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 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.     

Fatty methyl ester hydrogenation to fatty alcohol part I: Correlation between catalyst properties and activity/selectivity

Fatty alcohols, derived from natural sources, are commercially produced by hydrogenation of fatty acids or methyl esters in slurry-phase or fixed-bed reactors. One slurry-phase hydrogenation of methyl ester process flows methyl esters and powdered copper chromite catalyst into tubular reactors under high hydrogen pressure and elevated temperature. In the present investigation, slurry-phase hydrogenations of C₁₂ methyl ester were carried out in semi-batch reactions at nonoptimal conditions (i.e., low hydrogen pressure and elevated temperature). These conditions were used to accentuate the host of side reactions that occur during the hydrogenation. Some 14 side reaction routes are outlined. As an extension of this study, copper chromite catalyst was produced under a number of varying calcination temperatures. Differences in catalytic activity and selectivity were determined by closely following side reaction products. Both activity and selectivity correlate well with the crystallinity of the copper chromite surface; they increase with decreasing crystallinity. The ability to follow the wide variety of side reactions may well provide an additional tool for the optimized design of hydrogenation catalysts.     

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.     

Methyl formate as a new building block in C1 chemistry

Methyl formate has been proposed as a building block molecule in C₁ chemistry. This paper examines the potential of this concept by reviewing the processes of synthesis of the molecule and the chemical reactions that it undergoes. Methyl formate can be produced by a variety of routes from a number of feedstocks. The reaction between methanol and carbon monoxide is an efficient process, used commercially. Combination of an efficient synthesis of methyl formate and its facile decomposition allows the molecule to be used as a means for separation, storage and transport of synthesis gas. The number of reactions that convert methyl formate to other chemicals is large. In particular, the synthesis of large volume chemicals such as methanol, acetic acid and ethylene glycol deserves serious consideration. Examples are provided of applications in the chemical and energy industries involving methyl formate. The reactions involved in the synthesis and transformation of methyl formate are mostly catalytic in nature. Many currently known catalytic systems are not efficient to compete with conventional routes involving methanol or synthesis gas. Fundamental research to understand the catalytic chemistry involved is highly desirable in order to improve the performance of the catalytic systems.     

The conversion of polysaccharides to hydrogen gas. Part II: The catalytic decomposition of formaldehyde in the aqueous phase

The aqueous phase decomposition of formaldehyde, to hydrogen gas, catalysed by platinum—copper chromite, has been carried out in the temperature range 20–60°C, at a solution pH of 12. The production of hydrogen was favoured by intermediate temperatures (40–50°C) and an activation energy of 22.2 kJ mol^?1 (5.3 kcal mol^?1) was recorded. The rate of reaction was first order with respect to OH^? ion concentration at low alkali concentrations and was first order with respect to HCHO concentration at all concentrations. At high alkali concentrations the reaction should become zero order with respect to OH^? ion concentration, but initial rates actually decrease under these conditions having passed through a maximum. The rate of reaction was directly proportional to catalyst weight at low catalyst loading, but the relationship became non-linear at high catalyst loadings. Conversions of formaldehyde to hydrogen gas were substantially less than theoretical. The decomposition reaction has to compete with a number of side reactions such as polymerization of formaldehyde at low temperatures (<40°C) and at higher temperatures with the Cannizzano reaction, aldol condensation, and possibly formaldehyde hydrogenation to methanol. In addition hydrogen loss may occur due to copper chromite reduction. A reaction mechanism is proposed involving a surface formate intermediate.     

On the mechanism of the methanol synthesis involving a catalyst based on zirconia support

The nature of the pivotal intermediate during the synthesis of methanol from CO₂/H₂, in the presence of ZnO/ZrO₂ aerogel catalyst is envisaged. The kinetic studies performed using in situ FTIR spectroscopy of the species formed on the surface of the catalyst in the absence and in the presence of hydrogen show that the initial reactive adsorbed species formed from C0₂ gas is the unidentate carbonate species. Its hydrogenation into the formate species is much faster than the hydrogenation of the formate species into methoxyl species. The comparison is based on a quantitative measurement of the rate constant of the hydrogenation of the various species. The results explain that during the C0₂/H₂ reaction only formate and methoxyl species are observed.     

