Interaction effects between CuO-ZnO-ZrO2 methanol phase and zeolite surface affecting stability of hybrid systems during one-step CO2 hydrogenation to DME

From CO2 to DME: Enhancement through Heteropoly Acids from a Catalyst Screening and Stability Study

The direct synthesis of dimethyl ether (DME) via CO₂ hydrogenation in a single step was studied using an improved class of bifunctional catalysts in a fixed bed reactor (T _R: 210-270 °C; 40 bar; gas hourly space velocity (GHSV) 19,800 NL kg_cat ^-1 h^-1; ratio CO₂/H₂/N₂ 3:9:2). The competitive bifunctional catalysts tested in here consist of a surface-basic copper/zinc oxide/zirconia (CZZ) methanol-producing part and a variable surface-acidic methanol dehydration part and were tested in overall 45 combinations. As dehydration catalysts, zeolites (ferrierite and β-zeolite), alumina, or zirconia were tested alone as well as with a coating of Keggin-type heteropoly acids (HPAs), i.e., silicotungstic or phosphotungstic acid. Two different mixing methods to generate bifunctional catalysts were tested: (i) a single-grain method with intensive intra-particular contact between CZZ and the dehydration catalyst generated by mixing in an agate mortar and (ii) a dual-grain approach relying on physical mixing with low contact. The influence of the catalyst mixing method and HPA loading on catalyst activity and stability was investigated. From these results, a selection of best-performing bifunctional catalysts was investigated in extended measurements (time on stream: 160 h/7 days, T _R: 250 and 270 °C; 40 bar; GHSV 19,800 NL kg_cat ^-1 h^-1; ratio CO₂/H₂/N₂ 3:9:2). Silicotungstic acid-coated bifunctional catalysts showed the highest resilience toward deactivation caused by single-grain preparation and during catalysis. Overall, HPA-coated catalysts showed higher activity and resilience toward deactivation than uncoated counterparts. Dual-grain preparation showed superior performance over single grain. Furthermore, silicotungstic acid coatings with 1 KU nm^-2 (Keggin unit per surface area of carrier) on Al₂O₃ and ZrO₂ as carrier materials showed competitive high activity and stability in extended 7-day measurements compared to pure CZZ. Therefore, HPA coating is found to be a well-suited addition to the CO₂-to-DME catalyst toolbox.

Ultra-thin ZrO2overcoating on CuO-ZnO-Al2O3catalyst by atomic layer deposition for improved catalytic performance of CO2hydrogenation to dimethyl ether

An ultra-thin overcoating of zirconium oxide (ZrO₂) film on CuO-ZnO-Al₂O₃(CZA) catalysts by atomic layer deposition (ALD) was proved to enhance the catalytic performance of CZA/HZSM-5 (H form of Zeolite Socony Mobil-5) bifunctional catalysts for hydrogenation of CO₂to dimethyl ether (DME). Under optimal reaction conditions (i.e. 240 °C and 2.8 MPa), the yield of product DME increased from 17.22% for the bare CZA/HZSM-5 catalysts, to 18.40% for the CZA catalyst after 5 cycles of ZrO₂ALD with HZSM-5 catalyst. All the catalysts modified by ZrO₂ALD displayed significantly improved catalytic stability of hydrogenation of CO₂to DME reaction, compared to that of CZA/HZSM-5 bifunctional catalysts. The loss of DME yield in 100 h of reaction was greatly mitigated from 6.20% (loss of absolute value) to 3.01% for the CZA catalyst with 20 cycles of ZrO₂ALD overcoating. Characterizations including hydrogen temperature programmed reduction, x-ray powder diffraction, and x-ray photoelectron spectroscopy revealed that there was strong interaction between Cu active centers and ZrO₂.

