY catalyst. Among the studied metals, calcium was identified as the most interesting (CH4 yield of 65% at 415 °C), which was ascribed to the slight improvement of the Ni0 dispersion.

Investigation on the Suitability of Engelhard Titanium Silicate as a Support for Ni-Catalysts in the Methanation Reaction

Methanation reaction of carbon dioxide is currently envisaged as a facile solution for the storage and transportation of low-grade energies, contributing at the same time to the mitigation of CO2 emissions. In this work, a nickel catalyst impregnated onto a new support, Engelhard Titanium Silicates (ETS), is proposed, and its catalytic performance was tested toward the CO2 methanation reaction. Two types of ETS material were investigated, ETS-4 and ETS-10, that differ from each other in the titanium content, with Si/Ti around 2 and 3% by weight, respectively. Catalysts, loaded with 5% of nickel, were tested in the CO2 methanation reaction in the temperature range of 300–500 °C and were characterized by XRD, SEM–EDX, N2 adsorption–desorption and H2-TPR. Results showed an interesting catalytic activity of the Ni/ETS catalysts. Particularly, the best catalytic performances are showed by Ni/ETS-10: 68% CO2 conversion and 98% CH4 selectivity at T = 400 °C. The comparison of catalytic performance of Ni/ETS-10 with those obtained by other Ni-zeolites catalysts confirms that Ni/ETS-10 catalyst is a promising one for the CO2 methanation reaction.

Recent Advances in Catalysis Based on Transition Metals Supported on Zeolites

This article reviews the current state and development of thermal catalytic processes using transition metals (TM) supported on zeolites (TM/Z), as well as the contribution of theoretical studies to understand the details of the catalytic processes. Structural features inherent to zeolites, and their corresponding properties such as ion exchange capacity, stable and very regular microporosity, the ability to create additional mesoporosity, as well as the potential chemical modification of their properties by isomorphic substitution of tetrahedral atoms in the crystal framework, make them unique catalyst carriers. New methods that modify zeolites, including sequential ion exchange, multiple isomorphic substitution, and the creation of hierarchically porous structures both during synthesis and in subsequent stages of post-synthetic processing, continue to be discovered. TM/Z catalysts can be applied to new processes such as CO₂ capture/conversion, methane activation/conversion, selective catalytic NO_x reduction (SCR-deNO_x), catalytic depolymerization, biomass conversion and H₂ production/storage.

Effect of Exchangeable Ions in Natural and Modified Zeolites on Ag Content, Ag Nanoparticle Formation and Their Antibacterial Activity

To broaden the application of silver nanoparticles (AgNPs), which are well-known antibacterial agents, they are supported on different substrates to prevent aggregation, increase their surface area and antibacterial efficiency, and to be separated from the system more effectively at the end of treatment. To produce nanocomposites that consist of silver nanoparticles on natural and modified zeolites, silver ions (Ag⁺) were loaded onto zeolite (natural, Na-modified, H-modified) and then thermally reduced to AgNPs. The effect of the exchangeable cations in zeolite on Ag⁺ uptake, AgNPs formation, size and morphology was investigated by the TEM, SEM, EDX, XPS, UV-vis, XRD and BET methods. The silver amount in the nanocomposites decreased in the following order Na-modified zeolite > natural zeolite > H-modified zeolite. Microscopic techniques showed formation of AgNPs of 1–14 nm on natural and Na-modified zeolite, while the diameter of metal particles on H-modified zeolite was 12–42 nm. Diffuse reflectance UV-vis and XPS methods revealed the presence of both silver ions and AgNPs in the materials indicating that partial reduction of Ag⁺ ions took place upon heating at 400 °C in air. Additionally, antibacterial properties of the nanocomposites were tested against Escherichia coli, and it was found that Ag–containing composites originating from the Na-modified zeolite demonstrated the highest activity.

