Microkinetic analysis and mechanism of the water gas shift reaction over copper 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.

Theoretical Calculations on Metal Catalysts Toward Water-Gas Shift Reaction: a Review

Water-gas shift (WGS) reaction offers a dominating path to hydrogen generation from fossil fuel, in which heterogeneous metal catalysts play a crucial part in this course. This review highlights and summarizes recent developments on theoretical calculations of metal catalysts developed to date, including surface structure (e. g., monometallic and polymetallic systems) and interface structure (e. g., supported catalysts and metal oxide composites), with special emphasis on the characteristics of crystal-face effect, alloying strategy, and metal-support interaction. A systematic summarization on reaction mechanism was performed, including redox mechanism, associative mechanism as well as hybrid mechanism; the development on chemical kinetics (e. g., molecular dynamics, kinetic Monte Carlo and microkinetic simulation) was then introduced. At the end, challenges associated with theoretical calculations on metal catalysts toward WGS reaction are discussed and some perspectives on the future advance of this field are provided.

A density functional theory study of a water gas shift reaction on Ag(111): potassium effect

Density functional theory (DFT) calculations are executed to investigate the effect of a potassium (K) promoter on the activity of the water gas shift reaction (WGSR) over an Ag(111) surface.

Rational design of highly efficient MXene-based catalysts for the water-gas-shift reaction

Water molecules linked by hydrogen bonds are responsible for the high efficiency of bi-functional catalysts for the water-gas-shift (WGS) reaction because water can act as a proton transfer medium. Herein, we propose an associative pathway for the WGS reaction assisted by water to realize hydrogen production. Based on this pathway, we show by first-principles calculations that a large family of oxygen-terminated two-dimensional transition metal carbides and nitrides (MXenes) deposited on Au clusters are promising catalysts for the WGS reaction. Remarkably, the rate-determining barriers for *CO → *COOH on Au/M_n+1X_nO₂ are in the range from 0.15 eV to 0.39 eV, indicating that WGS can occur at much lower temperatures. Furthermore, a comprehensive microkinetic model is constructed to describe the turnover frequencies (TOF) for the product under the steady-state conditions. More importantly, there is a perfect linear scaling relationship between the rate-determining barriers of the WGS and the free energy of the adsorbed hydrogen. Besides, the potential energy diagrams for CO reforming reveal that the F terminations introduced in experiments have only a slight influence on the catalytic performance of the oxygen-terminated MXenes. Our work not only opens a new avenue towards the WGS reaction but also provides many ideal catalysts for hydrogen production.

Achieving Theory-Experiment Parity for Activity and Selectivity in Heterogeneous Catalysis Using Microkinetic Modeling

Microkinetic modeling based on density functional theory (DFT) energies plays an essential role in heterogeneous catalysis because it reveals the fundamental chemistry for catalytic reactions and bridges the microscopic understanding from theoretical calculations and experimental observations. Microkinetic modeling requires building a set of ordinary differential equations (ODEs) based on the calculation results of thermodynamic properties of adsorbates and kinetic parameters for the reaction elementary steps. Solving a microkinetic model can extract information on catalytic chemistry, including critical reaction intermediates, reaction pathways, the surface species distribution, activity, and selectivity, thus providing vital guidelines for altering catalysts.

However, the quantitative reliability of traditional microkinetic models is often insufficient to conclusively extrapolate the mechanistic details of complex reaction systems. This can be attributed to several factors, the most important of which is the limitation of obtaining an accurate estimation of the energy inputs via traditional calculation methods. These limitations include the difficulty of using static DFT methods to calculate reaction energies of adsorption/desorption processes, often rate-controlling or selectivity-determining steps, and the inadequate consideration of surface coverage effects. In addition, the robust microkinetic software is rare, which also complicates the resolution of complex catalytic systems.