Advanced zeolite and ordered mesoporous silica-based catalysts for the conversion of CO2 to chemicals and fuels

For many years, capturing, storing or sequestering CO₂ from concentrated emission sources or from air has been a powerful technique for reducing atmospheric CO₂. Moreover, the use of CO₂ as a C1 building block to mitigate CO₂ emissions and, at the same time, produce sustainable chemicals or fuels is a challenging and promising alternative to meet global demand for chemicals and energy. Hence, the chemical incorporation and conversion of CO₂ into valuable chemicals has received much attention in the last decade, since CO₂ is an abundant, inexpensive, nontoxic, nonflammable, and renewable one-carbon building block. Nevertheless, CO₂ is the most oxidized form of carbon, thermodynamically the most stable form and kinetically inert. Consequently, the chemical conversion of CO₂ requires highly reactive, rich-energy substrates, highly stable products to be formed or harder reaction conditions. The use of catalysts constitutes an important tool in the development of sustainable chemistry, since catalysts increase the rate of the reaction without modifying the overall standard Gibbs energy in the reaction. Therefore, special attention has been paid to catalysis, and in particular to heterogeneous catalysis because of its environmentally friendly and recyclable nature attributed to simple separation and recovery, as well as its applicability to continuous reactor operations. Focusing on heterogeneous catalysts, we decided to center on zeolite and ordered mesoporous materials due to their high thermal and chemical stability and versatility, which make them good candidates for the design and development of catalysts for CO₂ conversion. In the present review, we analyze the state of the art in the last 25 years and the potential opportunities for using zeolite and OMS (ordered mesoporous silica) based materials to convert CO₂ into valuable chemicals essential for our daily lives and fuels, and to pave the way towards reducing carbon footprint. In this review, we have compiled, to the best of our knowledge, the different reactions involving catalysts based on zeolites and OMS to convert CO₂ into cyclic and dialkyl carbonates, acyclic carbamates, 2-oxazolidones, carboxylic acids, methanol, dimethylether, methane, higher alcohols (C₂₊OH), C₂₊ (gasoline, olefins and aromatics), syngas (RWGS, dry reforming of methane and alcohols), olefins (oxidative dehydrogenation of alkanes) and simple fuels by photoreduction. The use of advanced zeolite and OMS-based materials, and the development of new processes and technologies should provide a new impulse to boost the conversion of CO₂ into chemicals and fuels.

A Review on Green Hydrogen Valorization by Heterogeneous Catalytic Hydrogenation of Captured CO2 into Value-Added Products

The catalytic hydrogenation of captured CO2 by different industrial processes allows obtaining liquid biofuels and some chemical products that not only present the interest of being obtained from a very low-cost raw material (CO2) that indeed constitutes an environmental pollution problem but also constitute an energy vector, which can facilitate the storage and transport of very diverse renewable energies. Thus, the combined use of green H2 and captured CO2 to obtain chemical products and biofuels has become attractive for different processes such as power-to-liquids (P2L) and power-to-gas (P2G), which use any renewable power to convert carbon dioxide and water into value-added, synthetic renewable E-fuels and renewable platform molecules, also contributing in an important way to CO2 mitigation. In this regard, there has been an extraordinary increase in the study of supported metal catalysts capable of converting CO2 into synthetic natural gas, according to the Sabatier reaction, or in dimethyl ether, as in power-to-gas processes, as well as in liquid hydrocarbons by the Fischer-Tropsch process, and especially in producing methanol by P2L processes. As a result, the current review aims to provide an overall picture of the most recent research, focusing on the last five years, when research in this field has increased dramatically.

