Methanol synthesis from carbon dioxide at atmospheric pressure over Cu/ZnO catalyst. Role of methoxide species formed on ZnO support

Methanol synthesis from CO₂ and H₂ was carried out over a Cu/ZnO catalyst (Cu/Zn = 3/7) at atmospheric pressure, and the surface species formed were analyzed by diffuse reflectance FT-IR spectroscopy and temperature programmed desorption method. Two types of formate species and zinc methoxide were formed in the course of the reaction. Zinc methoxide was readily hydrolyzed to methanol. H₂O formed through the reverse water gas shift reaction was suggested to be involved in the hydrolysis of zinc methoxide.     

CO2 Hydrogenation to Methanol Over Cu/ZnO/Al2O3 Catalysts Prepared by a Novel Gel-Network-Coprecipitation Method

A novel gel-network-coprecipitation process has been developed to prepare ultrafine Cu/ZnO/Al₂O₃ catalysts for methanol synthesis from CO₂ hydrogenation. It is demonstrated that the gel-network-coprecipitation method can allow the preparation of the ultrafine Cu/ZnO/Al₂O₃ catalysts by homogeneous coprecipitation of the metal nitrate salts in the gel network formed by gelatin solution, which makes the metallic copper in the reduced catalyst exist in much smaller crystallite size and exhibit a much higher metallic copper-specific surface area. The effect of the gel concentration of gelatin on the structure, morphology and catalytic properties of the Cu/ZnO/Al₂O₃ catalysts for methanol synthesis from hydrogenation of carbon dioxide was investigated. The Cu/ZnO/Al₂O₃ catalysts prepared by the gel-network-coprecipitation method exhibit a high catalytic activity and selectivity in CO₂ hydrogenation to methanol.     

The effect of ZnO in methanol synthesis catalysts on Cu dispersion and the specific activity

The effect of ZnO in Cu/ZnO catalysts prepared by the coprecipitation method has been studied using measurements of the surface area of Cu, the specific activity for the methanol synthesis by hydrogenation of CO₂, and XRD. Although the Cu surface area increases with increasing ZnO content (0–50 wt%) as is generally known, the specific activity of the Cu/ZnO catalysts with various weight ratios of Cu:ZnO is greater than that of a ZnO-free Cu catalyst. These facts clearly indicate that the role of ZnO in Cu/ZnO catalysts can be ascribed to both increases in the Cu dispersion and the specific activity. The XRD results indicate the formation of a Cu–Zn alloy in the Cu particles of the Cu/ZnO catalysts, leading to the increase in specific activity. It is thus considered that the Cu–Zn surface alloy or a Cu–Zn site is the active site for methanol synthesis in addition to metallic copper atoms that catalyze several hydrogenation steps during the methanol synthesis. Furthermore, the advantage of the coprecipitation method through a precursor of aurichalcite is ascribed to both improvements in the Cu surface area and the specific activity. This revised version was published online in July 2006 with corrections to the Cover Date.     

Methanol Synthesis from CO2 Using Skeletal Copper Catalysts Containing Co-precipitated Cr2O3 and ZnO

