Methanol conversion over ZSM-12, ZSM-22 and EU-1 zeolites: from DME to hydrocarbons production

Copper-doped ZnO-ZrO2 solid solution catalysts for promoting methanol synthesis from CO2 hydrogenation

Copper-doped ZnO-ZrO₂ solid solution catalysts were synthesized via co-precipitation for promoting CH₃OH synthesis via hydrogenation of CO₂. Various testing methods were applied to investigate the effect of various copper contents on the catalysts. The catalytic performance was evaluated by a fixed bed reactor. XRD, HRTEM and Raman spectra collectively indicated that a ZnO-ZrO₂ solid solution catalyst with 3% Cu had a higher Cu dispersion, while the H₂-TPR results confirmed that a catalyst with 3% Cu had more Cu active sites under low temperature H₂ pretreatment. When the copper content increased to 5% and 10%, the catalyst showed a better Cu crystallinity and a worse Cu dispersion, which could have a negative effect. Therefore, the CO₂ conversion and methanol yield with a 3% CuZnO-ZrO₂ catalyst at 5 MPa, 250°C and 12 000 ml/(g h) increased by 8.6% and 7.6%, respectively. Moreover, the CH₃OH selectivity and catalytic stability of the solid solution catalyst were better than those of the traditional CZA catalyst.

Towards the Circular Economy of Rare Earth Elements: Lanthanum Leaching from Spent FCC Catalyst by Acids

Rare earth elements (REEs) are strategic materials widely used in different applications from Information and Communication Technologies (ICT) to catalysis, which are expected to grow more in the future. In order to reduce the impact of market price and reduce the environmental effect from soil extraction, recovery/purification strategies should be exploited. This paper presents a combined acid-leaching/oxalate precipitation process to recover lanthanum from spent FCC catalyst using nitric acid. Preferred to hydrochloric and sulphuric acid (preliminary assessed), HNO3 showed a good capability to completely leach lanthanum. The combination with an oxalate precipitation step allowed demonstrating that a highly pure (>98% w/w) lanthanum solid can be recovered, with a neglectable amount of poisoning metals (Ni, V) contained into the spent catalyst. This could open a reliable industrial perspective to recover and purify REE in the view of a sustainable recycling strategy.

Process Simulation and Environmental Aspects of Dimethyl Ether Production from Digestate-Derived Syngas

The production of dimethyl ether from renewables or waste is a promising strategy to push towards a sustainable energy transition of alternative eco-friendly diesel fuel. In this work, we simulate the synthesis of dimethyl ether from a syngas (a mixture of CO, CO₂ and H₂) produced from gasification of digestate. In particular, a thermodynamic analysis was performed to individuate the best process conditions and syngas conditioning processes to maximize yield to dimethyl etehr (DME). Process simulation was carried out by ChemCAD software, and it was particularly focused on the effect of process conditions of both water gas shift and CO₂ absorption by Selexol^® on the syngas composition, with a direct influence on DME productivity. The final best flowsheet and the best process conditions were evaluated in terms of CO₂ equivalent emissions. Results show direct DME synthesis global yield was higher without the WGS section and with a carbon capture equal to 85%. The final environmental impact was found equal to −113 kgCO₂/GJ, demonstrating that DME synthesis from digestate may be considered as a suitable strategy for carbon dioxide recycling.

The Effect of Zeolite Features on the Dehydration Reaction of Methanol to Dimethyl Ether: Catalytic Behaviour and Kinetics

The synthesis of dimethyl ether (DME) is an important step in the production of chemical intermediate because it is possible to prepare it by direct hydrogenation of CO₂. This paper reports the effect of different zeolitic frameworks (such as: BEA, EUO, FER, MFI, MOR, MTW, TON) on methanol conversion, DME selectivity and catalyst deactivation. The effect of crystal size, Si/Al ratio and acidity of the investigated catalysts have been also studied. Finally, the kinetic parameters (such as: ∆H, ∆S and ∆G) have been evaluated together with pre-exponential factor and activation energy for catalysts with FER and MFI structure topology.

Silica-Related Catalysts for CO2 Transformation into Methanol and Dimethyl Ether

The climate situation that the planet is experiencing, mainly due to the emission of greenhouse gases, poses great challenges to mitigate it. Since CO2 is the most abundant greenhouse gas, it is essential to reduce its emissions or, failing that, to use it to obtain chemicals of industrial interest. In recent years, much research have focused on the use of CO2 to obtain methanol, which is a raw material for the synthesis of several important chemicals, and dimethyl ether, which is advertised as the cleanest and highest efficiency diesel substitute fuel. Given that the bibliography on these catalytic reactions is already beginning to be extensive, and due to the great variety of catalysts studied by the different research groups, this review aims to expose the most important catalytic characteristics to take into account in the design of silica-based catalysts for the conversion of carbon dioxide to methanol and dimethyl ether.

