The synergy between Cu and ZnO in methanol synthesis catalysts

The hydrogenation of CO₂ over physically-mixed Cu/SiO₂ and ZnO/SiO₂ was carried out to clarify the synergetic effect between Cu and ZnO in Cu/ZnO methanol synthesis catalysts. The activity of the physical mixtures significantly increased with increasing reduction temperature in the range of 573–723 K. TEM-EDX results definitely showed that ZnO_x moieties migrated from ZnO/SiO₂ particles onto the surface of Cu particles when the physical mixtures were reduced at high temperatures above 573 K. Upon the migration of the ZnO_x species, the oxygen coverage on the surface of Cu, measured after the hydrogenation of CO₂, increased with the reduction temperature. The results clearly showed that the synergetic effect of ZnO in the physical mixtures can be ascribed to the creation of active sites such as Cu⁺ which the ZnO_x moieties stabilize on the Cu surface. Further, XRD results showed that the migrated ZnO_x species partly dissolved into the Cu particles to form a Cu—Zn alloy.     

Hydrogenation of methyl acetate to ethanol by Cu/ZnO catalyst encapsulated in SBA‐15

The hydrogenation of methyl acetate (MA) is one of the important key processes for synthesis of ethanol from syngas. This work reports a highly efficient Cu‐ZnO/SBA‐15 catalyst prepared by facile solid‐state grinding method. Both copper and zinc species were encapsulated in SBA‐15 in high dispersion with the presence of organic template. The mixed homogeneity and interaction between copper and zinc species was enhanced as well with the help of organic template, resulting in the formation of Cu⁺ species in the reduced catalysts. Moreover, TOF_Cu(0) linearly increased with the Cu⁺/Cu⁰ ratio, indicating that a high proportion of Cu⁺/Cu⁰ induced by ZnO should be a key prerequisite to achieve favorable hydrogenation performance. It seems that the Cu⁺ species originated from Cu‐ZnO_x species are more active than that from Cu‐O‐Si species in the activation of MA. These results may provide an inspiration in rational design of Cu‐ZnO‐based catalysts for esters hydrogenation. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2839–2849, 2017     

CO<Subscript>2</Subscript> hydrogenation to methanol over Cu/ZnO catalysts synthesized via a facile solid-phase grinding process using oxalic acid

Reduced Cu/ZnO catalyst was synthesized through solid phase grinding of the mixture of oxalic acid, copper nitrate and zinc nitrate, followed by subsequent calcination in N₂ atmosphere without further H₂ reduction. The catalysts were characterized by various techniques, such as XRD, TG-DTA, TPR and N₂O chemisorption. Characterization results suggested that during the calcination in N₂, as-ground precursor (oxalate complexes) decomposed to CuO and ZnO, releasing considerable amount of CO, which could be used for in situ reduction of CuO to Cu^o. The in situ reduced O/I-Cu/ZnO catalyst was evaluated in CO₂ hydrogenation to methanol, which exhibited superior catalytic performance to its counterpart O/H-Cu/ZnO catalyst obtained through conventional H₂ reduction. The decomposition of precursor and reduction of CuO happened simultaneously during the calcination in N₂, preventing the growth of active Cu⁰ species and aggregation of catalyst particles, which was inevitable during conventional H₂ reduction process. This method is simple and solvent-free, opening a new route to prepare metallic catalysts without further reduction.     

On the Issue of the Active Site and the Role of ZnO in Cu/ZnO Methanol Synthesis Catalysts

The problem concerning the active site and the role of ZnO in Cu/ZnO-based methanol synthesis catalysts can be consistently explained based on the literature results by distinguishing CO₂ and CO hydrogenations. Although only metallic copper has some activities for methanol synthesis by the hydrogenation of CO₂, Cu-Zn alloying in Cu particles is responsible for the major promotional role of ZnO in industrial Cu/ZnO-based catalysts. The morphology effect reported in the literature will probably appear for the system of highly dispersed Cu particles supported on ZnO. As for the hydrogenation of CO, Cu⁺ species or Cu-O-Zn sites are the active sites for methanol synthesis. The spillover effect of the Cu-ZnO system is not significant compared to the effect of ZnO on the creation of the Cu-O-Zn site.     

