Preparation of Cu/ZnO/Al2O3 catalyst under microwave irradiation for slurry methanol synthesis

Cu/ZnO/Al₂O₃ catalysts with Cu/Zn/Al ratios of 6/3/1 were precipitated and aged by conventional and microwave heating methods and tested in the slurry phase reactor for methanol synthesis. The effect of technological condition of precipitation and aging process under microwave irradiation on the catalytic performance was investigated to optimize the preparing condition of Cu/ZnO/Al₂O₃ catalyst. The results showed that the microwave irradiation during precipitation process could improve the activity of the catalyst, but had little effect on the stability. While the microwave irradiation during aging process has a great benefit to both the activity and stability of the catalyst, the catalyst aged at 80°C for 1 h under microwave irradiation possessed higher methanol space time yield (STY) and more stable catalytic activity. The activity and stability of the catalyst was further enhanced when microwave irradiation was used in both precipitation and aging processes; the optimized condition for the catalyst precursor preparation was precipitation at 60°C and aging at 80°C under microwave irradiation.     

Cu/ZnO/AlOOH catalyst for methanol synthesis through CO<Subscript>2</Subscript> hydrogenation

Catalytic conversion of CO₂ to methanol is gaining attention as a promising route to using carbon dioxide as a new carbon feedstock. AlOOH supported copper-based methanol synthesis catalyst was investigated for direct hydrogenation of CO₂ to methanol. The bare AlOOH catalyst support was found to have increased adsorption capacity of CO₂ compared to conventional Al₂O₃ support by CO₂ temperature-programmed desorption (TPD) and FT-IR analysis. The catalytic activity measurement was carried out in a fixed bed reactor at 523 K, 30 atm and GHSV 6,000 hr^?1 with the feed gas of CO₂/H₂ ratio of 1/3. The surface basicity of the AlOOH supported Cu-based catalysts increased linearly according to the amount of AlOOH. The optimum catalyst composition was found to be Cu : Zn : Al=40 : 30 : 30 at%. A decrease of methanol productivity was observed by further increasing the amount of AlOOH due to the limitation of hydrogenation rate on Cu sites. The AlOOH supported catalyst with optimum catalyst compositions was slightly more active than the conventional Al₂O₃ supported Cu-based catalyst.     

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.     

CO removal from reformed fuel over Cu/ZnO/Al2O3 catalysts prepared by impregnation and coprecipitation methods

A composition of Cu/ZnO/Al₂O₃ catalysts prepared by the impregnation method was optimized for water gas shift reaction (WGSR) coupled with CO oxidation in the reformed gas. The optimum composition of the impregnated catalyst for high WGSR activity was 5 wt.% Cu/5 wt.% ZnO/Al₂O₃. The optimum loading amounts of Cu and ZnO in the impregnated catalyst were smaller than those in the coprecipitated catalyst. Its catalytic activity above 200 °C was comparable to that of the conventional coprecipitated Cu/ZnO/Al₂O₃ catalyst. However, the activity of the impregnated Cu/ZnO/Al₂O₃ catalysts was significantly lowered at 150 °C, whereas no deactivation was observed for the coprecipitated catalyst at the same temperature. It was found that deactivation occurred over impregnated catalysts with H₂O and/or O₂ in the reaction gas; it prevented CO adsorption on the surface.     

Synthesis of nickel catalysts supported on Zr-doped ordered mesoporous Al<Subscript>2</Subscript>O<Subscript>3</Subscript> and their catalytic performance for low-temperature CO<Subscript>2</Subscript> reforming of CH<Subscript>4</Subscript>

A series of Zr-doped ordered mesoporous Al₂O₃ with various Zr contents were synthesized by evaporation-induced self-assembly strategy and the Ni-based catalysts supported on these Al₂O₃ materials were prepared by impregnation method. These catalysts with large specific surface area, big pore volume, uniform pore size possess excellent catalytic performance for the low-temperature carbon dioxide reforming of methane. The activities of these catalysts were tested in carbon dioxide reforming of methane reaction with temperature increasing from 500 to 650?°C and the stabilities of these catalysts were evaluated for long time reaction at 650?°C. It was found that when Zr/(Zr?+?Al) molar ratio?=?0.5%, the Ni/0.5ZrO₂–Al₂O₃ catalyst showed the highest activity, and exhibited superior stabilization compared to the Ni-based catalyst supported on traditional ordered mesoporous Al₂O₃. The “confinement effect” from mesoporous channels of alumina matrix is helpful to stabilize the Ni nanoparticles. As a promoter, Zr could stabilize the ordered mesoporous framework by reacting with Al₂O₃ to form ZrO₂–Al₂O₃ solid solution. Since ZrO₂ enhances the dissociation of carbon dioxide, more oxygen intermediates are given to remove the carbon formed during the reaction.     

