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.

Methanol synthesis from CO2 and H2 using supported Pd alloy catalysts

A number of Pd based materials have been synthesised and evaluated as catalysts for the conversion of carbon dioxide and hydrogen to methanol, a useful platform chemical and hydrogen storage molecule. Monometallic Pd catalysts show poor methanol selectivity, but this is improved through the formation of Pd alloys, with both PdZn and PdGa alloys showing greatly enhanced methanol productivity compared with monometallic Pd/Al2O3 and Pd/TiO2 catalysts. Catalyst characterisation shows that the 1 : 1 β-PdZn alloy is present in all Zn containing post-reaction samples, including PdZn/Ga2O3, with the Pd2Ga alloy formed for the Pd/Ga2O3 sample. The heat of mixing was calculated for a variety of alloy compositions with high values determined for both PdZn and Pd2Ga alloys, at ca. -0.6 eV per atom and ca. -0.8 eV per atom, respectively. However, ZnO is more readily reduced than Ga2O3, providing a possible explanation for the preferential formation of the PdZn alloy, rather than PdGa, when in the presence of Ga2O3.

The Critical Role of βPdZn Alloy in Pd/ZnO Catalysts for the Hydrogenation of Carbon Dioxide to Methanol

The rise in atmospheric CO₂ concentration and the concomitant rise in global surface temperature have prompted massive research effort in designing catalytic routes to utilize CO₂ as a feedstock. Prime among these is the hydrogenation of CO₂ to make methanol, which is a key commodity chemical intermediate, a hydrogen storage molecule, and a possible future fuel for transport sectors that cannot be electrified. Pd/ZnO has been identified as an effective candidate as a catalyst for this reaction, yet there has been no attempt to gain a fundamental understanding of how this catalyst works and more importantly to establish specific design criteria for CO₂ hydrogenation catalysts. Here, we show that Pd/ZnO catalysts have the same metal particle composition, irrespective of the different synthesis procedures and types of ZnO used here. We demonstrate that all of these Pd/ZnO catalysts exhibit the same activity trend. In all cases, the β-PdZn 1:1 alloy is produced and dictates the catalysis. This conclusion is further supported by the relationship between conversion and selectivity and their small variation with ZnO surface area in the range 6–80 m²g^–1. Without alloying with Zn, Pd is a reverse water-gas shift catalyst and when supported on alumina and silica is much less active for CO₂ conversion to methanol than on ZnO. Our approach is applicable to the discovery and design of improved catalysts for CO₂ hydrogenation and will aid future catalyst discovery.

A computational study of direct CO2 hydrogenation to methanol on Pd surfaces

The reaction mechanism of direct CO₂ hydrogenation to methanol is investigated in detail on Pd (111), (100) and (110) surfaces using density functional theory (DFT), supporting investigations into emergent Pd-based catalysts. Hydrogen adsorption and surface mobility are firstly considered, with high-coordination surface sites having the largest adsorption energy and being connected by diffusion channels with low energy barriers. Surface chemisorption of CO₂, forming a partially charged CO₂^δ-, is weakly endothermic on a Pd (111) whilst slightly exothermic on Pd (100) and (110), with adsorption enthalpies of 0.09, -0.09 and -0.19 eV, respectively; the low stability of CO₂^δ- on the Pd (111) surface is attributed to negative charge accumulating on the surface Pd atoms that interact directly with the CO₂^δ- adsorbate. Detailed consideration for sequential hydrogenation of the CO₂ shows that HCOOH hydrogenation to H₂COOH would be the rate determining step in the conversion to methanol, for all surfaces, with activation barriers of 1.41, 1.51, and 0.84 eV on Pd (111), (100) and (110) facets, respectively. The Pd (110) surface exhibits overall lower activation energies than the most studied Pd (111) and (100) surfaces, and therefore should be considered in more detail in future Pd catalytic studies.

Mono- and Bimetallic Nanoparticles Stabilized by an Aromatic Polymeric Network for a Suzuki Cross-Coupling Reaction

This work addresses the Suzuki cross-coupling between 4-bromoanisole (BrAn) and phenylboronic acid (PBA) in an environmentally benign ethanol-water solvent catalysed by mono- (Pd) and bimetallic (PdAu, PdCu, PdZn) nanoparticles (NPs) stabilised within hyper-cross-linked polystyrene (HPS) bearing tertiary amino groups. Small Pd NPs of about 2 nm in diameters were formed and stabilized by HPS independently in the presence of other metals. High catalytic activity and complete conversion of BrAn was attained at low Pd loading. Introduction of Zn to the catalyst composition resulted in the formation of Pd/Zn/ZnO NPs, which demonstrated nearly double activity as compared to Pd/HPS. Bimetallic core-shell PdAu/HPS samples were 3-fold more active as compared to Pd/HPS. Both Pd/HPS and PdAu/HPS samples revealed promising stability confirmed by catalyst recycling in repeated reaction runs.

