Recent advances in the routes and catalysts for ethanol synthesis from syngas

Ethanol, as one of the important bulk chemicals, is widely used in modern society. It can be produced by fermentation of sugar, petroleum refining, or conversion of syngas (CO/H₂). Among these approaches, conversion of syngas to ethanol (STE) is the most environmentally friendly and economical process. Although considerable progress has been made in STE conversion, control of CO activation and C-C growth remains a great challenge. This review highlights recent advances in the routes and catalysts employed in STE technology. The catalyst designs and pathway designs are summarized and analysed for the direct and indirect STE routes, respectively. In the direct STE routes (i.e., one-step synthesis of ethanol from syngas), modified catalysts of methanol synthesis, modified catalysts of Fischer-Tropsch synthesis, Mo-based catalysts, noble metal catalysts and multifunctional catalysts are systematically reviewed based on their catalyst designs. Further, in the indirect STE routes (i.e., multi-step processes for ethanol synthesis from syngas via methanol/dimethyl ether as intermediates), carbonylation of methanol/dimethyl ether followed by hydrogenation, and coupling of methanol with CO to form dimethyl oxalate followed by hydrogenation, are outlined according to their pathway designs. The goal of this review is to provide a comprehensive perspective on STE technology and inspire the invention of new catalysts and pathway designs in the near future.

A predicted new catalyst to replace noble metal Pd for CO oxidative coupling to DMO

The reaction mechanisms of CO oxidative coupling to dimethyl oxalate (DMO) on different β-Mo2C(001) based catalysts have been studied by the density functional theory (DFT) method.

Enhanced metal-support interaction between Pd and hierarchical Nb2O5via oxygen defect induction to promote CO oxidative coupling to dimethyl oxalate

Production of ethylene glycol from coal is a particularly interesting route as it is an economic alternative to the petrochemical-based route. In this process, effectively generating dimethyl oxalate (DMO) is a crucial step by CO oxidative coupling reaction under Pd-based catalysts. However, the aggregation of Pd species over the support is still an issue that relates to the deterioration of catalytic activity and stability. To this end, enhancing the metal-support interaction is urgently required. In this work, hierarchical Nb₂O₅ (H-Nb₂O₅) microspheres with abundant oxygen defects were synthesized to anchor the Pd species thus promoting the electron transfer between Pd species and Nb species associated with the generation of interfacial Pd-NbO_x sites. Besides, the thinned electron density of Pd species resulting from the electron-withdrawing effect of Nb species is beneficial for activating the adsorbed CO molecules, leading to superior catalytic activity. The Pd/H-Nb₂O₅ catalyst exhibited 63.1% of CO conversion (theoretical maximum conversion: 64.3%) and 92.9% of DMO selectivity, with a DMO weight time yield of 1297.9 g kg_cat.^-1 h^-1, and remained robust even after 50 h of time on stream evaluation. Current work provides a deep insight into the CO activation mechanism and helps improve the catalytic stability by boosting interfacial electron interaction via oxygen defects induction, and also sheds light on the design and synthesis of high-performance catalysts in other heterogeneous catalysis fields.

Highly Effective Pd/MgO/γ-Al2O3 Catalysts for CO Oxidative Coupling to Dimethyl Oxalate: The Effect of MgO Coating on γ-Al2O3

The support of MgO/γ-Al₂O₃ was initially prepared by a multiple impregnation method and Pd was placed on the surface of the MgO/γ-Al₂O₃ support via incipient wetness impregnation. Pd/MgO/γ-Al₂O₃ (Pd/MAO) catalysts were systematically characterized by X-ray diffraction (XRD), Brunauer-Emmett-Teller (BET), CO₂-temperature-programmed desorption (TPD), transmission electron microscopy (TEM), CO-Fourier transform infrared (CO-FTIR), and X-ray photoelectron spectroscopy (XPS) and tested in the CO oxidative coupling to dimethyl oxalate (DMO) reaction. Compared to Pd/γ-Al₂O₃, the catalytic activities of the Pd/MAO catalysts improved significantly. The Pd/MAO catalyst with a 30% mass ratio of Mg to γ-Al₂O₃ delivers 3 times higher STY of DMO than that of Pd/γ-Al₂O₃. It has been demonstrated that MgO covered γ-Al₂O₃ layer-by-layer forming MAO supports, which can increase surface basicity and the interaction between Pd particles and the MAO supports. Moreover, the relationship between metal and support interaction and catalytic performance was discussed.