A Study of Methyl Formate Production from Carbon Dioxide Hydrogenation in Methanol over a Copper Zinc Oxide Catalyst

Abstract  

A preliminary study of the production of methyl formate (MF) from CO₂ hydrogenation in liquid methanol was carried out over a Cu/ZnO/Al₂O₃ based catalyst which was synthesized by a precipitation technique following a well established route. The effects of amine concentration, hydrogen pressure, temperature, CO and water addition on the activity and selectivity of MF were investigated. It is of interest to note that the addition of 1% trimethylamine can dramatically increase the initial turnover frequency with the MF being the major product. It is evident that the formation of CO₂-amine adduct promotes the catalytic hydrogenation of CO₂ on the surface of the catalyst.     

Study on the Mechanism of CO Formation in Reverse Water Gas Shift Reaction Over Cu/SiO2 Catalyst by Pulse Reaction, TPD and TPR

The mechanism of reverse water gas shift reaction over Cu catalyst was studied by pulse reaction with QMS monitoring, temperature programmed desorption (TPD) and temperature programmed reduction (TPR) of Cu/SiO₂ catalyst. The reduced and/or oxidized copper offered low catalytic activity for the dissociation of CO₂ to CO in the pulse reaction study with 1 ml volume of He/CO₂, but the rate of CO formation was significantly enhanced with H₂ participating in the reaction. The TPD spectra of CO₂ obtained by feeding H₂/CO₂ over copper at 773 K provided strong evidence of the formation of formate at high temperature. The formate derived from the association of H₂ and CO₂ is proposed to be the key intermediate for CO production. The formate dissociation mechanism is the major reaction route for CO production.     

Isotope Effects in Methanol Synthesis and the Reactivity of Copper Formates on a Cu/SiO2 Catalyst

Here we investigate isotope effects on the catalytic methanol synthesis reaction and the reactivity of copper-bound formate species in CO₂–H₂ atmospheres on Cu/SiO₂ catalysts by simultaneous IR and MS measurements, both steady-state and transient. Studies of isotopic variants (H/D, ¹²C/¹³C) reveal that bidentate formate dominates the copper surface at steady state. The steady-state formate coverages of HCOO (in 6 bar 3:1 H₂:CO₂) and DCOO (in D₂:CO₂) are similar and the steady-state formate coverages in both systems decrease by ~80% from 350 K to 550 K. Over the temperature range 413 K–553 K, the steady-state methanol synthesis rate shows a weak H/D isotope effect (1.05 ± 0.05) with somewhat higher activation energies in H₂:CO₂ (79 kJ/mole) than D₂:CO₂ (71 kJ/mole) over the range 473 K–553 K. The reverse water gas shift (RWGS) rates are higher than methanol synthesis and also shows a weak positive H/D isotope effect with higher activation energy for H₂/CO₂ than D₂/CO₂ (108 vs. and 102 kJ/mole) The reactivity of the resulting formate species in 6 bar H₂, 6 bar D₂ and 6 bar Ar is strongly dominated by decomposition back to CO₂ and H₂. H₂ and D₂ exposure compared to Ar do not enhance the formate decomposition rate. The decomposition profiles on the supported catalyst deviate from first order decay, indicating distributed surface reactivity. The average decomposition rates are similar to values previously reported on single crystals. The average activation energies for formate decomposition are 90 ± 17 kJ/mole for HCOO and 119 ± 11 kJ/mole for DCOO. By contrast to the catalytic reaction rates, the formate decomposition rate shows a strong H/D kinetic isotope effect (H/D ~8 at 413 K), similar to previously observed values on Cu(110).     

In situ FTIR studies of methanol adsorption and dehydrogenation over Cu/SiO2 catalyst

In situ FTIR spectroscopy was used to identify the adsorbed species and the intermediates during methanol dehydrogenation over Cu/SiO₂ catalyst, and a schematic reaction network was proposed. Methoxy species on copper, which were derived from adsorbed methanol, dehydrogenated into formaldehyde. Then several competitive pathways took place. The adsorbed formaldehyde could desorb to the gas phase, or react with another adsorbed methoxy group to form methyl formate, and/or undergo further dehydrogenation to CO and H₂. Carbon monoxide formed from the decomposition first adsorbed on high-index planes of copper, and then on low-index planes as the reaction progressed. With the increase of temperature, the concentration of formaldehyde and CO in gas phase increased, and that of methyl formate decreased.     

