Synthesis of methanol over highly dispersed Cu-Fe based catalysts derived from layered double hydroxides

In this paper, catalysts with different aluminum contents were prepared by a co-precipitation method using LDHs (layered double hydroxides) as the precursors through the adjustment of Cu2+ : Fe2+, and the catalysts were named LDO catalysts. The effect of aluminum on CO2 hydrogenation to methanol was investigated by evaluating the characterization. With the addition of Al, Ar physisorption results showed an increase in BET-specific surface area, TEM demonstrated a decrease in catalyst particle diameter, XRD showed that Cu and Fe existed in the catalyst mainly in the form of CuFe2O4 and CuO, XPS demonstrated a decrease in electron cloud density and an increase in base sites and oxygen vacancies, and CO2-TPD and H2-TPD results indicated that Al promoted the dissociation and adsorption of CO2 and H2. When the reaction temperature was 230 °C, the pressure was 4 MPa, H2/CO2 = 2.5 and the space velocity was 2000 ml (h gcat)-1, the best conversion (14.87%) and the highest methanol selectivity (39.53%) of the catalyst were obtained at 30% aluminum content.

A Simple Strategy Stabilizing for a CuFe/SiO2 Catalyst and Boosting Higher Alcohols’ Synthesis from Syngas

Stable F-T-based catalyst development in direct CO hydrogenation to higher alcohols is still a challenge at present. In this study, CuFe/SiO2 catalysts with a SiO2 support treated with a piranha solution were prepared and evaluated in a long-term reaction. The treated catalyst showed higher total alcohols’ selectivity and great stability during a reaction of more than 90 h. It was found that the treatment with the piranha solution enriched the surface hydroxyl groups on SiO2, so that the Cu–Fe active components could be firmly anchored and highly dispersed on the support, resulting in stable catalytic performance. Furthermore, the in situ DRIFTS revealed that the adsorption strength of CO on Cu+ on the treated catalyst surface was weakened, which made the C-O bond less likely to be cleaved and thus significantly inhibited the formation of hydrocarbon products. Meanwhile, the non-dissociated CO species were obviously enriched on the Cu0 surface, promoting the formation of alcohol products, and thus the selectivity of total alcohols was increased. This strategy will shed light on the design of supported catalysts with stabilized structures for a wide range of catalytic reactions.

Layered Double Hydroxide/Nanocarbon Composites as Heterogeneous Catalysts: A Review

The synthesis and applications of composites based on layered double hydroxides (LDHs) and nanocarbons have recently seen great development. On the one hand, LDHs are versatile 2D compounds that present a plethora of applications, from medicine to energy conversion, environmental remediation, and heterogeneous catalysis. On the other, nanocarbons present unique physical and chemical properties owing to their low-dimensional structure and sp2 hybridization of carbon atoms, which endows them with excellent charge carrier mobility, outstanding mechanical strength, and high thermal conductivity. Many reviews described the applications of LDH/nanocarbon composites in the areas of energy and photo- and electro-catalysis, but there is still scarce literature on their latest applications as heterogeneous catalysts in chemical synthesis and conversion, which is the object of this review. First, the properties of the LDHs and of the different types of carbon materials involved as building blocks of the composites are summarized. Then, the synthesis methods of the composites are described, emphasizing the parameters allowing their properties to be controlled. This highlights their great adaptability and easier implementation. Afterwards, the application of LDH/carbon composites as catalysts for C–C bond formation, higher alcohol synthesis (HAS), oxidation, and hydrogenation reactions is reported and discussed in depth.

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.

Copper and Iron Cooperation on Micro-Spherical Silica during Methanol Synthesis via CO2 Hydrogenation

A series of mono- and bi-metallic copper and iron samples were prepared by impregnation method on micro-spherical silica and used for the synthesis of methanol via CO2 hydrogenation. Compared with conventional carrier oxides, micro-spherical silica has obvious advantages in terms of absorption capacity and optimal distribution of active phases on its surface, also exhibiting excellent heat resistance properties and chemical stability. The prepared catalysts were characterized by various techniques including XRF, XRD, SEM, TEM, H2-TPR and CO2-TPD techniques, while catalytic measurements in CO2 hydrogenation reaction to methanol were performed in a fixed bed reactor at a reaction pressure of 30 bar and temperature ranging from 200 to 260 °C. The obtained results revealed that the mutual interaction of copper–iron induces promotional effects on the formation of methanol, especially on systems where Fe enrichment on the silica support favours the presence of a larger concentration of oxygen vacancies, consequently responsible for higher CO2 adsorption and selective methanol production. Surface reconstruction phenomena rather than coke or metal sintering were responsible for the slight loss of activity recorded on the catalyst samples during the initial phase of reaction; however, with no appreciable change on the product selectivity.

