Doubling the life of Cu/ZnO methanol synthesis catalysts via use of Si as a structural promoter to inhibit sintering

Cu/ZnO/Al2O3 catalysts used to synthesize methanol undergo extensive deactivation during use, mainly due to sintering. Here, we report on formulations wherein deactivation has been substantially reduced by the targeted use of a small quantity of a Si-based promoter, resulting in accrued activity benefits that can exceed a factor of 1.8 versus unpromoted catalysts. This enhanced stability also provides longer lifetimes, up to double that of prior generation catalysts. Detailed characterization of a library of aged catalysts has allowed the most important deactivation mechanisms to be established and the chemical state of the silicon promoter to be identified. We show that silicon is incorporated within the ZnO lattice, providing a pronounced improvement in the hydrothermal stability of this component. These findings have important implications for sustainable methanol production from H2 and CO2.

Effect of Reaction Time and Hydrothermal Treatment Time on the Textural Properties of SBA-15 Synthesized Using Sodium Silicate as a Silica Source and Its Efficiency for Reducing Tobacco Smoke Toxicity

The synthesis of SBA-15 has been optimized using sodium silicate, an inexpensive precursor of SBA-15. In this work, the influence of synthesis times of the precipitation and the hydrothermal treatment steps, on the textural properties developed as well as for reducing the toxic compounds generated in tobacco smoking, has been studied. The hydrothermal treatment has been proved to be necessary to obtain materials with adequate performance in this particular application. Twenty-four hours of hydrothermal treatment provide materials with the best properties. Although the reaction stage usually involves the mixing of reagents during 24 h, 40 min is enough to obtain a material with stick-like morphology and typical textural properties. Moreover, between 1 and 2 h of reaction time, the material proved to have the best performance for the purpose of reducing the toxicity of the products generated during the tobacco smoking process. These results are of great significance for an eventual scaling up to industrial scale of the SBA-15 manufacturing process. Results of a pilot plant experiment in a batch of 4 kg of SBA-15 are reported.

Quantum-Sized Zinc Oxide Nanoparticles Synthesised within Mesoporous Silica (SBA-11) by Humid Thermal Decomposition of Zinc Acetate

A modified facile method is presented to synthesise quantum-sized zinc oxide nanoparticles within the pores of a mesoporous silica host (SBA-11). This method eliminates the 3 h alcohol reflux and the basic solution reaction steps of zinc acetate. The mesoporous structure and the ZnO nanoparticles were analysed by X-ray diffractometry, transmission electron microscopy, energy-dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy, nitrogen sorption analysis and UV–VIS spectroscopy. These tests confirm the synthesis of ~1 nm sized ZnO within the pores of SBA-11 and that the porous structure remained intact after ZnO synthesis.

Facile and Versatile Sol-Gel Strategy for the Preparation of a High-Loaded ZnO/SiO2 Adsorbent for Room-Temperature H2S Removal

Preparation of well-dispersed ZnO nanograins is necessary to improve their reactivity toward room-temperature H₂S removal. However, the challenge to design such a ZnO-based adsorbent with high ZnO loading is yet to be fulfilled. Herein, a facile sol-gel strategy is reported for the preparation of ZnO/SiO₂ adsorbents for efficient H₂S removal, by innovating a gel-drying method and simultaneously controlling ZnO grain formation through optimizing the molar ratio of ethylene glycol (EG)/nitrates in its precursors. The fabricated adsorbent embedded well-dispersed ZnO nanograins, of approximately 10-15 nm, into a SiO₂ matrix (57 wt % ZnO loading) and thus yielded a high H₂S removal capacity of 108.9 mg S/g sorbent. Therein, EG was used as a modifier for inhibiting the formation of a denser SiO₂ network during the gel drying process and was used as a fuel for promoting the decomposition of nitrates and increasing the surface area of the composites in the subsequent calcination. Modulating the molar ratio of EG/nitrates ≤ 2 in precursors or traditional drying of the gel in an oven should be avoided because these would lead to the oxidation of EG by metallic nitrates and form carboxylate complexes during the gel-drying process. Although the produced ZnO grains had a very small size of less than 5 nm, a layer of monodentate ZnCO₃ impurity was formed on the ZnO surface, which will drastically decrease the reactivity of ZnO toward H₂S. According to the encouraging results from CuO and Co₃O₄, this strategy has proved to be versatile for the preparation of other metal oxide/SiO₂ adsorbents.

