Influence of titania on zirconia promoted Cu/SiO2 catalysts for methanol synthesis from CO/H2 and CO2/H2

The effects of adding mixtures of titania and zirconia on the methanol synthesis activity and selectivity of Cu/SiO₂ were investigated. The synthesis of methanol from both CO/H₂ and CO₂/H₂ mixtures was examined at 0.65 MPa and temperatures between 448 and 573 K. For CO hydrogenation, the addition of ZrO₂ alone increased the methanol synthesis activity of Cu/SiO₂ by up to three-fold. Substitution of a portion of the ZrO₂ by TiO₂ decreased the methanol synthesis activity of the catalyst relative to that observed when only ZrO₂ is added. ZrO₂ addition also enhanced the methane synthesis activity by as much as seven fold. In the case of CO₂ hydrogenation, the maximum methanol synthesis activity is achieved when a 50/50 wt% mixture of ZrO₂ and TiO₂ is added to Cu/SiO₂. Neither the presence of the oxide additive nor its composition had any effect on the activity of the reverse water–gas-shift reaction, which suggests that this reaction proceeds only on Cu. The observed effects of ZrO₂ and TiO₂ on the catalytic activity of methanol synthesis from CO and CO₂, and methane synthesis from CO, are interpreted in terms of the strength and concentration of acidic and basic groups on the surface of the dispersed oxide.     

An in situ high pressure FT-IR study of CO2/H2 interactions with model ZnO/SiO2, Cu/SiO2 and Cu/ZnO/SiO2 methanol synthesis catalysts

In situ FT-IR spectroscopy allows the methanol synthesis reaction to be investigated under actual industrial conditions of 503 K and 10 MPa. On Cu/SiO₂ catalyst formate species were initially formed which were subsequently hydrogenated to methanol. During the reaction a steady state concentration of formate species persisted on the copper. Additionally, a small quantity of gaseous methane was produced. In contrast, the reaction of CO₂ and H₂ on ZnO/SiO₂ catalyst only resulted in the formation of zinc formate species: no methanol was detected. The interaction of CO₂ and H₂ with Cu/ZnO/SiO₂ catalyst gave formate species on both copper and zinc oxide. Methanol was again formed by the hydrogenation of copper formate species. Steady-state concentrations of copper formate existed under actual industrial reaction conditions, and copper formate is the pivotal intermediate for methanol synthesis. Collation of these results with previous data on copper-based methanol synthesis catalysts allowed the formulation of a reaction mechanism.     

The difference in the active sites for CO2 and CO hydrogenations on Cu/ZnO-based methanol synthesis catalysts

The effect of Zn in copper catalysts on the activities for both CO₂ and CO hydrogenations has been examined using a physical mixture of Cu/SiO₂+ZnO/SiO₂ and a Zn-containing Cu/SiO₂ catalyst or (Zn)Cu/SiO₂. Reduction of the physical mixture with H₂ at 573–723 K results in an increase in the yield of methanol produced by the CO₂ hydrogenation, while no such a promotion was observed for the CO hydrogenation, indicating that the active site is different for the CO₂ and CO hydrogenations. However, the methanol yield by CO hydrogenation is significantly increased by the oxidation treatment of the (Zn)Cu/SiO₂ catalyst. Thus it is concluded that the Cu–Zn site is active for the CO₂ hydrogenation as previously reported, while the Cu–O–Zn site is active for the CO hydrogenation.     

In situ IR studies on the mechanism of methanol synthesis from CO/H2 and CO2/H2 over Cu-ZnO-Al2O3 catalyst

Methanol synthesis from CO/H₂ and CO₂/H₂ was carried out at atmospheric pressure over Cu/ZnO/Al₂O₃ catalyst. The formation and variation of surface species were recorded by in situ FT-IR spectroscopy. The result revealed that both CO and CO₂ can serve as the primary carbon source for methanol synthesis. For CO/H₂ feed gas, only HCOO-Zn was detected; however, for CO₂/H₂, both HCOO-Zn and HCOO-Cu were observed, and without CH₃O-Cu. HCOO-Zn was the key intermediate. A scheme of methanol synthesis and reverse water-gas shift (RGWS) reaction was proposed.     

