A Review on Deactivation and Regeneration of Catalysts for Dimethyl Ether Synthesis

Reversible and Irreversible Structural Changes in Cu/ZnO/ZrO2 Catalysts during Methanol Synthesis

The structure and chemical state of heterogeneous catalysts are closely related to their operational stability. Knowing these relationships as precisely as possible is thus essential for further catalyst development. This work focuses on the deactivation of a Cu/ZnO/ZrO2-type catalyst for methanol synthesis. Experiments were performed in a parallel setup, with which time-dependent changes in the catalyst material can be observed. Elucidation of potential deactivation pathways is described for catalyst aging at different times on stream (0, 50, 935 h). Data from X-ray absorption spectroscopy, X-ray photoelectron spectroscopy, N2 physisorption, and transmission electron microscopy measurements reveal that sintering of Cu0 domains and restructuring within ZnO domains mainly contribute to deactivation. Subsequent reactivation by reduction (in H2/N2) reverts the observed structural changes only to a limited extent. Moreover, this work highlights the participation of ZrO2 as a promoter and reveals redispersion of zirconia after initial reduction.

From CO2 to DME: Enhancement through Heteropoly Acids from a Catalyst Screening and Stability Study

The direct synthesis of dimethyl ether (DME) via CO₂ hydrogenation in a single step was studied using an improved class of bifunctional catalysts in a fixed bed reactor (T _R: 210-270 °C; 40 bar; gas hourly space velocity (GHSV) 19,800 NL kg_cat ^-1 h^-1; ratio CO₂/H₂/N₂ 3:9:2). The competitive bifunctional catalysts tested in here consist of a surface-basic copper/zinc oxide/zirconia (CZZ) methanol-producing part and a variable surface-acidic methanol dehydration part and were tested in overall 45 combinations. As dehydration catalysts, zeolites (ferrierite and β-zeolite), alumina, or zirconia were tested alone as well as with a coating of Keggin-type heteropoly acids (HPAs), i.e., silicotungstic or phosphotungstic acid. Two different mixing methods to generate bifunctional catalysts were tested: (i) a single-grain method with intensive intra-particular contact between CZZ and the dehydration catalyst generated by mixing in an agate mortar and (ii) a dual-grain approach relying on physical mixing with low contact. The influence of the catalyst mixing method and HPA loading on catalyst activity and stability was investigated. From these results, a selection of best-performing bifunctional catalysts was investigated in extended measurements (time on stream: 160 h/7 days, T _R: 250 and 270 °C; 40 bar; GHSV 19,800 NL kg_cat ^-1 h^-1; ratio CO₂/H₂/N₂ 3:9:2). Silicotungstic acid-coated bifunctional catalysts showed the highest resilience toward deactivation caused by single-grain preparation and during catalysis. Overall, HPA-coated catalysts showed higher activity and resilience toward deactivation than uncoated counterparts. Dual-grain preparation showed superior performance over single grain. Furthermore, silicotungstic acid coatings with 1 KU nm^-2 (Keggin unit per surface area of carrier) on Al₂O₃ and ZrO₂ as carrier materials showed competitive high activity and stability in extended 7-day measurements compared to pure CZZ. Therefore, HPA coating is found to be a well-suited addition to the CO₂-to-DME catalyst toolbox.

Maximizing biodiesel production from waste cooking oil with lime-based zinc-doped CaO using response surface methodology

Biodiesel is one of the alternative fuels, commonly produced chemically from oil and methanol using a catalyst. This study aims to maximize biodiesel production from cheap and readily available sources of waste cooking oil (WCO) and lime-based Zinc-doped calcium oxide (Zn-CaO) catalyst prepared with a wet impregnation process. The Zn-CaO nanocatalyst was produced by adding 5% Zn into the calcinated limestone. The morphology, crystal size, and vibrational energies of CaO and Zn-CaO nanocatalysts were determined using SEM, XRD, and FT-IR spectroscopy techniques, respectively. The response surface methodology (RSM), which is based on the box-Behnken design, was used to optimize the key variables of the transesterification reaction. Results showed that when Zn was doped to lime-based CaO, the average crystalline size reduced from 21.14 to 12.51 nm, consequently, structural irregularity and surface area increased. The experimental parameters of methanol to oil molar ratio (14:1), catalyst loading (5% wt.), temperature (57.5 °C), and reaction time (120 min) led to the highest biodiesel conversion of 96.5%. The fuel characteristics of the generated biodiesel fulfilled the American (ASTM D6571) fuel standards. The study suggests the potential use of WCO and lime-based catalyst as efficient and low-cost raw materials for large-scale biodiesel production intended for versatile applications.