In this Account, we review our recent works toward refining the predictions of microkinetic modeling in heterogeneous catalysis and achieving theory–experiment parity for activity and selectivity. First, we introduce CATKINAS, a microkinetic software developed in our group, and show how it disentangles the problem that traditional microkinetic software has and how it can now be applied to obtain kinetic results for more sophisticated reaction systems. Second, we describe a molecular dynamics method developed recently to obtain the free-energy changes for the adsorption/desorption process to fill in the missing energy inputs. Third, we show that a rigorous consideration of surface coverage effects is pivotal for building more realistic models and obtaining accurate kinetic results. Following a series of studies on acetylene hydrogenation reactions on Pd catalysts, we demonstrate how this new approach can provide an improved quantitative understanding of the mechanism, active site, and intrinsic structural sensitivity. Finally, we conclude with a brief outlook and the remaining challenges in this field.

Theoretical insights into TM@PHEs as single-atom catalysts for water splitting based on density functional theory

Single-atom catalysis is the new frontier of heterogeneous catalysis and has attracted considerable attention as it exhibits great potential in hydrogen evolution to mitigate energy crisis and environmental issues. The support materials for single-atom catalysts (SACs) play a significant role in stabilizing the metal atoms, preventing their aggregation, and enhancing the catalytic activity. Two-dimensional sp² hybridized PHE-graphene might be a real support for SACs due to the potential energy well induced by its enneagon, hexagon and pentagon carbon rings. In this study, eleven transition metal (TM) atoms adsorbed on PHE-graphene (TM@PHEs) are taken into account based on density functional theory (DFT) and PHE-graphene is proved to be an ideal single-atom carrier for water splitting. In particular, the TM@PHEs (TM = Fe, Ni, Ru, and Pd) exhibit high catalytic activity toward the hydrogen evolution reaction (HER). The reaction path of water splitting is also determined. Due to their much lower energy barrier, both Fe@PHE and Ru@PHE are more promising SACs. In addition, the charge density difference, Bader charge analysis and spin projected density of states (PDOS) are investigated.

CATKINAS: A large-scale catalytic microkinetic analysis software for mechanism auto-analysis and catalyst screening

As an effective method to analyze complex catalytic reaction networks, microkinetic modeling is gaining increasing popularity in the catalytic activity evaluation and rational design of heterogeneous catalysts. An automated simulator with stable and reliable performance is especially useful and in great request. Here we introduce the CATKINAS package developed for large-scale microkinetic modeling and analysis. Featuring with a multilevel solver and a multifunctional analyzer, CATKINAS can provide both accurate solutions and various quantitative and automatic analysis for a wide range of catalytic systems. The structure and the basic workflow are overviewed with the multilevel solver particularly illustrated. Also, we take the CO methanation reaction as an example to illustrate the application and efficiency of the CATKINAS package.

Microkinetic Modeling: A Tool for Rational Catalyst Design

The design of heterogeneous catalysts relies on understanding the fundamental surface kinetics that controls catalyst performance, and microkinetic modeling is a tool that can help the researcher in streamlining the process of catalyst design. Microkinetic modeling is used to identify critical reaction intermediates and rate-determining elementary reactions, thereby providing vital information for designing an improved catalyst. In this review, we summarize general procedures for developing microkinetic models using reaction kinetics parameters obtained from experimental data, theoretical correlations, and quantum chemical calculations. We examine the methods required to ensure the thermodynamic consistency of the microkinetic model. We describe procedures required for parameter adjustments to account for the heterogeneity of the catalyst and the inherent errors in parameter estimation. We discuss the analysis of microkinetic models to determine the rate-determining reactions using the degree of rate control and reversibility of each elementary reaction. We introduce incorporation of Brønsted-Evans-Polanyi relations and scaling relations in microkinetic models and the effects of these relations on catalytic performance and formation of volcano curves are discussed. We review the analysis of reaction schemes in terms of the maximum rate of elementary reactions, and we outline a procedure to identify kinetically significant transition states and adsorbed intermediates. We explore the application of generalized rate expressions for the prediction of optimal binding energies of important surface intermediates and to estimate the extent of potential rate improvement. We also explore the application of microkinetic modeling in homogeneous catalysis, electro-catalysis, and transient reaction kinetics. We conclude by highlighting the challenges and opportunities in the application of microkinetic modeling for catalyst design.