Copper and Iron Cooperation on Micro-Spherical Silica during Methanol Synthesis via CO2 Hydrogenation

A series of mono- and bi-metallic copper and iron samples were prepared by impregnation method on micro-spherical silica and used for the synthesis of methanol via CO2 hydrogenation. Compared with conventional carrier oxides, micro-spherical silica has obvious advantages in terms of absorption capacity and optimal distribution of active phases on its surface, also exhibiting excellent heat resistance properties and chemical stability. The prepared catalysts were characterized by various techniques including XRF, XRD, SEM, TEM, H2-TPR and CO2-TPD techniques, while catalytic measurements in CO2 hydrogenation reaction to methanol were performed in a fixed bed reactor at a reaction pressure of 30 bar and temperature ranging from 200 to 260 °C. The obtained results revealed that the mutual interaction of copper–iron induces promotional effects on the formation of methanol, especially on systems where Fe enrichment on the silica support favours the presence of a larger concentration of oxygen vacancies, consequently responsible for higher CO2 adsorption and selective methanol production. Surface reconstruction phenomena rather than coke or metal sintering were responsible for the slight loss of activity recorded on the catalyst samples during the initial phase of reaction; however, with no appreciable change on the product selectivity.

Hydrogenation of carbon dioxide (CO2) to fuels in microreactors: a review of set-ups and value-added chemicals production

A review of CO2 hydrogenation to fuels and value-added chemicals in microreactors.

CuO-In2O3 Catalysts Supported on Halloysite Nanotubes for CO2 Hydrogenation to Dimethyl Ether

Hydrogenation of CO2 relative to valuable chemical compounds such as methanol or dimethyl ether (DME) is an attractive route for reducing CO2 emissions in the atmosphere. In the present work, the hydrogenation of CO2 into DME over CuO-In2O3, supported on halloysite nanotubes (HNT) was investigated in the temperature range 200–300 °C at 40 atm. HNT appears to be novel promising support for bifunctional catalysts due to its thermal stability and the presence of acidic sites on its surface. CuO-In2O3/HNT catalysts demonstrate higher CO2 conversion and DME selectivity compared to non-indium CuO/HNT catalysts. The catalysts were investigated by N2 adsorption, X-ray diffraction, hydrogen-temperature programmed reduction and transition electron microscopy. The acid sites were analyzed by temperature programmed desorption of ammonia. It was shown that CuO/HNT was unstable under reaction conditions in contrast to CuO-In2O3/HNT. The best CuO-In2O3/HNT catalyst provided CO2 conversion of 7.6% with 65% DME selectivity under P = 40 atm, T = 250 °C, gas hour space velocity 12,000 h−1 and H2:CO2 = 3:1.

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.

Design, Fundamental Principles of Fabrication and Applications of Microreactors

This study highlights the development of small-scale reactors, in the form of microstructures with microchannel networking. Microreactors have achieved an impressive reputation, regarding chemical synthesis ability and their applications in the engineering, pharmaceutical, and biological fields. This review elaborates on the fabrication, construction, and schematic fundamentals in the design of the microreactors and microchannels. The materials used in the fabrication or construction of the microreactors include silicon, polymer, and glass. A general review of the application of microreactors in medical, biological, and engineering fields is carried out and significant improvements in these areas are reported. Finally, we highlight the flow patterns, mixing, and scaling-up of multiphase microreactor developments, with emphasis on the more significant industrial applications.

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.

CuZnZr-Zeolite Hybrid Grains for DME Synthesis: New Evidence on the Role of Metal-Acidic Features on the Methanol Conversion Step

The assessment of the catalytic performance of “hybrid” metal/zeolite catalysts (based on FER or MFI structure and CuZnZr metal complexes) in the methanol dehydration step to DME has been studied in this work. The results clearly show that there is an important effect of the interaction between metal and acid sites affecting the acid catalyst performances. Additionally, deactivation, studied by means of a Timo-on-Stream (TOS) test, was affected by the type of zeolite structure used for hybrid catalyst preparation. The decrease in DME selectivity can be attributed to the cooperation of metal and acid sites in the production of different compounds (mainly methyl formate and dimethoxy methane) converting methanol and DME. The presence of these compounds (indicating different reaction pathways active) was found to be dependent on the zeolite structure and on the type of co-precipitation medium (water or ethanol) used to prepare the hybrid catalyst.

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.