Study on Ammonia-induced Catalyst Poisoning in the Synthesis of Dimethyl Oxalate

On an industrial plant, we observed and examined the ammonia-poisoning catalyst for the synthesis of dimethyl oxalate (DMO). We investigated the catalytic activity in response to the amount of ammonia and revealed the mechanism of such poisoning by X-ray photoelectron spectroscopy (XPS) characterization. Our results show that only 0.002% ammonia in the feed gas can significantly deactivate the Pd-based catalyst. Two main reasons were proposed: one is that the competitive adsorption of ammonia on the active component Pd hinders the carbon    monoxide (CO) coupling reaction and the redox cycle between Pd0 and Pd2+; and the other is that the high-boiling nitrogen-containing amine compounds formed by reacting with ammonia have adsorbed on the catalyst, which hinders the progress of the catalytic reaction. The deactivation caused by the latter is irreversible. The catalytic activity can be completely restored by a low-temperature liquid-phase in-situ regeneration treatment. 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). 

CO direct esterification to dimethyl oxalate and dimethyl carbonate: the key functional motifs for catalytic selectivity

The direct esterification of CO involves processes using CO as the starting material and ester chemicals as products. Dimethyl oxalate (DMO) and dimethyl carbonate (DMC) are two different products of the direct CO esterification reaction. However, the effective control of the reaction pathway and direct synthesis of DMO and DMC are challenging. In this review, we summarize the recent research progress on the direct esterification of CO to DMO/DMC and reveal the functional motifs responsible for the catalytic selectivity. Firstly, we discuss the microstructure of catalysts for the direct esterification of CO to DMO and DMC, including the valence state and the aggregate state of Pd. Then, the influence of characteristics of the support on the selectivity is analyzed. Importantly, the aggregate state of the active component, Pd is deemed as a vital functional motif for catalytic selectivity. The isolated Pd is conducive for the formation of DMC, while the aggregated Pd is beneficial for the formation of DMO. This review will provide rational guidance for the direct esterification of CO to DMO and DMC.

Zn2+ stabilized Pd clusters with enhanced covalent metal-support interaction via the formation of Pd-Zn bonds to promote catalytic thermal stability

Pd-Based heterogeneous catalysts have been demonstrated to be efficient in numerous heterogeneous reactions. However, the effect of the support resulting in covalent metal-support interaction (CMSI) has not been researched sufficiently. In this work, a Lewis base is modulated over MgAl-LDH to investigate the support effects and it is further loaded with Pd clusters to research the metal-support interactions. MgAl-LDH with ultra-low Pd loading (0.0779%) shows CO conversion (55.0%) and dimethyl oxalate (DMO) selectivity (93.7%) for CO oxidative coupling to DMO, which was gradually deactivated after evaluation for 20 h. To promote the stability of Pd/MgAl-LDH, Zn2+ ions were introduced into the MgAl-LDH support to strengthen the CMSI by forming Pd-Zn bonds, which further increased the adsorption energy of the Pd clusters on ZnMgAl-LDH, and this was verified by X-ray absorption fine structure (XAFS) measurements and density functional theory (DFT) calculations. The stability of the Pd/ZnMgAl-LDH catalyst could be maintained for at least 100 h. This work highlights that covalent metal-support interactions can be strengthened by forming new metal-metal bonds, which could be extended to other systems for the stabilization of noble metals over supports.

Catalytic performance of Pdn (n = 1, 2, 3, 4 and 6) clusters supported on TiO2-V for the formation of dimethyl oxalate via the CO catalytic coupling reaction: a theoretical study

The formation of dimethyl oxalate (DMO) via CO catalytic coupling on a series of catalysts including Pdn (n = 1, 2, 3, 4 and 6) clusters loaded on TiO2-V has been explored by density functional theory (DFT) calculation. The results show that different Pdn clusters have a remarkable influence on DMO formation. The Pd1/TiO2-V catalyst is not suitable for the CO catalytic coupling reaction since CO is easily bound to the O atom on the surface of TiO2-V leading to the formation of CO2. The activity of four catalysts complies with the following order of Pd4/TiO2-V > Pd6/TiO2-V > Pd2/TiO2-V > Pd3/TiO2-V by comparing the activation energy barriers of the rate-determining steps in the optimal paths. Charge analysis implies that less charge is transferred from the Pd4/TiO2-V and Pd6/TiO2-V catalysts to CO than on the other catalysts, which leads to the relatively weak adsorption of CO, and therefore CO has a greater tendency to react with other species on the surface. In addition, Pd6/TiO2-V also exhibits relatively higher selectivity toward DMO than the other three catalysts. Therefore, Pd6 is regarded as a suitable cluster, which is supported on TiO2-V demonstrating high catalytic activity and selectivity to DMO.