SSIA: A sensitivity-supervised interlock algorithm for high-performance microkinetic solving

Microkinetic modeling has drawn increasing attention for quantitatively analyzing catalytic networks in recent decades, in which the speed and stability of the solver play a crucial role. However, for the multi-step complex systems with a wide variation of rate constants, the often encountered stiff problem leads to the low success rate and high computational cost in the numerical solution. Here, we report a new efficient sensitivity-supervised interlock algorithm (SSIA), which enables us to solve the steady state of heterogeneous catalytic systems in the microkinetic modeling with a 100% success rate. In SSIA, we introduce the coverage sensitivity of surface intermediates to monitor the low-precision time-integration of ordinary differential equations, through which a quasi-steady-state is located. Further optimized by the high-precision damped Newton's method, this quasi-steady-state can converge with a low computational cost. Besides, to simulate the large differences (usually by orders of magnitude) among the practical coverages of different intermediates, we propose the initial coverages in SSIA to be generated in exponential space, which allows a larger and more realistic search scope. On examining three representative catalytic models, we demonstrate that SSIA is superior in both speed and robustness compared with its traditional counterparts. This efficient algorithm can be promisingly applied in existing microkinetic solvers to achieve large-scale modeling of stiff catalytic networks.

Computational Methods in Heterogeneous Catalysis

The unprecedented ability of computations to probe atomic-level details of catalytic systems holds immense promise for the fundamentals-based bottom-up design of novel heterogeneous catalysts, which are at the heart of the chemical and energy sectors of industry. Here, we critically analyze recent advances in computational heterogeneous catalysis. First, we will survey the progress in electronic structure methods and atomistic catalyst models employed, which have enabled the catalysis community to build increasingly intricate, realistic, and accurate models of the active sites of supported transition-metal catalysts. We then review developments in microkinetic modeling, specifically mean-field microkinetic models and kinetic Monte Carlo simulations, which bridge the gap between nanoscale computational insights and macroscale experimental kinetics data with increasing fidelity. We finally review the advancements in theoretical methods for accelerating catalyst design and discovery. Throughout the review, we provide ample examples of applications, discuss remaining challenges, and provide our outlook for the near future.

Metal-Oxide-Mediated Subtractive Manufacturing of Two-Dimensional Carbon Nitride for High-Efficiency and High-Yield Photocatalytic H2 Evolution

g-C₃N₄ is a promising visible-light-driven photocatalyst for H₂ evolution reaction; however, the achievement of the high photocatalytic performance is primarily limited by the low separation efficiency of the photogenerated charge carriers and partly restricted by the slow kinetics of charge transfer. 2D g-C₃N₄ can significantly improve the charge generation, transfer, and separation efficiencies. The 2D g-C₃N₄-based Z-scheme heterostructure can further enhance the charge-carrier separation and simultaneously increase the redox ability, thereby further boosting the photocatalytic performance. Here we report a transition-metal-oxide (TMO)-mediated subtractive manufacturing process toward the large-scale synthesis of 2D g-C₃N₄ and the simultaneous formation of a 2D/2D TMO/g-C₃N₄ Z-scheme heterojunction. The TMOs serve as catalysts to facilitate the hydrolysis reaction of the bulk g-C₃N₄ in the presence of moist air, forming 2D g-C₃N₄. The resulting 2D/2D TMO/g-C₃N₄ catalysts, in particular, 2D/2D Co₃O₄/g-C₃N₄, exhibit high-efficiency and high-yield photocatalytic H₂ evolution due to the suppression of electron-hole pair recombination and enhanced redox ability. The 2D/2D Co₃O₄/g-C₃N₄ photocatalyzes the H₂ evolution with a rate of ∼370 μmol h^-1 within λ > 400 nm. The external quantum efficiency of 2D/2D Co₃O₄/g-C₃N₄ at λ = 405 nm reaches 53.6%, which is among the highest values for g-C₃N₄-based catalysts.