Methanol Synthesis from CO2, CO,and H2over Cu(100) and Ni/Cu(100)

The catalytic activity of Cu(100) and Ni/Cu(100) with respect to the methanol synthesis from various mixtures containing CO₂, CO, and H₂have been studied in a combined UHV/high pressure cell apparatus at reaction conditions,P_tot=1.5 bar andT=543 K. For the clean Cu(100) surface it is found that admission of CO to a reaction mixture containing CO₂and H₂does not lead to an increase in the rate of methanol formation, which indirectly suggests that the role of CO in the industrial methanol process relates to the change in reduction potential of the synthesis gas. For the Ni/Cu(100) surface it is found that Ni does not promote the rate of methanol formation from mixtures containing CO₂and H₂. In opposition, admission of CO to the reaction mixture leads to a significant increase in the rate of methanol formation with a turnover frequency/Ni site∼60×the turnover frequency/Cu site at Ni coverages below 0.1 ML making it a rather substantial promoting effect. It is found that the admission of CO to the synthesis gas creates segregation of Ni to the surface, whereas this is not the case for a reaction involving CO₂and H₂. It is suggested that CO acts strictly as a promotor in the system and we ascribe the increase in activity to a promotion through gas phase induced surface segregation of Ni.     

Mechanism of CO formation in reverse water–gas shift reaction over Cu/Al2O3 catalyst

The mechanism of the reverse water–gas shift reaction over a Cu catalyst was studied by CO₂ hydrogenation, temperature-programmed reduction of the Cu catalyst and pulse reaction with QMS monitoring. In comparison with the reaction of CO₂ alone, hydrogen can significantly promote the CO formation in the RWGS reaction. The formate derived from association of H₂ and CO₂ is proposed to be the key intermediate for CO production. Formate dissociation mechanism is the major reaction route for CO production. Cu(I) species were formed from the oxidation of Cu⁰ associated with CO₂ dissociation. This revised version was published online in July 2006 with corrections to the Cover Date.     

Methanol Synthesis on Potassium-Modified Cu(100) from CO + H2 and CO + CO2 + H2

Methanol cannot be produced from CO + H₂ on a clean copper surface, but a promotional effect of potassium on methanol synthesis from mixtures of CO + H₂ and CO + CO₂ + H₂ at a total pressure of 1.5 bar on a Cu(100) surface is shown in this work. The experiments are performed in a UHV chamber connected with a high-pressure cell (HPC). The methanol produced is measured with a gas chromatograph and the surface is characterized with surface science techniques. The results show that potassium is a promoter for the methanol synthesis from CO + H₂, and that the influence of CO₂ is negligible. Investigation of the post-reaction surface with TPD indicates that potassium carbonate is present and plays an important role. The activation energy is determined as 42 ± 3 kJ/mol for methanol synthesis on K/Cu(100) from CO + H₂.     

Methanol synthesis over Cu/SiO2 catalysts

The rates of CO and CO/CO₂ hydrogenation at 4.2 MPa and 523 K are reported for a series of Cu/SiO₂ catalysts containing 2 to 88 wt.% Cu. These catalysts were prepared on a variety of silica sources using several different Cu deposition techniques. In CO/CO₂ hydrogenation, the rate of methanol formation is proportional to the exposed Cu surface area of the reduced catalyst precursor, as determined by N₂O frontal chromatography. The observed rate, 4.2×10^–3 mole CH₃OH/Cu site-sec, is within a factor of three of the rates reported by others over Cu/ZnO and Cu/ZnO/Al₂O₃ catalysts under comparable conditions. These results suggest that the ZnO component is only a moderate promoter in methanol synthesis. Hydrogenation of CO over these catalysts also gives methanol with high selectivity, but the synthesis rate is not proportional to the Cu surface area. This implies that another type of site, either alone or in cooperation with Cu, is involved in the synthesis of methanol from CO.     