Fabricating a sustained releaser of heparin using SBA-15 mesoporous silica

The sustained release of heparin in sufficient amounts and over long time is a challenge to drive the development of functional materials. In this paper SBA-15 mesoporous silica is selected in the search for a favorable morphology and optimized surface state for the sustained release of heparin. In situ carbonization of the template in the as-synthesized sample enables SBA-15 to possess narrowed channels with rougher surfaces, while modification with (aminopropyl)triethoxysilane (APTES) through a one-pot synthesis offers SBA-15 with positive charges to attract heparin through electro-static interactions. The structure of modified SBA-15 samples is assessed with XRD (powder X-ray diffraction analysis), nitrogen adsorption-desorption and electron microscopy techniques, and their performance is evaluated in adsorption and release of heparin. These modifications improve the heparin adsorption in SBA-15 and thus promote its sustained release, prolonging the release-equilibrium time up to 60 days. Among them, the SBA-15 sample modified with APTES can trap three times as much heparin as the parent SBA-15, and the release ratio is elevated to 80% (that of SBA-15 is 38%), realizing the best performance of controlling heparin release to date.

Sustained release of heparin on enlarged-pore and functionalized MCM-41

Mesoporous silica MCM-41 and SBA-15 were chosen to study the adsorption and release of bulky biomolecule heparin, in order to develop new heparin controlled delivery system and expand the application of mesoporous materials in life science. To explore how the structure of support such as pore size and surface state affects the accommodation and release of heparin, we used decane as swelling agent to enlarge pores of MCM-41, introduced amino groups for improving the biocompatibility of support, and controllably retained templates in the as-synthesized sample. The influence of modification on the structure of samples was investigated by XRD and N(2) adsorption-desorption, whereas their performance of adsorbing and releasing heparin was assessed with that of toluidine blue method. Both enlarged pore and organic modification significantly promoted the adsorption and prolonged the release of heparin in MCM-41, and the release was characterized with a three-stage release model. The mechanism of heparin release from mesoporous material was studied by fitting the release profiles to the theoretical equation. As expected, some mesoporous composites could release heparin in the long term with tuned dosage.

Pore structure and surface area of silica SBA-15: influence of washing and scale-up

The removal of the surfactant (EO(20)PO(70)EO(20)) by washing before final calcination is a critical step in the synthesis of silica SBA-15. In contrast to washing with pure water or ethanol, washing with water and ethanol may, depending on the quantity of solvent used, alter the homogeneity and order of the pores, but also lead to an increase of the surface area of SBA-15. A reduction of solvent volume and a controlled washing protocol allow the synthesis of high surface area SBA-15 materials with a narrow monomodal pore size distribution. For larger batch sizes the influence of the quantity of solvent on the quality of the SBA-15 is reduced.

The reduction of copper in porous matrices—the role of electrostatic stabilisation

The redox properties of Cu(II) species in FAU matrices have been studied by temperature programmed reduction (TPR) in hydrogen and by XAFS analysis of the products obtained after (stationary) reduction treatments at various temperatures. The influence of the matrix polarity was investigated by comparing aluminosilicate FAU (Y zeolite) with siliceous FAU. In addition, the influence of Zn ions on the reduction process was studied. It was found that both the matrix composition and the presence of zinc ions exert a significant influence on the course of the reduction. In Y zeolite, heat treatment which is known to transfer Cu(II) ions to remote sites (SI, SI', SII') affects the reduction process dramatically. Cu(II) is most easily reduced in siliceous FAU, but the reduction proceeds in two clearly separated steps. Between these steps, small Cu(0) nuclei coexist with Cu(I) species, apparently unable to activate hydrogen for the autocatalytic reduction of the remaining Cu ions. The polarity of the matrix causes an upshift of the Cu(II) reduction temperature (in TPR by ca. 80 K for sites in the large cavity, by ca. 105 K for the remote sites), but the reduction of Cu(I) depends strongly on the simultaneous presence of Cu(0) and on its ability to activate hydrogen and induce an autocatalytic reduction mechanism. While Cu(I) species in the large cavities are easily reduced to the metal, tending to segregate from the zeolite lattice, Cu(I) ions in remote sites are strongly stabilized towards further reduction and even traces of Cu metal form only at very high temperatures. In the presence of zinc ions, the Cu metal particles formed were found to be smaller than in zinc-free samples.