Steam Reforming of Methanol Over Cu/CeO2 Catalysts Studied in Comparison with Cu/ZnO and Cu/Zn(Al)O Catalysts

A series of Ce_1-xCu_xO_2- mixed oxides were synthesized using a co-precipitation method and tested as catalysts for the steam reforming of methanol. XRD patterns of the Ce_1-xCu_xO_2- mixed oxides indicated that Cu²⁺ ions were dissolved in CeO₂ lattices to form a solid solution by calcination at 773K when x < 0.2. A TPR (temperature-programmed reduction) investigation showed that the CeO₂ promotes the reduction of the Cu²⁺ species. Two reduction peaks were observed in the TPR profiles, which suggested that there were two different Cu²⁺ species in the Ce_1-xCu_xO_2- mixed oxides. The TPR peak at low temperature is attributed to the bulk Cu²⁺ species which dissolved into the CeO₂ lattices, and the peak at high temperature is due to the CuO species dispersed on the surface of CeO₂. The Ce_1-xCu_xO_2- mixed oxides were reduced to form Cu/CeO₂ catalysts for steam reforming of methanol, and were compared with Cu/ZnO, Cu/Zn(Al)O and Cu/AL₂O₃ catalysts. All the Cu-containing catalysts tested in this study showed high selectivities to CO₂ (over 97%) and H₂. A 3.8wt% Cu/CeO₂ catalyst showed a conversion of 53.9% for the steam reforming of methanol at 513K (W/F = 4.9 g h mol^-1), which was higher than that over Cu/ZnO (37.9%), Cu/Zn(Al)O (32.3%) and Cu/AL₂O₃ (11.2%) with the same Cu loading under the same reaction conditions. It is likely that the high activity of the Cu/CeO₂ catalysts may be due to the highly dispersed Cu metal particles and the strong metalsupport interaction between the Cu metal and CeO₂ support. Slow deactivations were observed over the 3.8wt% Cu/CeO₂ catalyst at 493 and 513K. The activity of the deactivated catalysts can be regenerated by calcination in air at 773K followed by reduction in H₂ at 673K, which indicated that a carbonaceous deposit on the catalyst surface caused the catalyst deactivation. Using the TPO (temperature-programmed oxidation) method, the amounts of coke on the 3.8wt% Cu/CeO₂ catalyst were 0.8wt% at 493K and 1.7wt% at 513K after 24h on stream.     

Gas phase hydrogenation of maleic anhydride to γ-butyrolactone by Cu–Zn–Ti catalysts

Cu–Zn–Ti catalysts were prepared by coprecipitation method. The calcined and reduced Cu–Zn–Ti catalysts were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), temperature-programmed reduction (TPR), and N₂ adsorption. The calcined Cu–Zn–Ti catalysts were composed of CuO, ZnO, and amorphous TiO₂. There were two kinds of CuO species present in the calcined Cu–Zn–Ti catalyst. At a lower copper content, CuO species interacted with ZnO and TiO₂; at a higher copper content, both the surface-anchored and bulk CuO species were present. After reduction, metallic copper (Cu^o) appeared in all Cu–Zn–Ti catalysts. Cu^o produced by reduction of the surface-anchored CuO favored the deep hydrogenation of maleic anhydride. ZnO and TiO₂ had synergistic effect on the catalytic activity of Cu–Zn–Ti catalysts in hydrogenation of maleic anhydride.     

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.     

The effect of the reduction temperature on the structure of Cu/ZnO/SiO2 catalysts for methanol synthesis

The structure of Cu/SiO₂ and Cu/ZnO/SiO₂ catalysts was studied after reduction at 450–1300 K. The influence of the ZnO promoter on the exposed Cu surface area and metal cluster size was determined by N₂O chemisorption and X-ray diffraction. After reduction at 450 K, the metal surface area amounted to 9 m²/g_cat for both catalysts. Oxygen uptake during N₂O chemisorption increased significantly up to reduction temperatures of 800–900 K. This increase was most prominent for the ZnO-promoted catalyst, although no oxygen uptake was observed for a similarly treated ZnO/SiO₂ sample. The behaviour of the promoted catalyst can be explained by formation of Zn⁰, surface alloying, and segregation of ZnO_x species on top of Cu clusters. The high thermostability of the catalysts was confirmed by in situ XRD measurements. The Cu crystallite size in both catalysts was about 4 nm, and did not increase when the reduction temperature was raised to 1100 K for 1 h.     