Skeletal Cu-Cr₂O₃-ZnO catalysts have been prepared by leaching CuAl₂ alloy particles at 273 K using 6.1 M aqueous NaOH solutions containing sodium chromate (Na₂CrO₄) and sodium zincate (Na₂Zn(OH)₄). The presence of sodium chromate and sodium zincate in the caustic solution was found to affect the pore structure and surface areas of the resulting catalysts. Both BET and Cu surface areas were increased by increasing the concentration of Na₂CrO₄ and of Na₂Zn(OH)₄.Increasing the Na₂CrO₄ level from 0 to 0.06 M in a 6.1M NaOH solution containing 0.2M Na₂Zn(OH)₄ caused the content of ZnO in the catalyst to decrease from 8.8 to 3.0 wt% whilst increasing the Cr₂ O₃ content from 0 to 1.7 wt%, indicating that the presence of Na₂CrO₄ in the leach liquor not only resulted in deposition of a Cr compound but also inhibited precipitation of zinc hydroxide onto skeletal Cu catalysts. On the other hand, increasing the concentration of Na₂Zn(OH)₄ from 0 to 0.6 M in a 6.1 M NaOH solution containing 0.008 M Na₂ CrO₄ resulted in increasing the ZnO loading from 0 to 8.9wt% with an almost constant content of Cr₂ O₃ (1.3 ± 0.2%) in the catalysts, revealing that sodium zincate only led to precipitation of zinc hydroxide and did not suppress Cr₂O₃ formation.Hydrogenation of CO₂ was studied using a gas mixture of 24% CO₂ in H₂ at a total pressure of 4MPa, space velocities up to 210000L kg^-1h^-1 and temperatures in the range 493-533K. The catalysts were found to be both highly active and selective for methanol synthesis. This study confirms the role of ZnO in promoting the activity of copper for methanol synthesis from CO₂ and improving the selectivity by inhibiting the reverse water-gas shift reaction. The role of Cr₂O₃ is to improve the structural development of high surface area skeletal copper.     

The active site for methanol synthesis on a Cu/ZnO/SiO2 catalyst

This note rectifies serious omissions from the references included in a recent paper by Fujitani et al. concerned with methanol synthesis over Cu/SiO₂ containing ZnO. This revised version was published online in July 2006 with corrections to the Cover Date.     

On the nature of surface structural changes in Cu/ZnO methanol synthesis catalysts

Infrared spectroscopic studies of CO adsorption have been used to elucidate the surface structure of Cu/ZnO methanol synthesis catalysts. Significant frequency shifts are observed as functions of the severity of the reduction treatment. The changes, which are unlike those observed in other supported Cu catalysts, cannot be interpreted solely by changes in morphology and abundance of different Cu surface planes. Rather, the band shifts are suggested to be related to the formation of Cu–Zn surface alloys under more severe reduction conditions. The formation/destruction of the surface alloys is apparently reversible and it is proposed that such processes may be the origin of many of the unusual steady state and transient kinetic behaviors observed for Cu/ZnO catalysts. This revised version was published online in June 2006 with corrections to the Cover Date.     

Deactivation of Supported Copper Catalysts for Methanol Synthesis

Binary Cu/ZnO and Cu/Al₂O₃ as well as ternary Cu/ZnO/Al₂O₃ catalysts were investigated with respect to their catalytic activity and stability in methanol synthesis. In a rapid aging test, activity measurements were carried out in combination with the determination of the specific Cu surface area. A close correlation between the loss of catalytic activity and the decrease in specific Cu surface area was found due to sintering of the Cu particles. Differences in the deactivation behavior and the area-activity relationship of each catalyst system imply that the catalysts should be grouped in different classes.     

Dynamical Changes in Cu/ZnO/Al2O3 Catalysts

A combination of various transient and steady-state kinetic experiments was used to provide evidence for dynamical changes in a Cu/ZnO/Al₂O₃ catalyst of industrial interest. From these it can be deduced that the reversible structural alterations strongly depend on the reaction conditions as well as on the pretreatment. The pretreatment was found to induce changes in the morphology of the metallic Cu particles to some extent, and surface alloying under more severe reducing conditions.     

An EXAFS study of Cu/ZnO and Cu/ZnO-Al2O3 methanol synthesis catalysts

Cu K-absorption edge and EXAFS measurements on binary Cu/ZnO and ternary Cu/ ZnO-Al₂O₃ catalysts of varying compositions on reduction with hydrogen at 523 K, show the presence of Cu microclusters and a species of Cu¹⁺ dissolved in ZnO apart from metallic Cu and Cu₂O. The proportions of different phases critically depend on the heating rate especially for catalysts of higher Cu content. Accordingly, hydrogen reduction with a heating rate of 10 K/min predominantly yields the metal species (>50%), while a slower heating rate of 0.8 K/min enhances the proportion of the Cu¹⁺ species ( 60%). Reduced Cu/ZnO-Al₂O₃ catalysts show the presence of metallic Cu (upto 20%) mostly in the form of microclusters and Cu¹⁺ in ZnO as the major phase ( 60%). The addition of alumina to the Cu/ZnO catalyst seems to favour the formation of Cu¹⁺/ZnO species.     