CO oxidative coupling to dimethyl oxalate over Pd-Me (Me = Cu, Al) catalysts: a combined DFT and kinetic study

CO oxidative coupling to dimethyl oxalate (DMO) on Pd(111), Pd-Cu(111) and Pd-Al(111) surfaces was systematically investigated by means of density functional theory (DFT) together with periodic slab models and micro-kinetic modeling. The binding energy results show that Cu and Al can be fine substrates to stably support Pd. The favorable pathway for DMO synthesis on these catalysts starts from the formation of two COOCH₃ intermediates, followed by the coupling to each other, and the catalytic activity follows the trend of Pd-Al(111) > Pd(111) > Pd-Cu(111). Additionally, the formation of DMO is far favorable than that of dimethyl carbonate (DMC) on these catalysts. The results were further demonstrated by micro-kinetic modeling. Therefore, Pd-Al bimetallic catalysts can be applied in practice to effectively enhance the catalytic performance and greatly reduce the cost. This study can help with fine-tuning and designing of high-efficient and low-cost Pd-based bimetallic catalysts.

Status and prospects in higher alcohols synthesis from syngas

Higher alcohols are important compounds with widespread applications in the chemical, pharmaceutical and energy sectors. Currently, they are mainly produced by sugar fermentation (ethanol and isobutanol) or hydration of petroleum-derived alkenes (heavier alcohols), but their direct synthesis from syngas (CO + H₂) would comprise a more environmentally-friendly, versatile and economical alternative. Research efforts in this reaction, initiated in the 1930s, have fluctuated along with the oil price and have considerably increased in the last decade due to the interest to exploit shale gas and renewable resources to obtain the gaseous feedstock. Nevertheless, no catalytic system reported to date has performed sufficiently well to justify an industrial implementation. Since the design of an efficient catalyst would strongly benefit from the establishment of synthesis-structure-function relationships and a deeper understanding of the reaction mechanism, this review comprehensively overviews syngas-based higher alcohols synthesis in three main sections, highlighting the advances recently made and the challenges that remain open and stimulate upcoming research activities. The first part critically summarises the formulations and methods applied in the preparation of the four main classes of materials, i.e., Rh-based, Mo-based, modified Fischer-Tropsch and modified methanol synthesis catalysts. The second overviews the molecular-level insights derived from microkinetic and theoretical studies, drawing links to the mechanisms of Fischer-Tropsch and methanol syntheses. Finally, concepts proposed to improve the efficiency of reactors and separation units as well as to utilise CO₂ and recycle side-products in the process are described in the third section.

Carbon monoxide oxidation catalysed by defective palladium chloride: DFT calculations, EXAFS, and in situ DRIRS measurements

We examined the potential catalytic role of the palladium chloride catalyst in CO oxidation using density functional theory and experimental investigations. The active plane of the palladium chloride catalyst is identified as (140). We found that the defective PdCl2(140) surface is able to facilitate the activation of O2 and subsequently promote the oxidation of CO. The most significant reaction channel, the Eley-Rideal mechanism (MER1), proceeds first by a peroxo-type (OOCO) intermediate formation, second by O adsorption with the first CO2 release, then by the second CO attraction and the second CO2 formation, and finally by the second CO2 desorption and restoration of the defective PdCl2(140) surface. The rate-determining step is the formation of the second CO2 in the whole catalytic cycle. Compared to the previously reported catalytic systems, the reaction activation barrier (0.54 eV) of CO oxidation in the PdCl2 catalyst is low, indicating PdCl2 as a potential high-performance catalyst for CO oxidation. The present results enrich our understanding of CO oxidation of Pd-based catalysts and provide a basis for fabricating Pd-based catalysts with high activity.