Techno-Economic Assessment of Bio-Syngas Production for Methanol Synthesis: A Focus on the Water-Gas Shift and Carbon Capture Sections

The biomass-to-methanol process may play an important role in introducing renewables in the industry chain for chemical and fuel production. Gasification is a thermochemical process to produce syngas from biomass, but additional steps are requested to obtain a syngas composition suitable for methanol synthesis. The aim of this work is to perform a computer-aided process simulation to produce methanol starting from a syngas produced by oxygen-steam biomass gasification, whose details are reported in the literature. Syngas from biomass gasification was compressed to 80 bar, which may be considered an optimal pressure for methanol synthesis. The simulation was mainly focused on the water-gas shift/carbon capture sections requested to obtain a syngas with a (H₂ - CO₂)/(CO + CO₂) molar ratio of about 2, which is optimal for methanol synthesis. Both capital and operating costs were calculated as a function of the CO conversion in the water-gas shift (WGS) step and CO₂ absorption level in the carbon capture (CC) unit (by Selexol^® process). The obtained results show the optimal CO conversion is 40% with CO₂ capture from the syngas equal to 95%. The effect of the WGS conversion level on methanol production cost was also assessed. For the optimal case, a methanol production cost equal to 0.540 €/kg was calculated.

Assessment of Green Methanol Production Potential and Related Economic and Environmental Benefits: The Case of China

Adopting a new paradigm for social development implies a transition to a circular economy. The above requires the reduction of greenhouse gas emissions, the utilization of wastes, and the use of renewable energy sources. The most promising way is the use of methanol for industrial and transport applications. China is experiencing a boom in methanol production and its use in almost every sector of the economy. The purpose of this study was to reveal economic benefits, carbon dioxide emissions and the potential production of green methanol. Fuel price history, energy costs and fuel economy were used for economic assessment. Life cycle analysis to evaluate carbon dioxide emissions was applied. It was revealed that only the use of green methanol as a fuel results in decreases in well-to-wheel CO2 emissions compared to fossil fuels. The potential methanol production by using recycled waste and wind power was determined. Its annual production can range from 6.83 to 32.43 million tones. On this basis, a gradual transition to a circular and methanol economy is possible. Policymakers are recommended to support green methanol production in China. It can result in boosting the application of vehicles fueled by methanol and can control CO2 emissions.

Valorization of OFMSW Digestate-Derived Syngas toward Methanol, Hydrogen, or Electricity: Process Simulation and Carbon Footprint Calculation

This paper explores a possible waste-based economy transition strategy. Digestate from the organic fraction of municipal solid waste (OFMSW) is considered, as well as a low-added value product to be properly valorized. In this regard, air gasification may be used to produce syngas. In this work, the production of methanol, hydrogen, or electricity from digestate-derived syngas was assessed by ChemCAD process simulation software. The process scheme of methanol production comprises the following parts: water gas shift (WGS) with carbon capture and storage units (CCS), methanol synthesis, and methanol purification. In the case of hydrogen production, after WGS-CCS, hydrogen was purified from residual nitrogen by pressure swing absorption (PSA). Finally, for electricity production, the digestate-derived syngas was used as fuel in an internal combustion engine. The main objective of this work is to compare the proposed scenarios in terms of CO2 emission intensity and the effect of CO2 storage. In particular, CCS units were used for methanol or hydrogen production with the aim of obtaining high equilibrium yield toward these products. On the basis of 100 kt/year of digestate, results show that the global CO2 savings were 80, 71, and 69 ktCO2eq/year for electricity, methanol, and hydrogen production, respectively. If carbon storage was considered, savings of about 105 and 99 ktCO2eq/year were achieved with methanol and hydrogen production, respectively. The proposed scenarios may provide an attractive option for transitioning into methanol or hydrogen economy of the future.

Understanding the impact of one-dimensional pore containing 10MR and 12MR and aluminium content on MTH reaction pathways: direct synthesis of heteroatom containing UZM-55

We directly synthesized one-dimensional zeolite UZM-55 as an aluminosilicate and catalyzed MTH to understand pore structure influence on catalytic properties.