Hydrogen Spillover in Ga2O3–Pd/SiO2 Catalysts for Methanol Synthesis from CO2/H2

The hydrogenation of CO₂ was investigated on Ga₂O₃-promoted Pd/SiO₂ catalyts and mechanical mixtures of Ga₂O₃/SiO₂ and Pd/SiO₂ catalysts (H₂/CO₂ = 3; P = 3.0 MPa; T = 523 K). By means of the latter it was possible to demonstrate that atomic hydrogen, H_s, can be generated by Pd⁰ far from Ga₂O₃, and move (spill-over) there to reach the other reactive species (formates) and complete the reaction cycle. The reaction results indicate that (as also evidenced by in situ FTIR) the Ga₂O₃-Pd/SiO₂ catalyst works as a true bi-functional system. The metal-promoter intimacy is not decisive in terms of the catalytic chemistry of the system, but the closeness between the Pd crystallites and the Ga₂O₃ surface patches boost the activity, owing to a minimized effort in the H_s supply to the latter.     

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.     

Cu/Zn/Al/Zr纳米纤维催化剂上的CO2加氢合成甲醇过程

A highly active Cu/Zn/Al/Zr fibrous catalyst was developed for methanol synthesis from CO₂ hydrogenation.Various factors that affect the activity of the catalyst,including the reaction temperature,pressure and space velocity,were investigated.The kinetic parameters in Graaf’s kinetic model for methanol synthesis were obtained.A quasistable economical process for CO₂ hydrogenation through CO circulation was simulated and higher methanol yield was obtained.     

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.     

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.     

EXAFS and XPS Investigations of Cu/ZnO Catalysts and Their Interaction with CO and Methanol

Several investigations have been carried out on Cu/ZnO catalysts by employing extended Xray absorption fine structure (EXAFS) and Xray photoelectron spectroscopy (XPS). EXAFS investigations of Cu/ZnO catalysts subjected to hydrogen reduction show the presence of Cu¹⁺ species and Cu microclusters. The proportion of Cu¹⁺ depends on the rate of increase of the reduction temperature and on the amount of alumina added. An XPS study of the interaction of CO with model Cu/ZnO catalysts prepared in situ in the electron spectrometer shows the formation of CO₂ ^-, CO₃ ^2- and C₂O₄ ^2- species, their proportion relative to CO increasing with the Cu¹⁺/Cu⁰ ratio. A study of the interaction of CH₃OH with Cu clusters deposited on ZnO films reveals reversible molecular adsorption and the formation of CH₃O on clean Cu clusters. If the Cu clusters are pretreated with oxygen, however, both CH₃O and HCOO^- species are produced. Model Cu/ZnO catalyst surfaces containing both Cu¹⁺ and Cu⁰ species show interesting oxidation properties. On a Cu⁰-rich catalyst surface, only the CH₃O species is formed on interaction with CH₃OH. On a Cu¹⁺rich surface, the HCOO^- ion is the predominant species.     

Role of ZnO in Cu/ZnO/Al2O3 catalyst for hydrogenolysis of butyl butyrate

For hydrogenolysis of butyl butyrate (BB), a series of Cu/ZnO/Al₂O₃ catalysts with different metal compositions were prepared, and characterized by N₂O chemisorption for measuring Cu surface area and by chromatographic experiment for determining the heat of BB adsorption. As a result, the presence of ZnO in Cu-based catalysts was found to enhance the catalytic activity of Cu due to dual function of ZnO. The Cu surface area was linearly correlated with the butanol productivity, demonstrating that ZnO exerts the structural function in Cu/ZnO/Al₂O₃ catalysts. Additionally, the role of ZnO as a chemical contributor was revealed such that its presence leads to lower activation energy of the surface reaction, thus resulting in higher Cu catalytic activity obtained at a low temperature such as 200 °C. Consequently, optimizing the Cu/Zn ratio in Cu/ZnO/Al₂O₃ catalyst is required to tune its structural and chemical characteristics of Cu metals, and thus to obtain a higher activity on the hydrogenolysis reaction.     