A novel Pd3O9@α-Al2O3 catalyst under a hydroxylated effect: high activity in the CO oxidation reaction

Considering the importance of palladium-based and doped metal-oxide catalysts in CO oxidation, we design a new Pd3O9@α-Al2O3 catalyst and simulate its efficiency under a hydroxylated effect. The structure, electronic structure and oxidation activity of the hydroxylated Pd3O9@α-Al2O3(0001) surface are investigated by density functional theory. Under the O-rich growth conditions, Pd preferentially replaces Al. The lowest formation energy of the Pd-doped α-Al2O3(0001) surface is 0.21 eV under conditions wherein the coverage of the Pd-doped α-Al2O3 is 0.75 on a pre-hydroxylated surface and the water coverage is 0.25, which leads to formation of a Pd3O9 cluster embedded in the Al2O3(0001) surface. The reaction mechanisms of CO oxidization have been elucidated first by CO adsorption and migration, second by O(v) formation with the first CO2 release, then by the first foreign O2 filling and CO co-adsorption, and finally by the second CO2 desorption and restoration of the hydroxylated Pd3O9@α-Al2O3(0001) surface. The rate-determining step is the formation of the first CO2 in the whole catalytic cycle. The results also indicate that the energy barrier for CO oxidization is obviously reduced compared to that of the undoped surface, which implies that the introduction of Pd can efficiently improve the oxidation reactivity of the α-Al2O3(0001) surface. Compared to the synthesized Ir1/FeO(x) (1.41 eV) and Pt1/FeO(x) (0.79 eV) catalysts, the reaction activation barrier of CO oxidation is lowered by 0.65 eV and 0.03 eV, respectively. Therefore, the Pd3O9@α-Al2O3 catalyst shows superior catalytic activity in CO oxidation. The present results enrich the understanding of the catalytic oxidation of CO by palladium-based catalysts and provide a clue for fabricating palladium-based catalysts with low cost and high activity.

(Pd–CuCl2)/γ-Al2O3: a high-performance catalyst for carbonylation of methyl nitrite to dimethyl carbonate

(Pd–CuCl₂)/γ-Al₂O₃ catalyst with excellent activity and selectivity was successfully developed for vapor-phase carbonylation of methyl nitrite to dimethyl carbonate (DMC).

An alternative synthetic approach for efficient catalytic conversion of syngas to ethanol

Ethanol is an attractive end product and a versatile feedstock because a widespread market exists for its commercial use as a fuel additive or a potential substitute for gasoline. Currently, ethanol is produced primarily by fermentation of biomass-derived sugars, particularly those containing six carbons, but coproducts 5-carbon sugars and lignin remain unusable. Another major process for commercial production of ethanol is hydration of ethylene over solid acidic catalysts, yet not sustainable considering the depletion of fossil fuels. Catalytic conversion of synthetic gas (CO + H2) could produce ethanol in large quantities. However, the direct catalytic conversion of synthetic gas to ethanol remains challenging, and no commercial process exists as of today although the research has been ongoing for the past 90 years, since such the process suffers from low yield and poor selectivity due to slow kinetics of the initial C-C bond formation and fast chain growth of the C2 intermediates. This Account describes recent developments in an alternative approach for the synthesis of ethanol via synthetic gas. This process is an integrated technology consisting of the coupling of CO with methanol to form dimethyl oxalate and the subsequent hydrogenation to yield ethanol. The byproduct of the second step (methanol) can be separated and used in circulation as the feedstock for the coupling step. The coupling reaction of carbon monoxide for producing dimethyl oxalate takes place under moderate reaction conditions with high selectivity (∼95%), which ideally leads to a self-closing, nonwaste, catalytic cycling process. This Account also summarizes the progress on the development of copper-based catalysts for the hydrogenation reaction with remarkable efficiencies and stability. The unique lamellar structure and the cooperative effect between surface Cu(0) and Cu(+) species are responsible for the activity of the catalyst with high yield of ethanol (∼91%). The understanding of nature of valence states of Cu could also guide the rational design of Cu-based catalysts for other similar reactions, particularly for hydrogenation catalytic systems. In addition, by regulating the reaction condition and the surface structure of the catalysts, the products in the hydrogenation steps, such as ethanol, methyl glycolate, and ethylene glycol, could be tuned efficiently. This synthetic approach enables a more sustainable ethanol, methyl glycolate, and ethylene glycol synthesis in industry and greatly reduces the dependence on petroleum resources and the emission of the greenhouse gas.

A nanostructured CeO2 promoted Pd/α-alumina diethyl oxalate catalyst with high activity and stability

A Pd–CeO₂/α-Al₂O₃ nanocatalyst was used as a catalyst for CO oxidative coupling to diethyl oxalate with the CO conversion significantly increased.

MgO: an excellent catalyst support for CO oxidative coupling to dimethyl oxalate

We firstly found that basic MgO can serve as an excellent support for Pd catalysts for CO oxidative coupling to DMO and further developed a low Pd loading (ca. 0.5 wt%) Pd/MgO catalyst with high activity, selectivity and stability.