Activity and stability of Cu/ZnO/Al2O3 catalyst promoted with B2O3 for methanol synthesis

The addition of B₂O₃ to a Cu/ZnO/Al₂O₃ catalyst increased the activity of the catalyst for methanol synthesis after an induction period during the reaction. The stability of the B₂O₃-containing Cu/ZnO/Al₂O₃ catalyst was greatly improved by the addition of a small amount of colloidal silica to the catalyst. This revised version was published online in July 2006 with corrections to the Cover Date.     

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.     

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.     

Oxidative coupling of methane by carbon dioxide: a highly C2 selective La2O3/ZnO catalyst

In the oxidative coupling of methane by carbon dioxide, La₂O₃/ZnO catalysts were found to have high C₂ selectivity and good stability. The coupling selectivity on La₂O₃/ZnO is about 90%, which is much higher than that on pure La₂O₃ or ZnO. The consumption ratio of carbon dioxide to methane is approximately one. X-ray diffraction analysis reveals that the structural forms of the oxides are unchanged during the reaction. The reaction mechanism for C₂ formation is discussed.     

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.     

A highly efficient Cu/ZnO/Al2O3 catalyst via gel-coprecipitation of oxalate precursors for low-temperature steam reforming of methanol

The impact of preparation methods on the structure and catalytic behavior of Cu/ZnO/Al₂O₃ catalysts for H₂ production from steam reforming of methanol (SRM) has been reported. The results show that the nanostructured Cu/ZnO/Al₂O₃ catalyst obtained by a novel gel-coprecipitation of oxalate precursors has a high specific surface area and high component dispersion, exhibiting much higher activity in the SRM reaction as compared to the catalysts prepared by conventional coprecipitation techniques. It is suggested that the superior catalytic performance of the oxalate gel-coprecipitation-derived Cu/ZnO/Al₂O₃ catalyst could be attributed to the generation of “catalytically active” copper material with a much higher metallic copper specific surface as well as a stronger Cu–Zn interaction due to an easier incorporation of zinc species into CuC₂O₄ · x H₂O precursors as a consequence of isomorphous substitution between copper and zinc in the oxalate gel-precursors.     

The reduction behavior of Mo/TiO2-Al2O3 catalyst

The effect of TiO₂ modified Al₂O₃ surface on the reducibility of MoO₃ has been studied by TPR and XPS. The results show that Mo⁶⁺ in Mo/TiO₂-Al₂O₃ can be reduced to much lower valency, especially at low Mo loading. The influence of the calcination temperature on the reduction of Mo⁶⁺ on Al₂O₃ and TiO₂-Al₂O₃ carriers is different. The data reveals that the reducibility of Mo⁶⁺ on Al₂O₃ slightly decreased, while that on TiO₂-Al₂O₃ increased when the calcination temperature was raised. It is suggested that the stronger tetrahedral site of the Al₂O₃ surface was first occupied by TiO₂ and main octahedral Mo⁶⁺ in polymeric species-; and a small crystalline MoO₃ formed on TiO₂-Al₂O₃, whereas the formation of tetrahedral Mo⁶⁺ species and Al₂(MoO₄)₃ phase was inhibited.     

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.     

Effect of Modifiers on the Reactivity of Cr2O3/Al2O3 and Cr2O3/TiO2 Catalysts for the Oxidative Dehydrogenation of Propane

Chromium oxide supported on alumina and titania supports was modified with oxides of sodium, vanadium and molybdenum. The modified and unmodified chromium oxide catalysts were characterized by several techniques. The presence of surface chromium oxide and surface molybdenum and vanadium oxide species was detected in the unmodified and molybdenum and vanadium oxide modified supported chromium oxide catalysts. The reducibility (T_max and H/Cr ratio) of the surface chromium species was not affected for the vanadium and molybdenum oxide modified catalysts; however, the reducibility changed noticeably for sodium modified supported chromium oxide catalysts. Studies of the reactivity of the ODH of propane revealed the effect of modifiers on the reactivity properties of the surface chromium oxide species. The activity and propene selectivity decreased for sodium modified supported chromium oxide catalysts. However, the activity increased for vanadium oxide modified catalysts and was similar for molybdenum oxide modified catalysts irrespective of the support. The propene selectivity was higher for molybdenum oxide modified chromium oxide catalysts. However, the propene selectivity for vanadium oxide modified catalysts depends on the support since it appears that the inherent selectivity of the surface vanadium oxide species is reflected.     