Temperature-programmed desorption studies of NH3 and H2O on the RuO2(110) surface: effects of adsorbate diffusion

Temperature-programmed desorption (TPD) is one of the most straightforward surface science experiments for the determination of the thermodynamic and kinetic parameters of a reaction. In our previous study (J. Phys. Chem. C, 2013, 117, 6136-6142), we proposed a model combining DFT methods with microkinetics to investigate the TPD spectra of NH3 and H2O on the RuO2(110) surface. Although our model predicted both the physisorption and chemisorption peaks of both adsorbates in agreement with the experimental TPD spectra, it failed to explain the region between the physisorption and chemisorption areas and underestimated the intensity of the adsorbate in these areas. Hence, to improve our model, in this study, we considered the diffusion of adsorbates from the sub-monolayer to the second layer. Accordingly, we simulated the TPD spectra of both NH3 and H2O on the RuO2(110) surface using condensation approximation. Our results indicate that the diffusion barriers of the adsorbates at high coverage are smaller than their direct desorption energies. Hence, the diffusion of the adsorbates to the second layer from the sub-monolayer at higher coverage is kinetically favorable, which then desorb directly even at low temperatures. Furthermore, the simulated TPD spectra clearly depict the previous experimental results of both adsorbates after considering the diffusion.

Microkinetic Analysis and Scaling Relations for Catalyst Design

Microkinetic analysis plays an important role in catalyst design because it provides insight into the fundamental surface chemistry that controls catalyst performance. In this review, we summarize the development of microkinetic models and the inclusion of scaling relationships in these models. We discuss the importance of achieving stoichiometric and thermodynamic consistency in developing microkinetic models. We also outline how analysis of the maximum rates of elementary steps can be used to determine which transition states and adsorbed intermediates are kinetically significant, allowing the derivation of general reaction kinetics rate expressions in terms of changes in binding energies of the relevant transition states and intermediates. Through these analyses, we present how to predict optimal surface coverages and binding energies of adsorbed species, as well as the extent of potential rate improvement for a catalytic system. For systems in which the extent of potential rate improvement is small because of limitations imposed by scaling relations, different approaches, including the addition of promoters and formation of catalysts containing multiple functionalities, can be used to break the scaling relations and obtain further rate enhancement.

Supercritical Antisolvent Precipitation of Amorphous Copper-Zinc Georgeite and Acetate Precursors for the Preparation of Ambient-Pressure Water-Gas-Shift Copper/Zinc Oxide Catalysts

A series of copper–zinc acetate and zincian georgeite precursors have been produced by supercritical CO₂ antisolvent (SAS) precipitation as precursors to Cu/ZnO catalysts for the water gas shift (WGS) reaction. The amorphous materials were prepared by varying the water/ethanol volumetric ratio in the initial metal acetate solutions. Water addition promoted georgeite formation at the expense of mixed metal acetates, which are formed in the absence of the water co‐solvent. Optimum SAS precipitation occurs without water to give high surface areas, whereas high water content gives inferior surface areas and copper–zinc segregation. Calcination of the acetates is exothermic, producing a mixture of metal oxides with high crystallinity. However, thermal decomposition of zincian georgeite resulted in highly dispersed CuO and ZnO crystallites with poor structural order. The georgeite‐derived catalysts give superior WGS performance to the acetate‐derived catalysts, which is attributed to enhanced copper–zinc interactions that originate from the precursor.

A new class of Cu/ZnO catalysts derived from zincian georgeite precursors prepared by co-precipitation

Zincian georgeite, an amorphous copper–zinc hydroxycarbonate, has been prepared by co-precipitation using acetate salts and ammonium carbonate.

Zincian georgeite, an amorphous copper–zinc hydroxycarbonate, has been prepared by co-precipitation using acetate salts and ammonium carbonate. Incorporation of zinc into the georgeite phase and mild ageing conditions inhibits crystallisation into zincian malachite or aurichalcite. This zincian georgeite precursor was used to prepare a Cu/ZnO catalyst, which exhibits a superior performance to a zincian malachite derived catalyst for methanol synthesis and the low temperature water–gas shift (LTS) reaction. Furthermore, the enhanced LTS activity and stability in comparison to that of a commercial Cu/ZnO/Al₂O₃ catalyst, indicates that the addition of alumina as a stabiliser may not be required for the zincian georgeite derived Cu/ZnO catalyst. The enhanced performance is partly attributed to the exclusion of alkali metals from the synthesis procedure, which are known to act as catalyst poisons. The effect of residual sodium on the microstructural properties of the catalyst precursor was investigated further from preparations using sodium carbonate.