Natural Kaolin-Based Ni Catalysts for CO2 Methanation: On the Effect of Ce Enhancement and Microwave-Assisted Hydrothermal Synthesis

Natural kaolin-based Ni catalysts have been developed for low-temperature CO2 methanation. The catalysts were prepared via a one-step co-impregnation of Ni and Ce onto a natural kaolin-derived metakaolin using a microwave-assisted hydrothermal method as an acid-/base-free synthesis method. The influences of microwave irradiation and Ce promotion on the catalytic enhancement including the CO2 conversion, CH4 selectivity, and CH4 yield were experimentally investigated by a catalytic test of as-prepared catalysts in a fixed-bed tubular reactor. The relationship between the catalyst properties and its methanation activities was revealed by various characterization techniques including X-ray fluorescence, X-ray diffraction, Brunauer-Emmett-Teller, scanning electron microscopy, selected area electron diffraction, transmission electron microscopy, elemental mapping, H2 temperature-programmed reduction, and X-ray absorption near-edge structure analyses. Among the two enhancement methods, microwave and Ce promotion, the microwave-assisted synthesis could produce a catalyst containing highly dispersed Ni particles with a smaller Ni crystallite size and higher catalyst reducibility, resulting in a higher CO2 conversion from 1.6 to 7.5% and a better CH4 selectivity from 76.3 to 79.9% at 300 °C. Meanwhile, the enhancement by Ce addition exhibited a great improvement on the catalyst activities. It was experimentally found that the CO2 conversion increased approximately 7-fold from 7.5 to 52.9%, while the CH4 selectivity significantly improved from 79.9 to 98.0% at 300 °C. Though the microwave-assisted synthesis could further improve the catalyst activities of Ce-promoted catalysts, the Ce addition exhibited a more prominent impact than the microwave enhancement. Cerium oxide (CeO2) improved the catalyst activities through mechanisms of higher CO2 adsorption capacity with its basic sites and the unique structure of CeO2 with a reversible valence change of Ce4+ and Ce3+ and high oxygen vacancies. However, it was found that the catalyst prepared by microwave-assisted synthesis and Ce promotion proved to be the optimum catalyst in this study. Therefore, the present work demonstrated the potential to synthesize a nickel-based catalyst with improved catalytic activities by adding a small amount of Ce as a catalytic promoter and employing microwave irradiation for improving the Ni dispersion.

Promising Catalytic Systems for CO2 Hydrogenation into CH4: A Review of Recent Studies

The increasing utilization of renewable sources for electricity production turns CO2 methanation into a key process in the future energy context, as this reaction allows storing the temporary renewable electricity surplus in the natural gas network (Power-to-Gas). This kind of chemical reaction requires the use of a catalyst and thus it has gained the attention of many researchers thriving to achieve active, selective and stable materials in a remarkable number of studies. The existing papers published in literature in the past few years about CO2 methanation tackled the catalysts composition and their related performances and mechanisms, which served as a basis for researchers to further extend their in-depth investigations in the reported systems. In summary, the focus was mainly in the enhancement of the synthesized materials that involved the active metal phase (i.e., boosting its dispersion), the different types of solid supports, and the frequent addition of a second metal oxide (usually behaving as a promoter). The current manuscript aims in recapping a huge number of trials and is divided based on the support nature: SiO2, Al2O3, CeO2, ZrO2, MgO, hydrotalcites, carbons and zeolites, and proposes the main properties to be kept for obtaining highly efficient carbon dioxide methanation catalysts.

Applications of Zeolites to C1 Chemistry: Recent Advances, Challenges, and Opportunities

C1 chemistry, which is the catalytic transformation of C1 molecules including CO, CO₂ , CH₄ , CH₃ OH, and HCOOH, plays an important role in providing energy and chemical supplies while meeting environmental requirements. Zeolites are highly efficient solid catalysts used in the chemical industry. The design and development of zeolite-based mono-, bi-, and multifunctional catalysts has led to a booming application of zeolite-based catalysts to C1 chemistry. Combining the advantages of zeolites and metallic catalytic species has promoted the catalytic production of various hydrocarbons (e.g., methane, light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from C1 molecules. The key zeolite descriptors that influence catalytic performance, such as framework topologies, nanoconfinement effects, Brønsted acidities, secondary-pore systems, particle sizes, extraframework cations and atoms, hydrophobicity and hydrophilicity, and proximity between acid and metallic sites are discussed to provide a deep understanding of the significance of zeolites to C1 chemistry. An outlook regarding challenges and opportunities for the conversion of C1 resources using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

Methane Borylation Catalyzed by Ru, Rh, and Ir Complexes in Comparison with Cyclohexane Borylation: Theoretical Understanding and Prediction