A Novel Process for Renewable Methane Production: Combining Direct Air Capture by K<Subscript>2</Subscript>CO<Subscript>3</Subscript>/Alumina Sorbent with CO<Subscript>2</Subscript> Methanation over Ru/Alumina Catalyst

CO₂ methanation over supported ruthenium catalysts is considered to be a promising process for carbon capture and utilization and power-to-gas technologies. In this work 4% Ru/Al₂O₃ catalyst was synthesized by impregnation of the support with an aqueous solution of Ru(OH)Cl₃, followed by liquid phase reduction using NaBH₄ and gas phase activation using the stoichiometric mixture of CO₂ and H₂ (1:4). Kinetics of CO₂ methanation reaction over the Ru/Al₂O₃ catalyst was studied in a perfectly mixed reactor at temperatures from 200 to 300 °C. The results showed that dependence of the specific activity of the catalyst on temperature followed the Arrhenius law. CO₂ conversion to methane was shown to depend on temperature, water vapor pressure and CO₂:H₂ ratio in the gas mixture. The Ru/Al₂O₃ catalyst was later tested together with the K₂CO₃/Al₂O₃ composite sorbent in the novel direct air capture/methanation process, which combined in one reactor consecutive steps of CO₂ adsorption from the air at room temperature and CO₂ desorption/methanation in H₂ flow at 300 or 350 °C. It was demonstrated that the amount of desorbed CO₂ was practically the same for both temperatures used, while the total conversion of carbon dioxide to methane was 94.2–94.6% at 300 °C and 96.1–96.5% at 350 °C.     

Simultaneous MS-IR Studies of Surface Formate Reactivity Under Methanol Synthesis Conditions on Cu/SiO<Subscript>2</Subscript>

The coverages and surface lifetimes of copper-bound formates on Cu/SiO₂ catalysts, and the steady-state rates of reverse water-gas shift and methanol synthesis have been measured simultaneously by mass (MS) and infrared (IR) spectroscopies under a variety of elevated pressure conditions at temperatures between 140 and 160 °C. DCOO lifetimes under steady state catalytic conditions in CO₂:D₂ atmospheres were measured by ¹²C–¹³C isotope transients (SSITKA). The values range from 220 s at 160 °C to 660 s at 140 °C. The catalytic rates of both reverse water gas shift (RWGS) and methanol synthesis are ~100-fold slower than this formate removal rate back to CO₂ + 1/2 H₂, and thus they do not significantly influence the formate lifetime or coverage at steady state. The formate coverage is instead determined by formate’s rapid production/decomposition equilibrium with gas phase CO₂ + H₂. The results are consistent with formate being an intermediate in methanol synthesis, but with the rate-controlling step being after formate production (for example, its further hydrogenation to methoxy). A 2–3 fold shorter life time (faster decomposition rate) was observed for formate under reactions conditions, with both D₂ and CO₂ present, than in pure Ar or D₂ + Ar alone. This effect, due in part to the effects of the coadsorbates produced under reaction conditions, illustrates the importance of using in situ techniques in the study of catalytic mechanisms. The carbon which appears in the methanol product spends a longer time on the surface than the formate species, 1.8 times as long at 140 °C. The additional delay on the surface is attributed in part to readsorption of methanol on the catalyst, thus obscuring the mechanistic link between formate and methanol.     