Micro-kinetic simulations of the catalytic decomposition of hydrazine on the Cu(111) surface

Hydrazine (N₂H₄) is produced at industrial scale from the partial oxidation of ammonia or urea. The hydrogen content (12.5 wt%) and price of hydrazine make it a good source of hydrogen fuel, which is also easily transportable in the hydrate form, thus enabling the production of H₂in situ. N₂H₄ is currently used as a monopropellant thruster to control and adjust the orbits and altitudes of spacecrafts and satellites; with similar procedures applicable in new carbon-free technologies for power generators, e.g. proton-exchange membrane fuel cells. The N₂H₄ decomposition is usually catalysed by the expensive Ir/Al₂O₃ material, but a more affordable catalyst is needed to scale-up the process whilst retaining reaction control. Using a complementary range of computational tools, including newly developed micro-kinetic simulations, we have derived and analysed the N₂H₄ decomposition mechanism on the Cu(111) surface, where the energetic terms of all states have been corrected by entropic terms. The simulated temperature-programmed reactions have shown how the pre-adsorbed N₂H₄ coverage and heating rate affect the evolution of products, including NH₃, N₂ and H₂. The batch reactor simulations have revealed that for the scenario of an ideal Cu terrace, a slow but constant production of H₂ occurs, 5.4% at a temperature of 350 K, while the discharged NH₃ can be recycled into N₂H₄. These results show that Cu(111) is not suitable for hydrogen production from hydrazine. However, real catalysts are multi-faceted and present defects, where previous work has shown a more favourable N₂H₄ decomposition mechanism, and, perhaps, the decomposition of NH₃ improves the production of hydrogen. As such, further investigation is needed to develop a general picture.

Active sites and mechanisms for H₂O₂ decomposition over Pd catalysts

A combination of periodic, self-consistent density functional theory (DFT-GGA-PW91) calculations, reaction kinetics experiments on a SiO2-supported Pd catalyst, and mean-field microkinetic modeling are used to probe key aspects of H2O2 decomposition on Pd in the absence of cofeeding H2 We conclude that both Pd(111) and OH-partially covered Pd(100) surfaces represent the nature of the active site for H2O2 decomposition on the supported Pd catalyst reasonably well. Furthermore, all reaction flux in the closed catalytic cycle is predicted to flow through an O-O bond scission step in either H2O2 or OOH, followed by rapid H-transfer steps to produce the H2O and O2 products. The barrier for O-O bond scission is sensitive to Pd surface structure and is concluded to be the central parameter governing H2O2 decomposition activity.

High-temperature water gas shift reaction on Ni–Cu/CeO2 catalysts: effect of ceria nanocrystal size on carboxylate formation

The WGS mechanism strongly depends on the Ni–Cu surface composition.

Bimetallic Ni–Cu alloy nanoparticles supported on silica for the water-gas shift reaction: activating surface hydroxyls via enhanced CO adsorption

Strong CO adsorption activates surface OH for enhanced WGS activity.

Plasmon-enhanced reverse water gas shift reaction over oxide supported Au catalysts

Visible light driven plasmon-enhanced reverse water gas shift reaction over Au/TiO₂catalysts for CO₂conversion.

Reactive removal of surface oxygen by H2, CO and CO/H2 on a Au/CeO2 catalyst and its relevance to the preferential CO oxidation (PROX) and reverse water gas shift (RWGS) reaction

CO and H₂ compete for the same active surface (lattice) oxygen species, but with a much lower reduction efficiency of H₂ compared to CO and CO–H₂ mixtures, during removal of active oxygen from a Au/CeO₂ catalyst by H₂, CO or CO/H₂ at temperatures between 30 and 300 °C.

Mechanistic study and catalyst development for selective carbon monoxide methanation

As for selective CO methanation over heterogeneous catalysts, numerous investigations of the reaction mechanism and catalyst development are reviewed.