On the development of metallic particles and their initial catalytic properties in the CO + H2 reaction over Co/Al2O3 catalyst

Formation of Co^o phases with different surface structure over 10 wt% Co/Al₂O₃ and their catalytic properties were induced by pretreatments in H₂ at 570 K for 1 h or 20 h. Electronic behaviour of the Co^o phase, which consists of small (after 1 h reduction) or large bulk-like particles (after 20 h reduction), did not change during the CO hydrogenation after 5 h on stream as was determined by XPS. On the basis of the measured C₂₊ hydrocarbon selectivities the CO molecules are suggested to dissociate on small Co particles to a larger extent than on large cobalt particles. The slight decrease in the catalytic activity with increasing time on stream obtained for the long-term reduced sample is explained by the change in the surface Co^o content detected by XPS. The increase in the catalytic activity along with the change in olefin selectivity, measured for the sample reduced for 1 h, is interpreted by the change of a reaction path involving the Co^o-support interface during the initial period of the reaction.     

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.     

Accommodation of impurities in α-Al2O3, α-Cr2O3 and α-Fe2O3

Atomic scale computer simulation was used to predict the mechanisms and energies associated with the accommodation of aliovalent and isovalent dopants in three host oxides with the corundum structure. Here we consider a much more extensive range of dopant ions than has previously been the case. This enables a rigorous comparison of calculated mechanism energetics. From this we predict that divalent ions are charge compensated by oxygen vacancies and tetravalent ions by cation vacancies over the full range of dopant radii. When defect associations are included in the model these conclusions remain valid. At equilibrium, defects resulting from extrinsic dopant solution dominate intrinsic processes, except for the largest dopant cations. Solution reaction energies increase markedly with increasing dopant radius. The behaviour of cluster binding energies is more complex.     

Influence of the calcination on the activity and stability of the Cu/ZnO/Al2O3 catalyst in liquid phase methanol synthesis

Catalyst Cu/ZnO/Al₂O₃ was prepared through co-precipitation method and investigated in a stirred slurry autoclave reactor system for methanol synthesis. The structure of the catalysts was studied by derivative thermogravimetry (DTG), X-ray diffraction (XRD) and H₂ temperature programmed reduction (H₂-TPR). The results show that the average size of CuO crystallite of the catalyst was 3.23 nm when the catalyst was calcined at 623 K for 2.0 h, and the catalyst with this size of CuO crystallite is highly active and stable. Its space time yield and deactivation rate reached 172.2 g/kg_cat·h and 0.43%/d, respectively under the reaction conditions of 513 K, 4.0 MPa, H₂/CO/CO₂ = 68/24/5 and space velocity = 810 ml/g_cat·h.     

Dehydrogenation of ethylbenzene to styrene over Fe2O3/Al2O3 catalysts in the presence of carbon dioxide

An Fe₂O₃ (10 wt%)/Al₂O₃ (90 wt%) catalyst prepared by a coprecipitation method was found to be effective for dehydrogenation of ethylbenzene to produce styrene in the presence of CO₂ instead of steam used in commercial processes. The dehydrogenation of ethylbenzene over the catalyst in the presence of CO₂ was considered to proceed both via a one-step pathway and via a two-step pathway. CO₂ was found to suppress the deactivation of the catalyst during the dehydrogenation of ethylbenzene. This revised version was published online in July 2006 with corrections to the Cover Date.     