Reduction of Copper in Porous Matrixes. Stepwise and Autocatalytic Reduction Routes

The reduction of Cu(II) oxide species in siliceous matrixes of different porosity (MFI, FAU, MCM-48) and in alumosilicate MFI was studied by temperature-programmed reduction in hydrogen (TPR), by X-ray absorption fine structure (after stationary hydrogen treatments), and by transmission electron microscopy. It was found that the reduction may proceed in one or in two reduction steps. The two-step scheme known for zeolites was observed also for Cu(II) in siliceous microporous matrixes, with similar temperature of Cu(II) reduction onset as for the alumosilicate MFI. Therefore, the two-step scheme cannot be explained by the stabilization of Cu ions by intra-zeolite electrical fields. CuOx clusters in MCM-48 were reduced in a one-step scheme (similar to bulk CuO) at high Cu content (6 wt %) but in a two-step scheme at low Cu content (1 wt %). The two reduction steps observed with most samples cannot be identified with the transitions of all Cu(II) to Cu(I) and of Cu(I) to Cu(0). Instead, Cu(0) nuclei were observed already at low reduction temperatures and were found to coexist with Cu ions over temperature ranges of different extension. This coexistence range was narrow in materials that favor aggregation of the Cu nuclei into particles: Cu-MCM-48 of low Cu content and Cu-ZSM-5. In the latter, metal segregation from the pore system was found to be accompanied by an autocatalytic initiation of the second reduction step. In the siliceous microporous matrixes, the Cu(0) nuclei were observed to coexist with Cu ions over wide temperature ranges (100 K for MFI) at temperatures far above that of Cu reduction in the bulk oxide. These observations suggest that oligomeric Cu metal nuclei which may have been formed, e.g., at the intersections of the MFI channel system, may be unable to activate hydrogen, which would be required for rapid reduction of the coexisting Cu ions.

Mesosynthesis of ZnO−Silica Composites for Methanol Nanocatalysis

Methanol catalysis meets chemistry under confined conditions. Methanol is regarded as one of the most important future energy sources. ZnO/Cu composite materials are very effective in heterogeneous catalysis for methanol production due to the so-called strong metal-support interaction effect (SMSI). Therefore, materials of superior structural design potentially representing model systems for heterogeneous catalysis are highly desired. Ultimately, such materials could help to understand the interaction between copper and zinc oxide in more detail than currently possible. We report the preparation of nanocrystalline, size-selected ZnO inside the pore system of ordered mesoporous silica materials. A new, liquid precursor for ZnO is introduced. It is seen that the spatial confinement significantly influences the chemical properties of the precursor as well as determines a hierarchical architecture of the final ZnO/SiO(2) nanocomposites. Finally, the ability of the materials to act as model systems in methanol preparation is investigated. The materials are characterized by a variety of techniques including electron microscopy, X-ray scattering, solid-state NMR, EPR, EXAFS, and Raman spectroscopy, and physisorption analysis.

A single-site hydroxyapatite-bound zinc catalyst for highly efficient chemical fixation of carbon dioxide with epoxides

A zinc-based hydroxyapatite catalyst in conjunction with a Lewis base proved to be efficient for the coupling of CO2 and epoxide in the absence of additional organic solvents under an atmospheric CO2 pressure; the work-up procedure is straightforward and the catalyst could be reused without loss of catalytic activity and selectivity.