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.     

Methanol synthesis by the hydrogenation of CO2 over Zn-deposited Cu(111) and Cu(110) surfaces

The hydrogenation of CO₂ over Zn-deposited Cu(111) and Cu(110) surfaces was performed at 523 K and 18 atm using a high pressure flow reactor combined with XPS apparatus. It was shown that the ZnO _x species formed on Cu(111) during reaction directly promoted the methanol synthesis. However, no such promotional effect of the Zn was observed for methanol formation on Cu(110). Thus, Zn on Cu(111) acts as a promoter, while Zn on Cu(110) acts as a poison. The activation energy and the turnover frequency are in fairly good agreement with those obtained for Cu/ZnO powder catalysts.     

Binary spinel cobaltites of nickel,copper and zinc as precursors of catalysts for carbon oxides methanation

The hydrogenation of carbon oxides (CO and CO₂) on bimetallic Cu/Co and Ni/Co as well as Co/ZnO catalysts obtained by reduction of the corresponding spinel cobaltites Me_xCo_3-xO₄ is investigated. The predominant hydrogenation process is methanation and in the case of nickel cobaltite high and stable activity and selectivity are reached, no carbon deposition and carbide formation being observed.     

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.     

Highly Active CNT-Promoted Cu–ZnO–Al2O3 Catalyst for Methanol Synthesis from H2/CO/CO2

With types of in-house-synthesized multi-walled carbon nanotubes (CNTs) and the nitrates of the corresponding metallic components, highly active CNT-promoted Cu–ZnO–Al₂O₃ catalysts, symbolized as Cu _i Zn _j Al _k -x%CNTs, were prepared by the co-precipitation method. Their catalytic performance for methanol synthesis from H₂/CO/CO₂ was studied and compared with the corresponding CNT-free co-precipitated catalyst, Cu _i Zn _j Al _k . It was shown experimentally that appropriate incorporation of a minor amount of the CNTs into the Cu _i Zn _j Al _k could significantly increase the catalyst activity for methanol synthesis. Under the reaction conditions of 493 K, 5.0 MPa, H_2/CO/CO₂/N₂ = 62/30/5/3 (v/v), GHSV = 8000 h^-1, the observed CO conversion and methanol formation rate over a co-precipitated catalyst of Cu₆Zn₃Al₁-12.5%CNTs reached 36.8% and 0.291 mol CH₃OH s^-1 (m²-surf. Cu)^-1, which was about 44 and 25% higher than those (25.5% and 0.233 mol CH₃OH s^-1 (m²-surf. Cu)^-1) over the corresponding CNT-free co-precipitated catalyst, Cu₆Zn₃Al₁. Addition of a minor amount (10–15 wt%) of the CNTs to the Cu₆Zn₃Al₁ catalyst was found to considerably increase specific surface area, especially Cu surface area of the catalyst. H₂-TPD measurements revealed that the CNTs and the pre-reduced CNT-promoted catalyst systems could reversibly adsorb and store a considerably greater amount of hydrogen under atmospheric pressure at temperatures ranging from room temperature to 573 K. This unique feature would be beneficial for generating microenvironments with higher stationary-state concentration of active hydrogen adspecies on the surface of the functioning catalyst, especially at the interphasial active sites since the highly conductive CNTs might promote hydrogen spillover from the Cu sites to the Cu/Zn interphasial active sites, and thus be favorable for increasing the rate of the CO hydrogenation reactions. Alternatively, the operation temperature for methanol synthesis over the CNT-promoted catalysts can be 15–20 degrees lower than that over the corresponding CNT-free contrast system. This would contribute considerably to an increase in equilibrium CO conversion and CH₃OH yield. The results of the present work indicated that the CNTs could serve as an excellent promoter.     