Methanol Synthesis

Methanol, like ammonia, is one of the key industrial chemicals produced by heterogeneous catalysis. As with the original ammonia catalyst (Fe/K/Al₂O₃), so with methanol, the original methanol synthesis catalyst, ZnO, was discovered by Alwin Mittasch. This was translated into an industrial process in which methanol was produced from CO/H₂ at 400?°C and 200 atm. Again, as with the ammonia catalyst where the final catalyst which is currently used was achieved only after exhaustive screening of putative “promoters”, so with methanol, exhaustive screening of additives was undertaken to promote the activity of the ZnO. Early successful promoters were Al₂O₃ and Cr₂O₃ which enhanced the stability of the ZnO but not its activity. The addition of CuO was found to increase the activity of the ZnO but the catalyst so produced was short lived. Current methanol synthesis catalysts are fundamentally Cu/ZnO/Al₂O₃, having high CuO contents of?~60?% with ZnO?~?30?% and Al₂O₃?~?10?%. Far from promoting the activity of the ZnO by incorporation of CuO, the active component of these Cu/ZnO/Al₂O₃ catalysts is Cu metal with the ZnO simply being involved as the preferred support. Other supports for the Cu metal, e.g. Al₂O₃, MgO, MnO, Cr₂O₃, ZrO₂ and even SiO₂ can also be used. In all of these catalysts the activity scales with the Cu metal area. The original feed has now changed from CO/H₂ to CO/CO₂/H₂ (10:10:80), radiolabelling studies having provided the unlikely discovery that it is the CO₂ molecule which is hydrogenated to methanol; the CO molecule acts as a reducing agent. The CO₂ is transformed to methanol on the Cu through the intermediacy of an adsorbed formate species. These Cu/ZnO/Al₂O₃ catalysts now operate at?~230° and between 50 and 100 atm. This important step change in the activity of methanol synthesis has resulted in a significant reduction in the energy required to produce methanol. The “step change” however has been incremental. It has been obtained on the basis of fundamental knowledge provided by a combination of surface science techniques, e.g. LEED, scanning tunnelling microscope, TPD, temperature programmed reaction spectroscopy, combined with catalytic mechanistic studies, including radiolabelling studies and chemisorption studies including reactive chemisorption studies, e.g. N₂O reactive frontal chromatography.     

V-promoted Ni/Al<Subscript>2</Subscript>O<Subscript>3</Subscript> catalyst for synthetic natural gas (SNG) production: Catalyst preparation methodologies

The effect of preparation method on the catalytic performance of V-promoted Ni/Al₂O₃ catalysts for synthetic natural gas (SNG) production via CO methanation has been investigated. The Ni-V/Al₂O₃ catalysts were prepared by co-impregnation (CI) method, deposition precipitation (DP) method as well as two sequential impregnation (SI) methods with different impregnation sequence. Among the prepared catalysts, the one prepared by CI method exhibited the best catalytic performance due to its largest H₂ uptake and highest metallic Ni dispersion. In a 91h-lifetime test, this catalyst showed high stability at high temperature and weight hourly space velocity. This work demonstrates that the catalytic performance of the V-promoted Ni/Al₂O₃ catalysts can be improved by carefully controlling the preparation method/conditions.     

Bimetallic Pd–Cu/ZnO–Al<Subscript>2</Subscript>O<Subscript>3</Subscript> and Pd–Cu/ZrO<Subscript>2</Subscript>–Al<Subscript>2</Subscript>O<Subscript>3</Subscript> catalysts for methanol synthesis

Monometallic copper and bimetallic palladium-copper catalysts supported on ZnO–Al₂O₃ and ZrO₂–Al₂O₃ were prepared by conventional impregnation method and tested in methanol synthesis reaction under elevated pressure (3.5 MPa) in gradientless reactor at 220°C. The physicochemical properties of prepared catalytic systems were studied using BET, X-ray, TPR-H₂, TPD-NH₃ techniques. The promotion effect of palladium on catalytic activity and selectivity of copper supported catalyst in methanol synthesis reaction was proven. The highest activity of this system is explained by the Pd–Cu alloy formation.     

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.     

CO oxidation from syngas (CO and H<Subscript>2</Subscript>) using nanoporous Pt/Al<Subscript>2</Subscript>O<Subscript>3</Subscript> catalyst

The concept of “waste-to-wealth” is spreading awareness to prevent global warming and recycle the restrictive resources. To contribute towards sustainable development, hydrogen energy is obtained from syngas (CO and H₂) generated from waste gasification, followed by CO oxidation and CO₂ removal. In H₂ generation, it is key to produce more purified H₂ from syngas using heterogeneous catalysts. In this respect, we prepared Pt/Al₂O₃ catalyst with nanoporous structure using precipitation method, and compared its catalytic activity with commercial alumina (Degussa). Based on the results of XRD and TEM, it was found that metal particles did not aggregate on the alumina surface and showed high dispersion. Optimum condition for CO conversion was 1.5 wt% Pt loaded on Al₂O₃ support, and pure hydrogen was obtained after removal of CO₂ gas.     