Spectroscopic and Kinetic Analysis of a New Low-Temperature Methanol Synthesis Reaction

The spectroscopy and kinetics of a new low-temperature methanol synthesis method were studied by using in situ DRIFTS on Cu/ZnO catalysts from syngas (CO/CO₂/H₂) using alcohol promoters. The adsorbed formate species easily reacted with ethanol or 2-propanol at 443 K and atmospheric pressure, and the reaction rate with 2-propanol was faster than that with ethanol. Alkyl formate was easily reduced to form methanol at 443 K and 1.0 MPa, and the hydrogenation rate of 2-propyl formate was found to be faster than that of ethyl formate. 2-Propanol used as promoter exhibited a higher activity than ethanol in the reaction of the low-temperature methanol synthesis.     

A Cu/Zn/Al/Zr Fibrous Catalyst that is an Improved CO<Subscript>2</Subscript> Hydrogenation to Methanol Catalyst

A series of Cu/Zn/Al/Zr CO₂ hydrogenation to methanol catalysts containing different ratios of Al/Zr were prepared using a co-precipitation procedure. SEM, TEM, and XRD characterization showed that all the catalysts comprised crystallites in a fibrous structure and their Cu/Zn crystallite dispersions were better than that of a commercial (COM) catalyst. It is suggested that the high dispersion and stability of the Cu/Zn crystallites due to the fibrous structure enhanced CO₂ hydrogenation, and the added Zr component further improved the catalyst. A 5% Zr addition gave a methanol space time yield 80% higher than that on the COM catalyst.     

Supported Cu Catalysts with Yttria-Doped Ceria for Steam Reforming of Methanol

The steam reforming of methanol was studied over Cu/Al₂O₃ catalysts with the addition of yttria-doped ceria (YDC). The YDC-modified catalysts were prepared by impregnating a -Al₂O₃ support with Y and Ce then with Cu. The addition of YDC drastically enhanced the activity of Cu/Al₂O₃ in the methanol reforming reaction. The enhanced activity was attributed to the increase of Cu⁺ species by YDC in the methanol reforming environment. However, the addition of YDC decreased the copper dispersion. The Cu dispersion could be enhanced by adding chromium oxide. The addition of YDC and Cr where Al₂O₃ was first impregnated with Cr then with YDC showed the most pronounced enhancement of the catalyst activity. At reaction temperatures of 200250 °C, the CO concentration in the products was smaller than 0.1%.     

Spectroscopic evidence for adsorption sites located at Cu/ZnO interfaces

FTIR spectra are reported of CO and formic acid adsorption on a series of Cu/ZnO/SiO₂ catalysts. Peaks due to linear CO adsorbed on copper diminished in intensity as the loading of ZnO was increased. This behaviour was explained in terms of ZnO island growth on the copper surface. Similarly, reduction of the copper concentration while maintaining a constant ZnO loading also resulted in further attenuation in bands ascribed to CO chemisorbed on copper. Formic acid exposure to a Cu/SiO₂ sample produced a formate species displaying a _as(COO) mode at 1585 cm^–1. Addition of a small quantity of ZnO to the catalyst resulted in substantial promotion of formate growth, which was accompanied by a shift (and broadening) of the _as(COO) vibration to 1660–1600 cm^–1. Since further ZnO incorporation poisoned formate creation it was concluded that formate species bonded to Cu and Zn sites located at interfacial positions had been formed. The role of such species in methanol synthesis is discussed.