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.

Multifunctional Catalyst Combination for the Direct Conversion of CO2 to Propane

The production of carbon-rich hydrocarbons via CO₂ valorization is essential for the transition to renewable, non-fossil-fuel-based energy sources. However, most of the recent works in the state of the art are devoted to the formation of olefins and aromatics, ignoring the rest of the hydrocarbon commodities that, like propane, are essential to our economy. Hence, in this work, we have developed a highly active and selective PdZn/ZrO₂+SAPO-34 multifunctional catalyst for the direct conversion of CO₂ to propane. Our multifunctional system displays a total selectivity to propane higher than 50% (with 20% CO, 6% C₁, 13% C₂, 10% C₄, and 1% C₅) and a CO₂ conversion close to 40% at 350 °C, 50 bar, and 1500 mL g^-1 h^-1. We attribute these results to the synergy between the intimately mixed PdZn/ZrO₂ and SAPO-34 components that shifts the overall reaction equilibrium, boosting CO₂ conversion and minimizing CO selectivity. Comparison to a PdZn/ZrO₂+ZSM-5 system showed that propane selectivity is further boosted by the topology of SAPO-34. The presence of Pd in the catalyst drives paraffin production via hydrogenation, with more than 99.9% of the products being saturated hydrocarbons, offering very important advantages for the purification of the products.

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).

Mechanistic Study of Carbon Dioxide Hydrogenation over Pd/ZnO-Based Catalysts: The Role of Palladium-Zinc Alloy in Selective Methanol Synthesis

Pd/ZnO catalysts show good activity and high selectivity to methanol during catalytic CO₂ hydrogenation. The Pd‐Zn alloy phase has usually been considered as the active phase, though mechanistic studies under operando conditions have not been conducted to verify this. Here, we report a mechanistic study under realistic conditions of methanol synthesis, using in situ and operando X‐ray absorption spectroscopy, X‐ray powder diffraction, and time‐resolved isotope labeling experiments coupled with FTIR spectroscopy and mass spectrometry. Pd‐Zn alloy‐based catalysts, prepared through reduction of a heterobimetallic Pd^IIZn^II acetate bridge complex, and which do not contain zinc oxide or any PdZn/ZnO interface, produce mostly CO. The Pd‐Zn phase is associated with the formation of CO, and does not provide the active sites required to produce methanol from the direct hydrogenation of carbon dioxide. The presence of a ZnO phase, in contact with a Pd‐Zn phase, is essential for efficient methanol production.

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.

Fabrication of PdZn alloy catalysts supported on ZnFe composite oxide for CO2 hydrogenation to methanol

The conversion of CO₂ to methanol is of great significance for providing a means of CO₂ fixation and the development of future fuels. Supported Pd catalysts have been demonstrated to be active for CO₂ hydrogenation to methanol and PdZn alloy plays a key role in this reaction. Therefore, using ZnO-enriched support to increase the amount of nanometric PdZn alloy particles on the surface is an effective strategy to develop ideal catalysts. Herein, we fabricated a PdZn alloy catalyst supported on ZnO-enriched ZnFe₂O₄ spinel for efficient CO₂ hydrogenation to methanol. The amount of formed PdZn alloy and catalyst structure influenced by ZnO concentration on ZnFe₂O₄ were explored to obtain the best Pd-Z₁FO catalyst, which achieves a methanol space-time yield (STY) of 593 gkg_cat^-1h^-1 (12 gg_Pd^-1h^-1) with CO₂ conversion of 14% under reaction conditions of 290 °C, 4.5 MPa and 21600 mLg^-1h^-1. Furthermore, the amount of exposed PdZn alloy sites were measured by using CO-pulse chemisorption and we find a linearity between methanol production rate and PdZn alloy sites.

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). 

CO2 hydrogenation to methanol and hydrocarbons over bifunctional Zn-doped ZrO2/zeolite catalysts

The tandem process of carbon dioxide hydrogenation to methanol and its conversion to hydrocarbons over mixed metal/metal oxide-zeotype catalysts is a promising path to CO₂ valorization.

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.

