Hydrogenation of CO2 to Dimethyl Ether over Brønsted Acidic PdZn Catalysts

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

Enhancing CO2 reduction through the catalytic effect of a novel silicon haeckelite-inspired 2D material

We propose a novel 2D material based on silicon haeckelite (Hck), whose structure contains a silicon atom arranged in a periodic pattern of pentagons and heptagons. Stacking the two layers gives rise to a planar geometry of the layers that compose it. This new structure presents a semiconductor character with a band gap of 0.17 eV. Furthermore, we studied CO2 reduction using molecular hydrogen to form formic acid, carbon monoxide, formaldehyde, methanol, and methane. All these have been studied theoretically at the Grimme D3BJ corrected TPSS/def2-SVP level. A massive biflake containing 132 Si atoms was used to model the Hck surface. According to the results, CO2 capture with Hck is a spontaneous step; in contrast, the same process for silicene mono- and bi-flakes studied previously was endergonic. After the capture of CO2, the addition of H2 to the substrate passes through an intermediate containing a Si-H bond. The formation of Si-H intermediates is the origin of the catalytic effect, facilitating H2 dissociation and acting as the hydrogen atom donor for the substrate. These intermediates are transformed by adding hydrogen atoms and losing water molecules, producing formic acid and formaldehyde as the most probable products, with rate-controlling steps of 29.2 and 27 kcal mol-1, whose values were less than those exhibited by the silicene biflake. This means that the silicon haeckelite biflake presents better catalytic activity than the silicene biflake. The results show that the novel 2D silicon hackelite material has remarkable potential for CO2 capture and reduction. The theoretical analysis of this innovative 2D structure provides valuable insights into the potential applications of silicene-based materials.

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 Deactivation and Regeneration of Catalysts for Dimethyl Ether Synthesis

The deactivation of catalysts and their regeneration are two very important challenges that need to be addressed for many industrial processes. The most quoted reasons for the deterioration of dimethyl ether synthesis (DME) concern the sintering and the hydrothermal leaching of copper particles, their migration to acid sites, the partial formation of copper and zinc hydroxycarbonates, the formation of carbon deposits, and surface contamination with undesirable compounds present in syngas. This review summarises recent findings in the field of DME catalyst deactivation and regeneration. The most-used catalysts, their modifications, along with a comparison of the basic parameters, deactivation approaches, and regeneration methods are presented.

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.

Combination of Cu/ZnO Methanol Synthesis Catalysts and ZSM-5 Zeolites to Produce Oxygenates from CO2 and H2

Cu/ZnO methanol catalysts were deposited over several ZSM-5 acid zeolites to directly synthesise oxygenates (methanol and dimethyl ether) from a CO2/H2 feed. Catalysts were prepared by two different preparation methodologies: chemical vapour impregnation (CZZ-CVI) and oxalate gel precipitation (CZZ-OG). Chemical vapour impregnation led to Cu/ZnO being deposited on the zeolite surface, whilst oxalate gel precipitation led to the formation of Cu/ZnO agglomerates. For both sets of catalysts a higher concentration of mild and strong acid sites were produced, compared to the parent ZSM-5 zeolites, and CZZ-CVI had a higher concentration of acid sites compared to CZZ-OG. Nevertheless, CZZ-OG shows considerably higher oxygenate productivity, 1322 mmol Kgcat−1 h−1, compared to 192 mmol Kgcat−1 h−1 over CZZ-CVI (ZSM-5(50), 250 ℃, 20 bar, CO2/H2 = 1/3, 30 ml min−1), which could be assigned to a combination of smaller particle size and enhanced methanol mass transfer within the zeolites.

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.

Ni Nanoparticles on Reducible Metal Oxides (Sm2O3, CeO2, ZnO) as Catalysts for CO2 Methanation

The activity of reducible metal oxide Sm2O3, CeO2, and ZnO as Ni nanoparticles support was investigated for CO2 methanation reaction. CO2 methanation was carried out between 200 °C to 450 °C with the optimum catalytic activity was observed at 450 °C. The reducibility of the catalysts has been comparatively studied using H2-Temperature Reduction Temperature (TPR) method. The H2-TPR analysis also elucidated the formation of surface oxygen vacancies at temperature above 600 °C for 5Ni/Sm2O3 and 5Ni/CeO2. The Sm2O3 showed superior activity than CeO2 presumably due to the transition of the crystalline phases under reducing environment. However, the formation of NiZn alloy in 5Ni/ZnO reduced the ability of Ni to catalyze methanation reaction. A highly dispersed Ni on Sm2O3 created a large metal/support interfacial interaction to give 69% of CO2 conversion with 100% selectivity at 450 °C. The 5Ni/Sm2O3 exhibited superior catalytic performances with an apparent phase transition from cubic to a mixture of cubic and monoclinic phases over a long reaction, presumably responsible for the enhanced conversion after 10 h of reaction. Copyright © 2021 by Authors, Published by BCREC Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).