Biodiesel Production from Soybean Oil Catalyzed by Li<Subscript>2</Subscript>CO<Subscript>3</Subscript>

In the present study, we synthesized biodiesel from soybean oil through a transesterification reaction catalyzed by lithium carbonate. Under the optimal reaction conditions of methanol/oil molar ratio 32:1, 12 % (wt/wt oil) catalyst amount, and a reaction temperature of 65 °C for 2 h, there was a 97.2 % conversion to biodiesel from soybean oil. The present study also evaluated the effects of methanol/oil ratio, catalyst amount, and reaction time on conversion. The catalytic activity of solid base catalysts was insensitive to exposure to air prior to use in the transesterification reaction. Results from ICP-OES exhibited non-significant leaching of the Li₂CO₃ active species into the reaction medium, and reusability of the catalyst was tested successfully in ten subsequent cycles. Free fatty acid in the feedstock for biodiesel production should not be higher than 0.12 % to afford a product that passes the EN biodiesel standard. Product quality, ester content, free glycerol, total glycerol, density, flash point, sulfur content, kinematic viscosity, copper corrosion, cetane number, iodine value, and acid value fulfilled ASTM and EN standards. Commercially available Li₂CO₃ is suitable for direct use in biodiesel production without further drying or thermal pretreatment, avoiding the usual solid catalyst need for activation at high temperature.     

Glycerol Hydrogenolysis to 1,2-Propanediol by Cu/ZnO/Al2O3 Catalysts

The effect of preparation methods on the Cu/ZnO/Al₂O₃ catalyst structure and catalytic activity on liquid glycerol hydrogenolysis to 1,2-propanediol has been investigated. The physicochemical properties of the catalysts were characterized by BET, XRD, TG/DTA, NH₃-TPD and TPR. The experimental results showed that the catalyst prepared by an oxalate gel–coprecipitation had the highest activity. At 200 °C and 400 psi hydrogen pressure, the glycerol conversion and 1,2-propanediol selectivity catalyzed by the Cu/ZnO/Al₂O₃ catalyst prepared via oxalate gel–coprecipitation were 92.3 and 94.5 % respectively. It was found that the 1,2-propanediol selectivity was dependent on hydrogen pressure and the un-desired by-products were mainly due to the side reactions caused by the presence of the intermediate acetol.     

Effect of H<Subscript>2</Subscript>O<Subscript>2</Subscript> modification of H<Subscript>3</Subscript>PW<Subscript>12</Subscript>O<Subscript>40</Subscript>@carbon for m-xylene oxidation to isophthalic acid

The production of isophthalic acid (IPA) from the oxidation of m-xylene (MX) by air is catalyzed by H₃PW₁₂O₄₀ (HPW) loaded on carbon and cobalt. We used H₂O₂ solution to oxidize the carbon to improve the catalytic activity of HPW@C catalyst. Experiments reveal that the best carbon sample is obtained by calcining the carbon at 700 °C for 4 h after being impregnated in the 3.75% H₂O₂ solution at 40 °C for 7 h. The surface characterization displays that the H₂O₂ modification leads to an increase in the acidic groups and a reduction in the basic groups on the carbon surface. The catalytic capability of the HPW@C catalyst depends on its surface chemical characteristics and physical property. The acidic groups play a more important part than the physical property. The MX conversion after 180 min reaction acquired by the HPW@C catalysts prepared from the activated carbon modified in the best condition is 3.81% over that obtained by the HPW@C catalysts prepared from the original carbon. The IPA produced by the former is 46.2% over that produced by the latter.     