Selective C2+ alcohol synthesis by CO2 hydrogenation via a reaction-coupling strategy

The synergy of primary and promoting catalysts in close proximity facilitates the migration and insertion of CO*/CHxO* species, thus accelerating HA productivity over a multifunctional catalyst.

Easily Recycled CuMgFe Catalysts Derived from Layered Double Hydroxides for Hydrogenolysis of Glycerol

A series of CuMgFe catalysts with different (Cu + Mg)/Fe molar ratios derived from hydrotalcites were prepared by coprecipitation for the hydrogenolysis of glycerol to 1,2-propanediol (1,2-PDO). X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray photoelectron spectra (XPS), vibrating sample magnetometer (VSM), hydrogen temperature-programmed reduction (H2-TPR), CO2-TPD, and H2-TPD (temperature-programmed desorption of CO2 and H2) were used to investigate the physicochemical properties of the catalysts. The CuMgFe-layered double oxides (CuMgFe-4LDO) catalyst with (Cu + Mg)/Fe molar ratio of 4 exhibited superior activity and stability. The high glycerol conversion and 1,2-propanediol selectivity over CuMgFe-4LDO catalyst were attributed to its strong basicity, excellent H2 activation ability, and an increase in the surface Cu content. The CuMgFe catalysts could be easily recycled with the assistance of an external magnetic field due to their magnetism.

Accelerated Redox Cycles of Fe(III)/Fe(II) and Cu(III)/Cu(II) by Photo-Induced Electron from N-CQDs for Enhanced Photo-Fenton Capability of CuFe-LDH

Layered double hydroxide (LDH) materials have shown charming photo-Fenton capability for the treatment of refractory organic wastewater. In this study, CuFe-LDH hybridized with N-doped carbon quantum dots (N-CQDs) was investigated to further enhance the photo-Fenton capability. The results showed that the assembly techniques of coprecipitation and the hydrothermal method could synthesize the target material, CuFe-LDH/N-CQDs, successfully. CuFe-LDH/N-CQDs could possess a 13.5% higher methylene blue (MB) removal rate than CuFe-LDH in 30 min due to the accelerated redox cycles of Fe(III)/Fe(II) and Cu(III)/Cu(II), resulting from the photo-induced electron transfer from N-CQDs to CuFe-LDH via a d–π conjugation electronic bridge. Moreover, CuFe-LDH/N-CQDs has excellent photo-Fenton capability in the pH range of 2–11, even after being reused five times. This study would provide an efficient and stable photo-Fenton catalyst for the treatment of refractory organic wastewater.

Designing Nanoparticles and Nanoalloys for Gas-Phase Catalysis with Controlled Surface Reactivity Using Colloidal Synthesis and Atomic Layer Deposition

Supported nanoparticles are commonly applied in heterogeneous catalysis. The catalytic performance of these solid catalysts is, for a given support, dependent on the nanoparticle size, shape, and composition, thus necessitating synthesis techniques that allow for preparing these materials with fine control over those properties. Such control can be exploited to deconvolute their effects on the catalyst's performance, which is the basis for knowledge-driven catalyst design. In this regard, bottom-up synthesis procedures based on colloidal chemistry or atomic layer deposition (ALD) have proven successful in achieving the desired level of control for a variety of fundamental studies. This review aims to give an account of recent progress made in the two aforementioned synthesis techniques for the application of controlled catalytic materials in gas-phase catalysis. For each technique, the focus goes to mono- and bimetallic materials, as well as to recent efforts in enhancing their performance by embedding colloidal templates in porous oxide phases or by the deposition of oxide overlayers via ALD. As a recent extension to the latter, the concept of area-selective ALD for advanced atomic-scale catalyst design is discussed.

Interfacial Fe5C2-Cu catalysts toward low-pressure syngas conversion to long-chain alcohols

Long-chain alcohols synthesis (LAS, C₅₊OH) from syngas provides a promising route for the conversion of coal/biomass/natural gas into high-value chemicals. Cu-Fe binary catalysts, with the merits of cost effectiveness and high CO conversion, have attracted considerable attention. Here we report a nano-construct of a Fe₅C₂-Cu interfacial catalyst derived from Cu₄Fe₁Mg₄-layered double hydroxide (Cu₄Fe₁Mg₄-LDH) precursor, i.e., Fe₅C₂ clusters (~2 nm) are immobilized onto the surface of Cu nanoparticles (~25 nm). The interfacial catalyst exhibits a CO conversion of 53.2%, a selectivity of 14.8 mol% and a space time yield of 0.101 g g_cat⁻¹ h⁻¹ for long-chain alcohols, with a surprisingly benign reaction pressure of 1 MPa. This catalytic performance, to the best of our knowledge, is comparable to the optimal level of Cu-Fe catalysts operated at much higher pressure (normally above 3 MPa).

