Modeling and Experimental Studies on Phase and Chemical Equilibria in High-Pressure Methanol Synthesis

Bifunctionality of Re Supported on TiO2 in Driving Methanol Formation in Low-Temperature CO2 Hydrogenation

Low temperature and high pressure are thermodynamically more favorable conditions to achieve high conversion and high methanol selectivity in CO2 hydrogenation. However, low-temperature activity is generally very poor due to the sluggish kinetics, and thus, designing highly selective catalysts active below 200 °C is a great challenge in CO2-to-methanol conversion. Recently, Re/TiO2 has been reported as a promising catalyst. We show that Re/TiO2 is indeed more active in continuous and high-pressure (56 and 331 bar) operations at 125-200 °C compared to an industrial Cu/ZnO/Al2O3 catalyst, which suffers from the formation of methyl formate and its decomposition to carbon monoxide. At lower temperatures, precise understanding and control over the active surface intermediates are crucial to boosting conversion kinetics. This work aims at elucidating the nature of active sites and active species by means of in situ/operando X-ray absorption spectroscopy, Raman spectroscopy, ambient-pressure X-ray photoelectron spectroscopy (AP-XPS), and diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS). Transient operando DRIFTS studies uncover the activation of CO2 to form active formate intermediates leading to methanol formation and also active rhenium carbonyl intermediates leading to methane over cationic Re single atoms characterized by rhenium tricarbonyl complexes. The transient techniques enable us to differentiate the active species from the spectator one on TiO2 support, such as less reactive formate originating from spillover and methoxy from methanol adsorption. The AP-XPS supports the fact that metallic Re species act as H2 activators, leading to H-spillover and importantly to hydrogenation of the active formate intermediate present over cationic Re species. The origin of the unique reactivity of Re/TiO2 was suggested as the coexistence of cationic highly dispersed Re including single atoms, driving the formation of monodentate formate, and metallic Re clusters in the vicinity, activating the hydrogenation of the formate to methanol.

A Detailed Process and Techno-Economic Analysis of Methanol Synthesis from H2 and CO2 with Intermediate Condensation Steps

In order to increase the typically low equilibrium CO2 conversion to methanol using commercially proven technology, the addition of two intermediate condensation units between reaction steps is evaluated in this work. Detailed process simulations with heat integration and techno-economic analyses of methanol synthesis from green H2 and captured CO2 are presented here, comparing the proposed process with condensation steps with the conventional approach. In the new process, a CO2 single-pass conversion of 53.9% was achieved, which is significantly higher than the conversion of the conventional process (28.5%) and its equilibrium conversion (30.4%). Consequently, the total recycle stream flow was halved, which reduced reactant losses in the purge stream and the compression work of the recycle streams, lowering operating costs by 4.8% (61.2 M€·a−1). In spite of the additional number of heat exchangers and flash drums related to the intermediate condensation units, the fixed investment costs of the improved process decreased by 22.7% (94.5 M€). This was a consequence of the increased reaction rates and lower recycle flows, reducing the required size of the main equipment. Therefore, intermediate condensation steps are beneficial for methanol synthesis from H2/CO2, significantly boosting CO2 single-pass conversion, which consequently reduces both the investment and operating costs.

Hydrogenation of Carbon Dioxide to Methanol over Non-Cu-based Heterogeneous Catalysts

The increasing atmospheric CO₂ level makes CO₂ reduction an urgent challenge facing the world. Catalytic transformation of CO₂ into chemicals and fuels utilizing renewable energy is one of the promising approaches toward alleviating CO₂ emissions. In particular, the selective hydrogenation of CO₂ to methanol utilizing renewable hydrogen potentially enables large scale transformation of CO₂ . The Cu-based catalysts have been extensively investigated in CO₂ hydrogenation. However, it is not only limited by long-term instability but also displays unsatisfactory catalytic performance. The supported metal-based catalysts (Pd, Pt, Au, and Ag) can achieve high methanol selectivity at low temperatures. The mixed oxide catalysts represented by M_a ZrO_x (M_a =Zn, Ga, and Cd) solid solution catalysts present high methanol selectivity and catalytic activity as well as excellent stability. This Review focuses on the recent advances in developing Non-Cu-based heterogeneous catalysts and current understandings of catalyst design and catalytic performance. First, the thermodynamics of CO₂ hydrogenation to methanol is discussed. Then, the progress in supported metal-based catalysts, bimetallic alloys or intermetallic compounds catalysts, and mixed oxide catalysts is discussed. Finally, a summary and a perspective are presented.

Challenges in the Greener Production of Formates/Formic Acid, Methanol, and DME by Heterogeneously Catalyzed CO2 Hydrogenation Processes

The recent advances in the development of heterogeneous catalysts and processes for the direct hydrogenation of CO₂ to formate/formic acid, methanol, and dimethyl ether are thoroughly reviewed, with special emphasis on thermodynamics and catalyst design considerations. After introducing the main motivation for the development of such processes, we first summarize the most important aspects of CO₂ capture and green routes to produce H₂. Once the scene in terms of feedstocks is introduced, we carefully summarize the state of the art in the development of heterogeneous catalysts for these important hydrogenation reactions. Finally, in an attempt to give an order of magnitude regarding CO₂ valorization, we critically assess economical aspects of the production of methanol and DME and outline future research and development directions.

Interplay between Reaction and Phase Behaviour in Carbon Dioxide Hydrogenation to Methanol

Condensation promotes CO₂ hydrogenation to CH₃ OH beyond equilibrium through in situ product separation. Although primordial for catalyst and reactor design, triggering conditions as well as the impact on sub-equilibrium reaction behaviour remain unclear. Herein we used an in-house designed micro-view-cell to gain chemical and physical insights into reaction and phase behaviour under high-pressure conditions over a commercial Cu/ZnO/Al₂ O₃ catalyst. Raman microscopy and video monitoring, combined with online gas chromatography analysis, allowed the complete characterisation of the reaction bulk up to 450 bar (1 bar=0.1 MPa) and 350 °C. Dew points of typical effluent streams related to a parametric study suggest that the improving reaction performance and reverting selectivities observed from 230 °C strongly correlate with (i) a regime transition from kinetic to thermodynamic, and (ii) a phase transition from a single supercritical to a biphasic reaction mixture. Our results advance a rationale behind transitioning CH₃ OH selectivities for an improved understanding of CO₂ hydrogenation under high pressure.