Effect of Surface Structure and Adsorption Activity on Implanting of b-Oriented ZSM-5 Zeolite Film on Modified α-Quartz Substrate

b-oriented ZSM-5 zeolite film was synthesized on the macropore α-quartz substrate modified with titanium dioxide (TiO₂), polyvinyl acetate (PVA), and chitosan (CTS) by hydrothermal crystallization. By comparing the binding energy and b-oriented angle of zeolite film on each modified α-quartz substrate, the orientations, and combinations derived from structure-adsorption relationship were investigated with Material Studio simulation. Furthermore, the effects of calcination temperature and ultraviolet (UV) irradiation time on the surface structure and adsorption activity of TiO₂ coating were studied. The increase adsorption potential energy and the formation of Ti-O-Si bind between zeolite crystal phase and substrate facilitate the continuous and uniform zeolite film growth. The TiO₂ interlayer with anatase phase after UV irradiation presents a smooth surface with high Ti-OH density, consequently to high selectivity of b-orientation growth for the ZSM-5 crystals. Compared with the traditional ZSM-5, the higher stability has been exhibited with b-oriented ZSM-5 film /TiO₂/α-quartz in the MTA reaction, and the methanol conversion and BTX selectivity remained higher than 90 and 70%, after 6 h reaction.

The Role of Active Sites Location in Partial Oxidation of Methane to Syngas for MCM-41 Supported Ni Nanoparticles

The supporting modes of active metal over mesoporous materials play an important role in catalytic performance. The location of Ni nanoparticles inside or outside the mesoporous channel of MCM-41 has a significant influence on the reactivity in partial oxidation of methane to syngas reaction. The characterization data using different techniques (Transmission Electron Microscope (TEM), X-Ray Diffraction (XRD), N2 adsorption-desorption, H2 Temperature-Programmed Reduction (H2-TPR), and Inductively Coupled Plasma (ICP)) indicated that nickel was located outside the mesoporous channels for the impregnation method (Ni/MCM-41), while nickel was encapsulated within MCM-41 via the one-step hydrothermal crystallization method (Ni-MCM-41). The nickel atoms were mainly dispersed predominantly inside the skeleton of zeolite. When the load amount of Ni increased, both of Ni species inside the skeleton or pore channel of zeolite increased, and the ordered structure of MCM-41 was destroyed gradually. Contributed by the strong interaction with MCM-41, the Ni particles of Ni-MCM-41 were highly dispersed with smaller particle size compared with supported Ni/MCM-41 catalyst. The Ni-MCM-41 displayed higher catalytic performance than Ni/MCM-41, especially 10% Ni-MCM-41 due to high dispersity of Ni. The confinement effect of MCM-41 zeolite also afforded high resistance of sintering and coking for 10% Ni-MCM-41 catalyst. Especially, 10% Ni-MCM-41 catalyst showed outstanding catalytic stability.

H-ZSM-5 Materials Embedded in an Amorphous Silica Matrix: Highly Selective Catalysts for Propylene in Methanol-to-Olefin Process

H-ZSM-5 materials embedded in an amorphous silica were successfully synthesized with three different Si/Al ratios (i.e., 40, 45, and 50). The presence of the MFI structure in the synthesized samples was confirmed by X-ray diffraction (XRD), Fourier transform infra-red (FT-IR), and solid state-nuclear magnetic resonance (SSNMR) techniques. The morphology and textural properties of the samples were investigated by scanning electron microscopy (SEM), TEM, and N2-physisorption measurements. Furthermore, acidic properties of the synthesized catalysts have been studied by NH3-TPD and FT-IR spectroscopy of CO adsorption studies. Variation of the Si/Al ratio affected the crystal morphology, porosity, and particle size, as well as the strength and distribution of acid sites. The synthesized zeolite materials possessed low acid-site density and exhibited high catalytic activity in the methanol-to-olefin (MTO) reaction. To study the intermediate species responsible for catalyst deactivation, the MTO reaction was carried out at high temperature (500 °C) to accelerate catalyst deactivation. Interestingly, the synthesized catalysts offered high selectivity towards the formation of propylene (C3=), in comparison to a commercial microporous crystalline H-ZSM-5 with Si/Al = 40, under the same reaction conditions. The synthesized H-ZSM-5 materials offered a selectivity ratio of C3=/C2= 12, while it is around 2 for the commercial H-ZSM-5 sample. The formation of hydrocarbon species during MTO reaction over zeolite samples has been systematically studied with operando UV-vis spectroscopy and online gas chromatography. It is proposed that the strength and type of acid sites of catalyst play a role in propylene selectivity as well as the fast growing of active intermediate species. The effective conversion of methanol into propylene in the case of synthesized H-ZSM-5 materials was observed due to possession of weak acid sites. This effect is more pronounced in H-ZSM-5 sample with a Si/Al ratio of 45.