CO bonding and hydrogenation activity of promoted noble metal catalysts during restructuring in high-pressure CO hydrogenation: FeIr/SiO2

Bimetallic FeIr/SiO₂ catalysts that are active for methanol production from synthesis gas (CO+H₂) bind CO less strongly, and exhibit higher activity for the hydrogenation of ethylene in the presence of CO, than catalysts that produce mainly methane. It is argued that promotion of the noble metal serves to weaken the adsorption of CO, thereby lowering its tendency to dissociate, and, most importantly, enhancing the surface coverage of hydrogen. Both factors are favorable for methanol formation. This revised version was published online in July 2006 with corrections to the Cover Date.     

Effects of space velocity on methanol synthesis from Co2/Co/H2 over Cu/ZnO/Al2O3 catalyst

The space velocity had profound and complicated effects on methanol synthesis from CO₂/CO/H₂ over Cu/ZnO/Al₂O₃ at 523 K and 3.0MPa. At high space velocities, methanol yields as well as the rate of methanol production increased continuously with increasing CO₂ concentration in the feed. Below a certain space velocity, methanol yields and reaction rates showed a maximum at CO₂ concentration of 5–10%. Different coverages of surface reaction intermediates on copper appeared to be responsible for this phenomenon. The space velocity that gave the maximal rate of methanol production also depended on the feed composition. Higher space velocity yielded higher rates for CO₂/ H₂ and the opposite effect was observed for the CO/H₂ feed. For CO₂/CO/H₂ feed, an optimal space velocity existed for obtaining the maximal rate.     

Porous MoxCy/SiO2 Material for CO2 Hydrogenation

The synthesis and characterization of an inexpensive porous Mo_xC_y/SiO₂ material is presented, which was obtained by mixing ammonium hexamolybdate, sucrose, and a mesoporous silica (SBA-15), with a subsequent heat treatment under inert atmosphere. This porous material presented a specific surface area of 170 m²/g. The catalytic behavior in CO₂ hydrogenation was compared with that of Mo₂C and α-MoC_1?x obtained from ammonium hexamolybdate and sucrose, using different Mo/C ratios. CO₂ hydrogenation tests were performed at moderate (100 kPa) and high pressures (2.0 MPa), and it was found that only CO, H₂O and CH₄ are formed at moderate pressures by the three materials, while at higher pressures, methanol and hydrocarbons (C₂H₆, C₃H₈) are also obtained. Differences in selectivity were observed at the high pressure tests. Mo₂C presented higher selectivity to CO and methanol compared with MoC_1?x, which showed preferential selectivity to hydrocarbons (CH₄, C₂H₆). The porous Mo_xC_y/SiO₂ material showed the highest CO₂ hydrogenation activity at high temperatures (270 and 300 °C), being a promising material for the conversion of CO₂ to CO and CH₄.

     

A new method of low-temperature methanol synthesis on Cu/ZnO/Al2O3 catalysts from CO/CO2/H2

A new synthesis method of low-temperature methanol proceeded on Cu/ZnO/Al₂O₃ catalysts from CO/CO₂/H₂ using 2-butanol as promoters. The Cu/ZnO/Al₂O₃ catalysts were prepared by co-impregnation of r-Al₂O₃ with an aqueous solution of copper nitrate and zinc nitrate. The total carbon turnover frequency (TOF), the yield and selectivity of methanol were the highest by using the Cu/ZnO/Al₂O₃ catalyst with copper loading of 5% and the Zn/Cu molar ratio of 1/1, which precursor were not calcined, and reduced at 493 K. The activity of the catalysts increased due to the presence of the CuO/ZnO phase in the oxidized form of impregnation Cu/ZnO/Al₂O₃ catalysts. The active sites of the Cu/ZnO/Al₂O₃ catalyst for methanol synthesis are not only metallic Cu but also special sites such as the Cu–Zn site, i.e. metallic Cu and the Cu–Zn site work cooperatively to catalyze the methanol synthesis reaction.     