Long-chain alcohols synthesis from syngas conversion is a promising route for the production of high-value chemicals. Here the authors show that a heterogeneous Fe₅C₂/Cu catalyst derived from layered double hydroxides precursor exhibits excellent performance with a space time yield of 0.101 g g_cat⁻¹ h⁻¹ at a low pressure of 1 MPa.

Hydroprocessing of Oleic Acid for Production of Jet-Fuel Range Hydrocarbons over Cu and FeCu Catalysts

In the present study, a series of monometallic Cu/SiO2-Al2O3 catalysts exhibited immense potential in the hydroprocessing of oleic acid to produce jet-fuel range hydrocarbons. The synergistic effect of Fe on the monometallic Cu/SiO2-Al2O3 catalysts of variable Cu loadings (5–15 wt%) was ascertained by varying Fe contents in the range of 1–5 wt% on the optimized 13% Cu/SiO2-Al2O3 catalyst. At 340 °C and 2.07 MPa H2 pressure, the jet-fuel range hydrocarbons yield and selectivities of 51.8% and 53.8%, respectively, were recorded for the Fe(3)-Cu(13)/SiO2-Al2O3 catalyst. To investigate the influence of acidity of support on the cracking of oleic acid, ZSM-5 (Zeolite Socony Mobil–5) and HZSM-5(Protonated Zeolite Socony Mobil–5)-supported 3% Fe-13% Cu were also evaluated at 300–340 °C and 2.07 MPa H2 pressure. Extensive techniques including N2 sorption analysis, pyridine- Fourier Transform Infrared Spectroscopy (Pyridine-FTIR), X-ray Diffraction (XRD), X-ray Photoelectron Spectroscopy (XPS), and H2-Temperature Programmed Reduction (H2-TPR) analyses were used to characterize the materials. XPS analysis revealed the existence of Cu1+ phase in the Fe(3)-Cu(13)/SiO2-Al2O3 catalyst, while Cu metal was predominant in both the ZSM-5 and HZSM-5-supported FeCu catalysts. The lowest crystallite size of Fe(3)-Cu(13)/SiO2-Al2O3 was confirmed by XRD, indicating high metal dispersion and corroborated by the weakest metal–support interaction revealed from the TPR profile of this catalyst. CO chemisorption also confirmed high metal dispersion (8.4%) for the Fe(3)-Cu(13)/SiO2-Al2O3 catalyst. The lowest and mildest Brønsted/Lewis acid sites ratio was recorded from the pyridine–FTIR analysis for this catalyst. The highest jet-fuel range hydrocarbons yield of 59.5% and 73.6% selectivity were recorded for the Fe(3)-Cu(13)/SiO2-Al2O3 catalyst evaluated at 300 °C and 2.07 MPa H2 pressure, which can be attributed to its desirable textural properties, high oxophilic iron content, high metal dispersion and mild Brønsted acid sites present in this catalyst.

The Support Effects on the Direct Conversion of Syngas to Higher Alcohol Synthesis over Copper-Based Catalysts

The types of supports employed profoundly influence the physicochemical properties and performances of as-prepared catalysts in almost all catalytic systems. Herein, Cu catalysts, with different supports (SiO2, Al2O3), were prepared by a facile impregnation method and used for the direct synthesis of higher alcohols from CO hydrogenation. The prepared catalysts were characterized using multiple techniques, such as X-ray diffraction (XRD), N2 sorption, H2-temperature-programmed reduction (H2-TPR), temperature-programmed desorption of ammonia (NH3-TPD), X-ray photoelectron spectroscopy (XPS) and in situ Fourier-transform infrared spectroscopy (FTIR), etc. Compared to the Cu/Al2O3 catalyst, the Cu/SiO2 catalyst easily promoted the formation of a higher amount of C1 oxygenate species on the surface, which is closely related to the formation of higher alcohols. Simultaneously, the Cu/Al2O3 and Cu/SiO2 catalysts showed obvious differences in the CO conversion, alcohol distribution, and CO2 selectivity, which were probably originated from differences in the structural and physicochemical properties, such as the types of copper species, the reduction behaviors, acidity, and electronic properties. Besides, it was also found that the gap in performances in two kinds of catalysts with the different supports could be narrowed by the addition of potassium because of its neutralization to surface acidy of Al2O3 and the creation of new basic sites, as well as the alteration of electronic properties.