Identification of C2-C5 products from CO2 hydrogenation over PdZn/TiO2-ZSM-5 hybrid catalysts

The combination of a methanol synthesis catalyst and a solid acid catalyst opens the possibility to obtain olefins or paraffins directly from CO2 and H2 in one step. In this work several PdZn/TiO2-ZSM-5 hybrid catalysts were employed under CO2 hydrogenation conditions (240-360 °C, 20 bar, CO2/N2/H2 = 1 : 1 : 3) for the synthesis of CH3OH, consecutive dehydration to dimethyl ether and further oxygenate conversion to hydrocarbons. No significant changes after 36 h reaction on the methanol synthesis catalyst (PdZn/TiO2) were observed by XRD, XAS or XPS. No olefins were observed, indicating that light olefins undergo further hydrogenation under the reaction conditions, yielding the corresponding alkanes. Increasing the aluminium sites in the zeolites (Si : Al ratio 80 : 1, 50 : 1 and 23 : 1) led to a higher concentration of mild Brønsted acid sites, promoting hydrocarbon chain growth.

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.

Enhanced CO2 methanation at mild temperature on Ni/zeolite from kaolin: effect of metal-support interface

Catalytic CO₂ hydrogenation to CH₄ offers a viable route for CO₂ conversion into carbon feedstock. The research aimed to enhance CO₂ conversion at low temperature and to increase the stability of Ni catalysts using zeolite as a support. NaZSM-5 (MFI), NaA (LTA), NaY (FAU), and NaBEA (BEA) synthesized from kaolin were impregnated with 15% Ni nanoparticles in order to elucidate the effect of surface area, porosity and basicity of the zeolite in increasing Ni activity at mild temperature of ∼200 °C. A highly dispersed Ni catalyst was produced on high surface area NaY meanwhile the mesoporosity of ZSM-5 has no significant effect in improving Ni dispersion. However, the important role of zeolite mesoporosity was observed on the stability of the catalyst. Premature deactivation of Ni/NaA within 10 h was due to the relatively small micropore size that restricted the CO₂ diffusion, meanwhile Ni/NaZSM-5 with a large mesopore size exhibited catalytic stability for 40 h of reaction. Zeolite NaY enhanced Ni activity at 200 °C to give 21% conversion with 100% CH₄ selectivity. In situ FTIR analysis showed the formation of hydrogen carbonate species and formate intermediates at low temperatures on Ni/NaY, which implied the efficiency of electron transfer from the basic sites of NaY during CO₂ reduction. The combination of Ni/NaY interfacial interaction and NaY surface basicity promoted CO₂ methanation reaction at low temperature.

Different Na-zeolites as supports of Ni metal were successfully synthesized from kaolin-based material. Combination of interfacial interaction Ni-support and surface basicity promoted CO₂ methanation reaction at a low temperature of ∼200 °C.

Investigation on the promotional role of Ga2O3 on the CuO-ZnO/HZSM-5 catalyst for CO2 hydrogenation

Dimethyl ether (DME) can be directly synthesized from carbon dioxide and hydrogen by mixing methanol synthesis catalysts and methanol dehydration catalysts. The activity and selectivity of the catalyst can be greatly affected by the promoter; herein, we presented a series of CuO-ZnO-Ga2O3/HZSM-5 hybrid catalysts, which were prepared by the coprecipitation method. The effect of the Ga2O3 content on the structure and performance of the Ga-promoted Cu-ZnO/HZSM-5 based catalysts was thoroughly investigated. The results showed that the addition of Ga2O3 significantly increased specific surface areas and Cu areas, decreased the size of Cu particles, maintained the proportion of Cu+/Cu0 on the surface of the catalyst, and strengthened the metal-support interaction, resulting in high catalytic performance.

Highly Selective Au/ZnO via Colloidal Deposition for CO2 Hydrogenation to Methanol: Evidence of AuZn Role

Gold, Au nanoparticles were deposited on ZnO, Al2O3, and Ga2O3 via colloidal method in order to investigate the role of support for CO2 hydrogenation to methanol. Au/ZnO was also produced using impregnation method to investigate the effect of colloidal method to improve methanol selectivity. Au/ZnO produced via sol immobilization showed high selectivity towards methanol meanwhile impregnation method produced Au/ZnO catalyst with high selectivity towards CO. The CO2 conversion was also influenced by the amount of Au weight loading. Au nanoparticles with average diameter of 3.5 nm exhibited 4% of CO2 conversion with 72% of methanol selectivity at 250 °C and 20 bar. The formation of AuZn alloy was identified as active sites for selective CO2 hydrogenation to methanol. Segregation of Zn from ZnO to form AuZn alloy increased the number of surface oxygen vacancy for CO2 adsorption to form formate intermediates. The formate was stabilized on AuZn alloy for further hydrogenation to form methanol.  The use of Al2O3 and Ga2O3 inhibited the formation of Au alloy, and therefore reduced methanol production. Au/Al2O3 showed 77% selectivity to methane, meanwhile Au/Ga2O3 produced 100% selectivity towards CO. Copyright © 2021 by Authors, Published by BCREC Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0). 