Tuning Adsorption Energies and Reaction Pathways by Alloying: PdZn versus Pd for CO2 Hydrogenation to Methanol

The tunability offered by alloying different elements is useful to design catalysts with greater activity, selectivity, and stability than single metals. By comparing the Pd(111) and PdZn(111) model catalysts for CO₂ hydrogenation to methanol, we show that intermetallic alloying is a possible strategy to control the reaction pathway from the tuning of adsorbate binding energies. In comparison to Pd, the strong electron-donor character of PdZn weakens the adsorption of carbon-bound species and strengthens the binding of oxygen-bound species. As a consequence, the first step of CO₂ hydrogenation more likely leads to the formate intermediate on PdZn, while the carboxyl intermediate is preferentially formed on Pd. This results in the opening of a pathway from carbon dioxide to methanol on PdZn similar to that previously proposed on Cu. These findings rationalize the superiority of PdZn over Pd for CO₂ conversion into methanol and suggest guidance for designing more efficient catalysts by promoting the proper reaction intermediates.

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.

A DFT study for CO2 hydrogenation on W(111) and Ni-doped W(111) surfaces

The first-step hydrogenation of CO2 to methanol via a HCOO route, COOH route, and RWGS + CO-hydro route on NixW(111) (x = 0, 1, 3) has been studied using density functional theory (DFT) calculations. CO2 and H could be chemically adsorbed on Ni-doped W(111) surfaces with relatively high adsorption energy, due to the synergistic effect of W that helps anchoring CO2 and Ni that facilitates the adsorption of H. The HCOO route is the main path for the first-step hydrogenation of CO2 with lower barriers on all three surfaces. Besides, competition between the HCOO route and RWGS + CO-hydro route could be enhanced with the increase in doped Ni on the W(111) surface. Furthermore, the first-step hydrogenation of CO2 hardly undergoes the COOH pathway because of the higher barriers, although the doping of Ni has slightly reduced the barrier of COOH formation. Our calculated results indicate that the W(111) and Ni-doped W(111) surface are potential candidate surfaces for CO2 hydrogenation to methanol, and Ni doping could influence the selectivity of reduction pathways.

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.

State of the art and perspectives in heterogeneous catalysis of CO2 hydrogenation to methanol

The ever-increasing amount of anthropogenic carbon dioxide (CO₂) emissions has resulted in great environmental impacts, the heterogeneous catalysis of CO₂ hydrogenation to methanol is of great significance.

Supported Intermetallic PdZn Nanoparticles as Bifunctional Catalysts for the Direct Synthesis of Dimethyl Ether from CO-Rich Synthesis Gas

The single-step syngas-to-dimethyl ether (STD) process entails economic and technical advantages over the current industrial two-step process. Pd/ZnO-based catalysts have recently emerged as interesting alternatives to currently used Cu/ZnO/Al₂ O₃ catalysts, but the nature of the active site(s), the reaction mechanism, and the role of Pd and ZnO in the solid catalyst are not well established. Now, Zn-stabilized Pd colloids with a size of 2 nm served as the key building blocks for the methanol active component in bifunctional Pd/ZnO-γ-Al₂ O₃ catalysts. The catalysts were characterized by combining high-pressure operando X-ray absorption spectroscopy and DFT calculations. The enhanced stability, longevity, and high dimethyl ether selectivity observed makes Pd/ZnO-γ-Al₂ O₃ an effective alternative system for the STD process compared to Cu/ZnO/γ-Al₂ O₃ .

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.

Solvent Free Synthesis of PdZn/TiO2 Catalysts for the Hydrogenation of CO2 to Methanol

Catalytic upgrading of CO₂ to value-added chemicals is an important challenge within the chemical sciences. Of particular interest are catalysts which are both active and selective for the hydrogenation of CO₂ to methanol. PdZn alloy nanoparticles supported on TiO₂ via a solvent-free chemical vapour impregnation method are shown to be effective for this reaction. This synthesis technique is shown to minimise surface contaminants, which are detrimental to catalyst activity. The effect of reductive heat treatments on both structural properties of PdZn/TiO₂ catalysts and rates of catalytic CO₂ hydrogenation are investigated. PdZn nanoparticles formed upon reduction showed high stability towards particle sintering at high reduction temperature with average diameter of 3–6 nm to give 1710 mmol kg⁻¹ h of methanol. Reductive treatment at high temperature results in the formation of ZnTiO₃ as well as PdZn, and gives the highest methanol yield.

DFT study of CO2 conversion on InZr3(110) surface

The InZr₃ alloy is a potential candidate catalyst for methanol and methane synthesis from CO₂ hydrogenation.