A thermogravimetric study of the partial oxidation of methanol for hydrogen production over a Cu/ZnO/Al2O3 catalyst

The partial oxidation of methanol for the production of hydrogen was investigated in both a fixed-bed microreactor and in a thermogravimetric analyzer (TG-FTIR) from 180 °C to 250 °C using a commercial Cu/ZnO/Al₂O₃ catalyst. In the microreactor, a hot spot in the undiluted catalyst bed of 4 K and 32 K was observed at 180 °C and 220 °C, respectively. Methanol conversion was strongly accelerated between 180 °C and 220 °C. In the TG-FTIR experiments, the reduced copper was completely oxidized to cuprite, Cu₂O, with increasing time-on-stream in the presence of oxygen and methanol (O₂/MeOH = 0.5) at 180 °C. The selectivity to formaldehyde increased in the same manner as the catalyst was oxidized to cuprite. In contrast, at 250 °C the catalyst remained completely reduced for the same O₂/MeOH ratio. Two main reaction pathways are proposed explaining the influence of the copper oxidation state on the product distribution.     

Selective synthesis of mixed alcohols from syngas over catalyst Fe2O3/Al2O3 in slurry reactor

The Fe₂O₃/Al₂O₃ catalyst was studied to selectively synthesize mixed alcohols from syngas in a continuously stirred slurry reactor with the oxygenated solvent Polyethylene Glycol-400 (PEG-400). The selectivity of mixed alcohols in the products reached as high as 95 wt.% and the C₂₊ alcohols (mainly ethanol) was more than 40 wt.% in the total alcohol products at the reaction conditions of 250 °C, 3.0 MPa, H₂/CO = 2 and space velocity = 360 ml/g_cat h. The hydrogen temperature programmed reduction (H₂-TPR) and X-ray photoelectron spectroscopy (XPS) measurements of the catalyst confirmed that the FeO phase was responsible for the high selectivity to mixed alcohols in the process. And the oxygenated solvent PEG-400 was also necessary for the selective synthesis of mixed alcohols in the reaction system.     

Characterization of hydrodesulfurization catalyst prepared by impregnating cobalt nitrate solution onto the sulfided MoO3/Al2O3 catalyst

CoMo/Al₂O₃ catalysts were prepared by impregnating Cobalt nitrate solution into oxidic or sulfided Mo/Al₂O₃. The properties of CoMo/Al₂O₃ catalysts were characterized by XRD, TPS, oxygen chemisorption and ESR. Catalytic activity of CoMo/Al₂O₃ catalyst was evaluated by thiophene HDS as a probe reaction. When CoMo/Al₂O₃ catalyst was prepared by impregnating Cobalt nitrate solution into sulfided Mo/Al₂O₃, the interaction between Mo and alumina became weaker and the formation of synergic phase was facilitated. These structural changes may explain higher HDS activity of CoMo/Al₂O₃ catalyst prepared by impregnating Cobalt nitrate solution into sulfided Mo/Al₂O₃.     

The synthesis of alcohols using Cu/ZnO/A12O3 + (Ce or Mn) catalysts

Cu/ZnO/A1₂O₃ catalysts modified by compounds of manganese or cerium were prepared by coprecipitation or by impregnation and were tested for the synthesis of alcohol mixtures from synthesis gas at pressures of up to 70 bar. They were also examined by XPS both before and after the reaction. With both the impregnated and the coprecipitated catalysts, manganese increased the selectivity to higher alcohols (mainly isobutanol). However, in the case of cerium, the location of the cerium ions appeared to determine the selectivity; it shifted towards alkanes and C0₂ when cerium was present at the surface of the catalyst (probably as Ce0₂), but to isobutanol when the cerium ions were present in the bulk. Changes were found in the selectivities of the catalyst doped with cerium with time on stream and these could be explained by a segregation of the cerium ions to the surface. Some of the mechanistic steps in the formation of higher alcohols as proposed in the literature were confirmed.     

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.