Hybridization of Nanodiamond and CuFe-LDH as Heterogeneous Photoactivator for Visible-Light Driven Photo-Fenton Reaction: Photocatalytic Activity and Mechanism

Establishing a heterojunction for two kinds of semiconductor catalysts is a promising way to enhance photocatalytic activity. In this study, nanodiamond (ND) and CuFe-layered double hydroxide (LDH) were hybridized by a simple coprecipitation method as a novel heterojunction to photoactivate H2O2. The ND/LDH possessed a hydrotalcite-like structure, large specific surface area (SBET = 99.16 m2/g), strong absorption of visible-light and low band gap (Eg = 0.94 eV). Under the conditions of ND/LDH dosage 0.0667 g/L, H2O2 concentration 19.6 mmol/L, and without initial pH adjustment, 93.5% of 10 mg/L methylene blue (MB) was degraded within 120 minutes, while only 78.3% of MB was degraded in the presence of LDH instead of ND/LDH. The ND/LDH exhibited excellent stability and maintained relatively high activity, sufficient to photoactivate H2O2 even after five recycles. The mechanism study revealed that in the heterojunction of ND/LDH, the photoelectrons transferred from the valence band of LDH (Cu/Fe 3d t2g) to the conduction band of LDH (Cu/Fe 3d eg) could spontaneously migrate onto the conduction band of ND, promoting the separation of photo-induced charges. Thus, the photoelectrons had sufficient time to accelerate the redox cycles of Cu3+/Cu2+ and Fe3+/Fe2+ to photoactivate H2O2 to produce hydroxyl radicals, resulting in excellent photo-Fenton efficiency on MB degradation.

Intermediate product regulation over tandem catalysts for one-pass conversion of syngas to ethanol

Selective conversion of syngas (CO/H₂) to ethanol is an attractive but challenging target.

Sulfate radical induced degradation of Methyl Violet azo dye with CuFe layered doubled hydroxide as heterogeneous photoactivator of persulfate

Persulfate (PS)-based advanced oxidation processes have aroused considerable attentions due to their higher efficiency and wider adaptability to the degradation of bio-recalcitrant organic contaminants. In this study, Cu-Fe layered doubled hydroxide (CuFe-LDH) was employed to degrade Methyl Violet (MV) through heterogeneous photo-activation of PS under visible-light irradiation. The reaction kinetics, degradation mechanism, catalyst stability were investigated in detail. Under the conditions of CuFe-LDH (3:1) dosage 0.2 g/L, PS concentration 0.2 g/L and without initial pH adjustment, 20 mg/L MV was almost completely degraded within 18 min. Electron Spin Resonance (ESR) test and radical quenching experiment indicated that sulfate radicals (SO₄^-) were the dominant reactive oxidants for the MV decolorization, while hydroxyl radicals (OH) were also involved. The CuFe-LDH/PS/Vis system was applicable at wide range of pH level (3-9). However, extreme pH level would lead to the reduction or transformation of SO₄^-. The catalyst CuFe-LDH exhibited excellent stability and maintained relatively high catalytic activity to PS even after four recycles. Mechanism study revealed that the redox cycle of Fe³⁺/Fe²⁺ and Cu²⁺/Cu³⁺ assisted by visible-light irradiation accounted for the enhanced generation of radicals in CuFe-LDH/PS/Vis system, resulting in the improved degradation of organic contaminants. Overall, the CuFe-LDH/PS/Vis process could be a promising approach for the removal of refractory organic pollutants in wastewater.

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.

On the nature of active phases and sites in CO and CO2 hydrogenation catalysts

Advanced characterisation techniques are shedding new light on the identification of active CO_x hydrogenation phases and sites.

Investigation of copper precursors in the synthesis of higher alcohols from syngas over CuZnAl catalysts without promoters

The catalytic performances of different CuZnAl catalysts prepared using copper nitrate, copper acetate and copper citrate for CO hydrogenation to higher alcohols (C₂₊OH) were studied in a slurry bed reactor.

Bimetallic Ni–Co catalysts supported on Mn–Al oxide for selective catalytic CO hydrogenation to higher alcohols

A sol–gel synthesis provides a facile method for preparing Ni–Co catalysts which contributed to the high selectivity for higher alcohols.

Ethanol synthesis from syngas over Cu(Pd)-doped Fe(100): a systematic theoretical investigation

The selectivity of ethanol formation are in the order of Fe₃Cu₆/Fe(100) > Fe₃Pd₆/Fe(100) > Fe₉/Fe(100) > Cu₉/Fe(100).