Selective production of methanol from syngas over LaTi1−xCuxO3 mixed oxides

Carbon monoxide hydrogenation was studied over partially substituted copper-containing LaTi_1–xCu_xO₃ oxides and on copper supported on La₂O₃. The unsubstituted (x = 0) oxide was weakly active for CO hydrogenation, whereas all the other oxides were more active and exhibited high selectivity to methanol. Particularly, for substitutions x = 0.5–0.6, where the perovskite structure was observed, CO conversions close to 22% and selectivity close to 80% were found. Cu/La₂O₃ was, however, less active and yielded CO₂ and hydrocarbons as the major products. Using X-ray photoelectron spectroscopy it was determined that under reaction conditions copper exists as reduced species. The L₃VV X-ray induced Auger transition at 1849.2 eV observed for a representative LaMn_0.5Cu_0.5O₃ catalyst prereduced and used in CO hydrogenation at 573 K, suggests that Cu⁺ species dominates in spent catalyst. These Cu⁺ species are believed to be stable under reaction conditions in the perovskite structure, only a slight Cu enrichment occurs on the topmost layer of catalysts.     

Catalytic combustion of volatile aromatic compounds over CuO-CeO<Subscript>2</Subscript> catalyst

Ce_1?x Cu _x O₂ oxide solid solution catalysts with different Ce/Cu mole ratios were synthesized by the one-pot complex method. The prepared Ce_1?x Cu _x O₂ catalysts were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and H₂ temperature-programmed reduction (H₂-TPR). Their catalytic properties were also investigated by catalytic combustion of phenyl volatile organic compounds (PVOCs: benzene, toluene, xylene, and ethylbenzene) in air. XRD analysis confirmed that the CuO species can fully dissolve into the CeO₂ lattice to form CeCu oxide solid solutions. XPS and H²-TPR results indicated that the prepared Ce_1?x Cu _x O₂ catalysts contain abundant reactive oxygen species and superior reducibility. Furthermore, the physicochemical properties of the prepared Ce_1?x Cu _x O₂ catalysts are affected by the Ce/Cu mole ratio. The CeCu₃ catalyst with Ce/Cu mole ratio of 3.0 contains abundant reactive oxygen species and exhibits superior catalytic combustion activity of PVOCs. Moreover, the ignitability of PVOCs is also affected by the respective physicochemical properties. The catalytic combustion conversions of ethylbenzene, xylene, toluene, and benzene are 99%, 98.9%, 94.3%, and 62.8% at 205, 220, 225, and 225 °C, respectively.     

Methanol synthesis over Cu/ZnO catalysts prepared by ball milling

Cu/ZnO catalysts (with a Cu/Zn atomic ratio of 30/70) have been prepared by high intensity mechanical mixing of copper and zinc oxide powder in air and under vacuum. During milling in vacuum gradual amorphisation of the constituents occurs, as evidenced by broadening of the Cu⁰ and ZnO diffraction peaks in XRD, but the two original phases remain. The result of such treatment is a catalyst with low BET area and low Cu metal surface area. Consequently, the activity of the vacuum milled samples in batch methanol production from synthesis gas (CO/CO₂/H₂=20/5/75) at 50 bar and 250°C is low. Milling in air leads to oxidation of the copper metal phase and much higher BET surface area and, after reduction, Cu metal surface area. Prolonged milling times in air result in more than 90% Cu²⁺ formation as evidenced by TPR. Activity in methanol synthesis for the air milled samples is comparable to a conventional Cu/ZnO catalyst prepared by coprecipitation. It is concluded that high intensity ball milling at ambient conditions is a promising method to prepare mixed oxide catalysts or catalyst precursors. This revised version was published online in July 2006 with corrections to the Cover Date.     

Steam reforming of methanol using Cu-ZnO catalysts supported on nanoparticle alumina

Methanol steam reforming was studied over several catalysts made by deposition of copper and zinc precursors onto nanoparticle alumina. The results were compared to those of a commercially available copper, zinc oxide and alumina catalyst. Temperature programmed reduction, BET surface area measurements, and N₂O decomposition were used to characterize the catalyst surfaces. XRD was used to study the bulk structure of the catalysts, and XPS was used to determine the chemical states of the surface species. The nanoparticle-supported catalysts achieved similar conversions as the commercial reference catalyst but at slightly higher temperatures. However, the nanoparticle-supported catalysts also exhibited a significantly lower CO selectivity at a given temperature and space time than the reference catalyst. Furthermore, the turnover frequencies of the nanoparticle-supported catalysts were higher than that of the commercial catalyst, which means that the activity of the surface copper is higher. It was determined that high alumina concentrations ultimately decrease catalytic activity as well as promote undesirable CH₂O formation. The lower catalytic activity may be due to strong Cu-Al₂O₃ interactions, which result in Cu species which are not easily reduced. Furthermore, the acidity of the alumina support appears to promote CH₂O formation, which at low Cu concentrations is not reformed to CO₂ and H₂. The CO levels present in this study are above what can be explained by the reverse water-gas-shift (WGS) reaction. While coking is not a significant deactivation pathway, migration of ZnO to the surface of the catalyst (or of Cu to the bulk of the catalyst) does explain the permanent loss of catalytic activity. Cu₂O is present on the spent nanoparticle catalysts and it is likely that the Cu⁺/Cu⁰ ratio is of importance both for the catalytic activity and the CO selectivity.     