Direct Synthesis of Dimethyl Ether from CO2: Recent Advances in Bifunctional/Hybrid Catalytic Systems

Dimethyl ether (DME) is a versatile raw material and an interesting alternative fuel that can be produced by the catalytic direct hydrogenation of CO2. Recently, this process has attracted the attention of the industry due to the environmental benefits of CO2 elimination from the atmosphere and its lower operating costs with respect to the classical, two-step synthesis of DME from syngas (CO + H2). However, due to kinetics and thermodynamic limits, the direct use of CO2 as raw material for DME production requires the development of more effective catalysts. In this context, the objective of this review is to present the latest progress achieved in the synthesis of bifunctional/hybrid catalytic systems for the CO2-to-DME process. For catalyst design, this process is challenging because it should combine metal and acid functionalities in the same catalyst, in a correct ratio and with controlled interaction. The metal catalyst is needed for the activation and transformation of the stable CO2 molecules into methanol, whereas the acid catalyst is needed to dehydrate the methanol into DME. Recent developments in the catalyst design have been discussed and analyzed in this review, presenting the different strategies employed for the preparation of novel bifunctional catalysts (physical/mechanical mixing) and hybrid catalysts (co-precipitation, impregnation, etc.) with improved efficiency toward DME formation. Finally, an outline of future prospects for the research and development of efficient bi-functional/hybrid catalytic systems will be presented.

Transforming carbon dioxide into jet fuel using an organic combustion-synthesized Fe-Mn-K catalyst

With mounting concerns over climate change, the utilisation or conversion of carbon dioxide into sustainable, synthetic hydrocarbons fuels, most notably for transportation purposes, continues to attract worldwide interest. This is particularly true in the search for sustainable or renewable aviation fuels. These offer considerable potential since, instead of consuming fossil crude oil, the fuels are produced from carbon dioxide using sustainable renewable hydrogen and energy. We report here a synthetic protocol to the fixation of carbon dioxide by converting it directly into aviation jet fuel using novel, inexpensive iron-based catalysts. We prepare the Fe-Mn-K catalyst by the so-called Organic Combustion Method, and the catalyst shows a carbon dioxide conversion through hydrogenation to hydrocarbons in the aviation jet fuel range of 38.2%, with a yield of 17.2%, and a selectivity of 47.8%, and with an attendant low carbon monoxide (5.6%) and methane selectivity (10.4%). The conversion reaction also produces light olefins ethylene, propylene, and butenes, totalling a yield of 8.7%, which are important raw materials for the petrochemical industry and are presently also only obtained from fossil crude oil. As this carbon dioxide is extracted from air, and re-emitted from jet fuels when combusted in flight, the overall effect is a carbon-neutral fuel. This contrasts with jet fuels produced from hydrocarbon fossil sources where the combustion process unlocks the fossil carbon and places it into the atmosphere, in longevity, as aerial carbon - carbon dioxide.

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.

On the conversion of CO2 to value added products over composite PdZn and H-ZSM-5 catalysts: excess Zn over Pd, a compromise or a penalty?

Zn was found to possess a dual role in composite PdZn–H-ZSM-5 catalysts for CO₂ hydrogenation reactions: it promotes methanol formation when alloyed with Pd, but inhibits hydrocarbon formation by ion exchange with Brønsted acid sites in H-ZSM-5.

Methanol Synthesis from CO2 Hydrogenation

In the future we will be phasing out the use of fossil fuels in favour of more sustainable forms of energy, especially solar derived forms such as hydroelectric, wind and photovoltaic. However, due to the variable nature of the latter sources which depend on time of day, and season of the year, we also need to have a way of storing such energy at peak production times for use in times of low production. One way to do this is to convert such energy into chemical energy, and the principal way considered at present is the production of hydrogen. Although this may be achieved directly in the future via photocatalytic water splitting, at present it is electrolytic production which dominates thinking. In turn, it may well be important to store this hydrogen in an energy dense liquid form such as methanol or ammonia. In this brief review it is emphasised that CO2 is the microscopic carbon source for current industrial methanol synthesis, operating through the surface formate intermediate, although when using CO in the feed, it is CO which is hydrogenated at the global scale. However, methanol can be produced from pure CO2 and hydrogen using conventional and novel types of catalysts. Examples of such processes, and of a demonstrator plant in construction, are given, which utilize CO2 (which would otherwise enter the atmosphere directly) and hydrogen which can be produced in a sustainable manner. This is a fast-evolving area of science and new ideas and processes will be developed in the near future.