Preparing and studying Pt/WO<Subscript>3</Subscript>/ZrO<Subscript>2</Subscript> catalysts for the isomerization of <Emphasis Type="Italic">n</Emphasis>-heptane

The effect of the temperature of WO₃/ZrO₂ support calcination in the range of 700–1000°C on the phase composition, acid, and catalytic properties of Pt/WO₃/ZrO₂ catalysts is studied. Using ammonia TPD, it is found that calcination in the temperature range of 850–950°C results in the formation of strong acid sites that increase the yield of the target products of the reaction of n-heptane isomerization: high octane di- and trimethylsubstituted isomers. DRIFT is used to determine the role of catalyst calcination in an air flow plays in the formation of charged platinum atoms, which results in higher catalyst activity.     

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.     

Glycerol Hydrogenolysis to 1,2-Propanediol by Cu/ZnO/Al2O3 Catalysts

The effect of preparation methods on the Cu/ZnO/Al₂O₃ catalyst structure and catalytic activity on liquid glycerol hydrogenolysis to 1,2-propanediol has been investigated. The physicochemical properties of the catalysts were characterized by BET, XRD, TG/DTA, NH₃-TPD and TPR. The experimental results showed that the catalyst prepared by an oxalate gel–coprecipitation had the highest activity. At 200 °C and 400 psi hydrogen pressure, the glycerol conversion and 1,2-propanediol selectivity catalyzed by the Cu/ZnO/Al₂O₃ catalyst prepared via oxalate gel–coprecipitation were 92.3 and 94.5 % respectively. It was found that the 1,2-propanediol selectivity was dependent on hydrogen pressure and the un-desired by-products were mainly due to the side reactions caused by the presence of the intermediate acetol.

     

Modification of Cu/Zn/Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Catalyst by Activated Carbon Based Metal Organic Frameworks as Precursor for Hydrogen Production

In this study, Cu/Zn/Al₂O₃-AC (AC?=?activated carbon) catalyst was synthesized and evaluated for dimethoxymethane (DMM) reformation to hydrogen. The Cu/Zn/Al₂O₃-AC catalyst was prepared using high surface area metal organic frameworks (MOFs) consisting of Cu₃(BTC)₂ (MOF-199) and Zn₄O(BDC)₃ (MOF-5) for Cu(II) and Zn(II) sources respectively, as precursors while γ-Al₂O₃ was applied as support. The synthesized catalyst was investigated by scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), Brunauer–Emmett–Teller analysis (BET), Temperature programmed desorption (NH₃-TPD) and Energy-dispersive X-ray spectroscopy (EDX) techniques. Complete DMM conversion was observed over Cu/Zn/Al₂O₃-AC catalyst (Cu:Zn:Al mole ratio of 6:3:2) under atmospheric pressure, T?=?533 K, GHSV?=?20 NL h^?1 g_cat^?1, N₂/H₂O/DMM?=?24/5/1 volume percent (vol%) with hydrogen productivity of 12.8 L H₂ h^?1 g_cat^?1 and 64% hydrogen concentration. Application of MOFs as precursors and modified activated carbon as an acidic component provided the catalyst with the porous structure and high specific surface area for the hydrolysis of DMM, subsequently, high selectivity and productivity of hydrogen was obtained.     

CO hydrogenation to higher alcohols over Ni- and Mo-modified Cu/CeO<Subscript>2</Subscript> catalyst

Ni-Mo promoted Cu/CeO₂ catalyst was synthesized by co-precipitation method using 28%wt NH₃·H₂O as the precipitant. The catalysts were characterized by BET, XRD, TPR and XPS. The results showed that Ni and Mo could promote the reducibility of Cu, and the interaction between Ni and Mo may be needed for catalytic activity and higher alcohols synthesis. Therefore, CuNiMo/CeO₂ catalyst showed a higher activity for higher alcohols synthesis than Cu/CeO₂. In the meantime, the effect of pyrogallol used in preparing the CuNiMo/CeO₂ catalyst was investigated. Pyrogallol had a significant influence on lowering the methanol selectivity and improving the C²⁺-OH selectivity. The methanol selectivity decreased from 52.99% to 44.81% and S _C2+OH /S _MeOH (MeOH denoted as methanol) ratio increased from 0.27 to 0.35. The XPS results gave evidence that pyrogallol can form complexes with Cu⁺ on the CeO₂ support, which causes methanol decrease. In addition, pyrogallol could serve as a “temperature addictive agent” to save power.