Partial Oxidation of Ethanol to Hydrogen over Ni–Fe Catalysts

A study has been conducted to identify the influence of zirconia phase and copper to zirconia surface area on the activity of Cu/ZrO₂ catalysts for the synthesis of methanol from either CO/H₂ or CO₂/H₂. To determine the effects of zirconia phase, a pair of Cu/ZrO₂ catalysts was prepared on tetragonal (t-) and monoclinic (m-) zirconia. The zirconia surface area and the Cu dispersion were essentially identical for these two catalysts. At 548 K, 0.65 MPa, and H₂/CO_x= 3 (x = 1, 2), the catalyst prepared on m-ZrO₂ was 4.5 times more active for methanol synthesis from CO₂/H₂ than that prepared on t-ZrO₂, and 7.5 times more active when CO/H₂ was used as the feed. Increasing the surface area of m-ZrO₂ and the ratio of Cu to ZrO₂ surface areas further increased the methanol synthesis activity. In situ infrared spectroscopy and transient-response experiments indicate that the higher rate of methanol synthesis from CO₂/H₂ over Cu/m-ZrO₂ is due solely to the higher concentration of active intermediates. By contrast, the higher rate of methanol synthesis from CO/H₂ is due to both a higher concentration of surface intermediates and the more rapid dynamics of their transformation over Cu/ZrO₂.     

A novel low-temperature methanol synthesis method from CO/H2/CO2 based on the synergistic effect between solid catalyst and homogeneous catalyst

The activity of a binary catalyst in alcoholic solvents for methanol synthesis from CO/H₂/CO₂ at low temperature was investigated in a concurrent synthesis course. Experiment results showed that the combination of homogeneous potassium formate catalyst and solid copper–magnesia catalyst enhanced the conversion of CO₂-containing syngas to methanol at temperature of 423–443 K and pressure of 3–5 MPa. Under a contact time of 100 g h/mol, the maximum conversion of total carbon approached the reaction equilibrium and the selectivity of methanol was 99%. A reaction pathway involving esterification and hydrogenolysis of esters was postulated based on the integrative and separate activity tests, along with the structural characterization of the catalysts. Both potassium formate for the esterification as well as Cu/MgO for the hydrogenolysis were found to be crucial to this homogeneous and heterogeneous synergistically catalytic system. CO and H₂ were involved in the recycling of potassium formate.     

The promoting effect of alcohols in a new process of low-temperature synthesis of methanol from CO/CO2/H2

The catalytic promoting effects of eleven different alcohols, as reaction medium, on the synthesis of methanol from feed gas of CO/CO₂/H₂ on Cu/ZnO solid catalyst were investigated. Added alcohol altered the reaction route to realize a low-temperature synthesis method where formate was an intermediate. Many alcohols showed catalytic promoting effect for methanol formation at temperature as low as 443 K, remarkably lower than that in the present industrial ICI process.     

CO2 Hydrogenation to Methanol Over Cu/ZnO/Al2O3 Catalyst: Kinetic Modeling Based on Either Single- or Dual-Active Site Mechanism

CO₂ hydrogenation to CH₃OH via heterogeneous catalysis is one of the most promising and available approaches for mitigation of anthropogenic CO₂ issues. In this work, thermodynamic equilibria of CO₂ to methanol were compared with experimental results at given conditions using a commercial Cu/ZnO/Al₂O₃ catalyst for CO hydrogenation to methanol. It was found that, the high pressure, low temperature, and high H₂/CO₂ ratio are favorable to methanol synthesis from CO₂. Furthermore, the kinetic data were measured with an isothermal integral reactor under temperature between 160 and 240 °C, lower than that for CO hydrogenation to methanol reaction. Based on the single-active site and dual-active site LH mechanisms, both kinetic models can achieve full illustration of the influence of the operating conditions and the mechanisms. According to comparative analysis of the error variances of model correlations and the adsorbate coverages on the active sites, the dual-site mechanism identified to be superior to the single-site one for methanol synthesis from CO₂ feedstock. Overall, this paper provides fundamental understanding of the thermodynamic and kinetic aspects of a central route for CO₂ Valorisation.