Structure and catalytic properties of Cu-Ni bimetallic catalysts for hydrogenation

The dependence of catalytic activity and selectivity of Cu-Ni bimetallic catalysts for oil hydrogenation on CuNi ratios have been investigated while they were reduced at low temperature (230 °C). Two maxima occurred at Cu₂Ni₁ and Cu₁Ni₃ in the activity-CuNi curve. Cu riched catalysts have higher selectivity than Ni riched ones, and may cause dehydrogenation and isomerization of linoleate at the beginning of the reaction. The structures of the catalysts reduced at different temperatures have been studied by means of XRD, XPS, EXAFS and FMR et al. The structure of the catalysts reduced at 230 °C can be described as an aggregate of Cu particles inlaid with Ni atoms and unreduced NiO, and the easily reduced Cu always segregates on the surface, while homogeneous solid solution particles can be formed in the case 400 °C being used as reduction temperature.     

Steam reforming of methanol using Cu-ZnO catalysts supported on nanoparticle alumina

Methanol steam reforming was studied over several catalysts made by deposition of copper and zinc precursors onto nanoparticle alumina. The results were compared to those of a commercially available copper, zinc oxide and alumina catalyst. Temperature programmed reduction, BET surface area measurements, and N₂O decomposition were used to characterize the catalyst surfaces. XRD was used to study the bulk structure of the catalysts, and XPS was used to determine the chemical states of the surface species. The nanoparticle-supported catalysts achieved similar conversions as the commercial reference catalyst but at slightly higher temperatures. However, the nanoparticle-supported catalysts also exhibited a significantly lower CO selectivity at a given temperature and space time than the reference catalyst. Furthermore, the turnover frequencies of the nanoparticle-supported catalysts were higher than that of the commercial catalyst, which means that the activity of the surface copper is higher. It was determined that high alumina concentrations ultimately decrease catalytic activity as well as promote undesirable CH₂O formation. The lower catalytic activity may be due to strong Cu-Al₂O₃ interactions, which result in Cu species which are not easily reduced. Furthermore, the acidity of the alumina support appears to promote CH₂O formation, which at low Cu concentrations is not reformed to CO₂ and H₂. The CO levels present in this study are above what can be explained by the reverse water-gas-shift (WGS) reaction. While coking is not a significant deactivation pathway, migration of ZnO to the surface of the catalyst (or of Cu to the bulk of the catalyst) does explain the permanent loss of catalytic activity. Cu₂O is present on the spent nanoparticle catalysts and it is likely that the Cu⁺/Cu⁰ ratio is of importance both for the catalytic activity and the CO selectivity.     

Gas‐Phase Hydrogenolysis of Glycerol Catalyzed by Cu/MOx Catalysts

The catalytic activities of Cu/MO_x (MO_x = Al₂O₃, TiO₂, and ZnO) catalysts in the gas‐phase hydrogenolysis of glycerol were studied at 180–300 °C under 0.1 MPa of H₂. Cu/MO_x (MO_x = Al₂O₃, TiO₂, and ZnO) catalysts were prepared by the incipient wetness impregnation method. After reduction, CuO species were converted to metallic copper (Cu⁰). Cu/Al₂O₃ catalysts with high acidity, high specific surface areas and small metallic copper size favored the formation of 1,2‐propanediol with a maximum selectivity of 87.9 % at complete conversion of glycerol and a low reaction temperature of 180 °C, and favored the formation of ethylene glycol and monohydric alcohols at high reaction temperature of 300 °C. Cu/TiO₂ and Cu/ZnO catalysts exhibited high catalytic activity toward the formation of hydroxyacetone with a selectivity of approx. 90 % in a wide range of reaction temperature.