Methane borylation catalyzed by Cp*M(Bpin)_n (M = Ru or Rh; HBpin = pinacolborane; n = 2 or 3) and (TMPhen)Ir(Bpin)₃ (TMPhen = 3,4,7,8-tetramethyl-1,10-phenanthroline) was investigated by DFT in comparison with cyclohexane borylation. Because Ru-catalyzed borylation has not been theoretically investigated yet, its reaction mechanism was first elucidated; Cp*Ru(Bpin)₃ 1-Ru is an active species, and Cp*Ru(Bpin)₃(H)(CH₃) 4-Ru is a key intermediate. In 4-Ru, the Ru is understood to have an ambiguous oxidation state between +IV and +VI because it has a H··Bpin bonding interaction with a bond order of about 0.5. Methane borylation occurs through oxidative addition of methane C-H bond followed by reductive elimination of borylmethane in all of these catalysts. The catalytic activity for methane borylation increases following the order Cp*Ru(Bpin)₃ < (TMPhen)Ir(Bpin)₃ < Cp*Rh(Bpin)₂. Cyclohexane borylation occurs in the same mechanism except for the presence of isomerization of a key intermediate. Chemoselectivity of methane over cyclohexane increases following the order Ir < Ru < Rh. In all of these catalysts, the rate-determining step (RDS) of cyclohexane borylation needs a larger ΔG°^‡ than the RDS of methane borylation because the more bulky cyclohexyl group induces larger steric repulsion with the ligand than methyl. One reason for the worse chemoselectivity of the Ir catalyst is its less congested transition state of the reductive elimination of borylcyclohexane. Herein, use of a strongly electron-donating ligand consisting of pyridine and N-heterocyclic carbene with bulky substituents is computationally proposed as a good ligand for the Ir catalyst; actually, the Ir complex of this ligand is calculated to be more active and more chemoselective than Cp*Rh(Bpin)₂ for methane borylation.

Zeolite-Supported Ni Catalysts for CO2 Methanation: Effect of Zeolite Structure and Si/Al Ratio

The urgent need to reduce CO2 emissions requires the development of efficient catalysts for the conversion of CO2 into chemicals and fuels. In this study, a series of nickel catalysts supported on ITQ-2 and ZSM-5 zeolites have been prepared, characterized and tested in the hydrogenation reaction of CO2 towards methane. Specifically, two ITQ-2 and two ZSM 5 zeolites with different aluminum content have been studied. For both types, the higher Si/Al ratio of the material, the more active the catalyst due probably to its higher hydrophobicity. The largest difference was found for the ITQ-2 samples, being the CO2 conversion for the sample with a greater Si/Al ratio 50 points higher at 350 °C. Comparing both zeolite structures, while similar catalytic results were obtained with the samples with lower Si/Al ratio, a distinctly higher activity was found for the ITQ-2 zeolite without aluminum, pure silica. Therefore, this result suggests that the presence of aluminum is of particular relevance. Among the studied materials, the catalyst supported on the delaminated ITQ-2 zeolite without Al was the most active catalyst. Its higher activity was mainly attributed to the smaller crystallite size of nickel supported on the large external surface area presented by this zeolite.

The Role of Alkali and Alkaline Earth Metals in the CO2 Methanation Reaction and the Combined Capture and Methanation of CO2

CO2 methanation has great potential for the better utilization of existing carbon resources via the transformation of spent carbon (CO2) to synthetic natural gas (CH4). Alkali and alkaline earth metals can serve both as promoters for methanation catalysts and as adsorbent phases upon the combined capture and methanation of CO2. Their promotion effect during methanation of carbon dioxide mainly relies on their ability to generate new basic sites on the surface of metal oxide supports that favour CO2 chemisorption and activation. However, suppression of methanation activity can also occur under certain conditions. Regarding the combined CO2 capture and methanation process, the development of novel dual-function materials (DFMs) that incorporate both adsorption and methanation functions has opened a new pathway towards the utilization of carbon dioxide emitted from point sources. The sorption and catalytically active phases on these types of materials are crucial parameters influencing their performance and stability and thus, great efforts have been undertaken for their optimization. In this review, we present some of the most recent works on the development of alkali and alkaline earth metal promoted CO2 methanation catalysts, as well as DFMs for the combined capture and methanation of CO2.