Graphical Abstract

     

CO2 hydrogenation to methanol over Cu/ZnO/ZrO2 catalysts prepared via a route of solid-state reaction

Cu/ZnO/ZrO₂ catalysts were prepared by a route of solid-state reaction and tested for the synthesis of methanol from CO₂ hydrogenation. The effects of calcination temperature on the physicochemical properties of as-prepared catalysts were investigated by N₂ adsorption, XRD, TEM, N₂O titration and H₂-TPR techniques. The results show that the dispersion of copper species decreases with the increase in calcination temperature. Meanwhile, the phase transformation of zirconia from tetragonal to monoclinic was observed. The highest activity was achieved over the catalyst calcined at 400 °C. This method is a promising alternative for the preparation of highly efficient Cu/ZnO/ZrO₂ catalysts.     

Role of promoters on Rh/SiO2 in CO hydrogenation: A comparison using DRIFTS

La, V, Zn, Cu, Fe, Li and Ag promoted Rh/SiO₂ catalysts were investigated for the synthesis of ethanol during CO hydrogenation at 230 °C and 1.8 atm. As is well known, the activity and selectivity depend heavily on the choice of promoter. Diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) was used to probe the effects of La, V, Zn and Cu on CO adsorption and hydrogenation. From the IR study, it was found that the behavior of CO adsorbed on the differently promoted catalysts was very different. While La enhanced total CO adsorption, the addition of V, Zn and Cu suppressed CO adsorption to different extents. The doubly promoted Rh-La/V/SiO₂ showed only moderate CO adsorption. Results from DRIFTS suggest that the higher catalytic activity (compared to the non-promoted catalyst) observed for the La singly promoted Rh/SiO₂ catalyst may primarily be caused by an increase in the concentration of the adsorbed CO species in the presence of H₂, possibly due to the formation of new active sites at the LaO_x-Rh interface. The higher catalytic activity of the V singly promoted Rh/SiO₂ catalyst could be ascribed to an increased desorption rate/reactivity of the adsorbed CO species. The La and V doubly promoted catalyst showed both new adsorbed CO species and increased desorption rate/reactivity of the adsorbed species during CO hydrogenation due to a synergistic promoting effect of La and V. The addition of Zn or Cu promoters significantly reduced the desorption rate/reactivity of the adsorbed CO species on Rh/SiO₂, leading apparently to the much reduced activities for CO hydrogenation observed.     

Creation of the active site for methanol synthesis on a Cu/SiO2 catalyst

The effect of ZnO/SiO₂ in a physical mixture of Cu/SiO₂ and ZnO/SiO₂ on methanol synthesis from CO₂ and H₂ was studied to clarify the role of ZnO in Cu/ZnO-based catalysts. An active Cu/SiO₂ was prepared by the following procedure: the Cu/SiO₂ and ZnO/SiO₂ catalysts with a different SiO₂ particle size were mixed and reduced with H₂ at 523-723 K, and the Cu/SiO₂ was then separated from the mixture using a sieve. The methanol synthesis activity of the Cu/SiO₂ catalyst increased with the reduction temperature and was in fairly good agreement with that previously obtained for the physical mixture of Cu/SiO₂ and ZnO/SiO₂. These results indicated that the active site for methanol synthesis was created on the Cu/SiO₂ upon reduction of the physical mixture with H₂. It was also found that ZnO itself had no promotional effect on the methanol synthesis activity except for the role of ZnO to create the active site. The active site created on the Cu/SiO₂ catalyst was found not to promote the formation of formate from CO₂ and H₂ on the Cu surface based on in situ FT-IR measurements. A special formate species unstable at 523 K with an OCO asymmetric peak at ~1585 cm^-1 was considered to be adsorbed on the active site. This revised version was published online in July 2006 with corrections to the Cover Date.