Vapor phase dehydrogenation of methanol to methyl formate in the catalytic membrane reactor with Cu/SiO2/ ceramic composite membrane

The Cu/SiO₂/ceramic composite membrane was prepared on the SiO₂/ceramic mesoporous membrane by an ion exchange method, and vapor phase dehydrogenation of methanol to methyl formate in the catalytic membrane reactor was investigated. It showed much better performance in the catalytic membrane reactor than that in the fixed-bed reactor under the same reaction conditions. At 240 °C, 57.3% conversion of methanol and 50.0% yield of methyl formate were achieved in the catalytic membrane reactor and only 43.1% conversion of methanol and 36.9% yield of methyl formate were achieved in the fixed-bed reactor.     

Deactivation of Cu/ZnO catalyst during dehydrogenation of methanol

The deactivation of Cu/ZnO catalyst during methanol dehydrogenation to form methyl formate has been studied. The Cu/ZnO catalyst was seriously deactivated under the reaction conditions: various temperatures of 493, 523 and 553 K, atmospheric pressure and methanol GHSV of 3000 ml (STP)/g-cat h. The weight loss due to reduction of ZnO in the Cu/ ZnO catalyst was monitored by a microbalance. X-ray induced Auger spectroscopy of Zn(L₃M_4,5M_4,5) showed the increase in the concentration of metallic Zn on the catalyst surface after the reaction. Temperature-programmed reduction (TPR) of the Cu/ZnO catalyst with methanol demonstrated that the reduction of ZnO in Cu/ ZnO was suppressed by introduction of CO₂ into the stream of helium-methanol. As the concentration of CO₂ in the feed gas increased, the weight loss of the Cu/ZnO catalyst due to the reduction of ZnO decreased. The deactivation of the Cu/ZnO catalyst in the methanol dehydrogenation was also retarded by the addition of CO₂. In particular, oxygen injection into the reactant feed regenerated the Cu/ ZnO catalyst deactivated during the reaction. Based on these observations, the cause of deactivation of the Cu/ZnO catalyst has been discussed.     

Influence of CO2 co-feeding on Fischer–Tropsch fuels production over carbon nanofibers supported cobalt catalyst

Nowadays, the syngas which is obtained from the reforming of coal, biomass or natural gas contain significantly amounts of CO₂ that cannot be separated and consequently, it can take part into the Fischer–Tropsch (FTS) catalytic activity. Therefore, the presence of CO₂ in the syngas flow should be taken into account. In the present study, the FTS CO hydrogenation process was compared to that of CO₂ on a carbon nanofibers supported Co catalyst. The influence of CO₂ content in the feed stream (H₂/CO/CO₂ ratio) on the reaction performance in terms of conversion and selectivity to the different products was described. Both the support and the prepared catalyst were characterized by nitrogen adsorption–desorption, temperature-programmed reduction (TPR) and X-ray diffraction (XRD). Results showed that CO hydrogenation was controlled by a Fischer–Tropsch regime, whereas CO₂ hydrogenation was controlled by a methanation process. When feed was composed of CO and CO₂ mixtures, the catalytic activity decreased with respect to that obtained with a CO₂-free feed stream. Moreover, the presence of CO₂ in feed stream favored the formation of lighter hydrocarbons and could block the production of further CO₂ via Water-Gas-Shift (WGS) 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.     

Formaldehyde,methanol and methyl formate from formic acid reaction over supported metal catalysts

The catalytic gas-phase decomposition of formic acid was studied over Au/Al₂O₃ and Pt/SBA-15 to investigate the formation of products other than H_2, CO₂, CO and H₂O. Formaldehyde, methanol and methyl formate were detected and identified as secondary products. Two calculation methods for H₂ selectivity (direct and indirect) were compared and assessed in terms of their validity at different temperatures, establishing that a direct quantification of H₂ is necessary for correct results. Based on selectivity trends of all the detected products a reaction scheme is proposed for the decomposition of formic acid and formation of formaldehyde, methanol and methyl formate.     

Ultrasonic hydrogenation of soybean oil

The rate of hydrogenation of soybean oil with either copper chromite or nickel catalysts increased more than a hundredfold with the aid of ultrasonication. In a continuous reaction system, the selectivity with copper catalyst for linolenate reduction was somewhat lower when ultrasonic energy was applied than when not applied. With ultrasonic energy, 87% hydrogenation of linolenate in soybean oil was obtained in 9 sec at 115 psig H₂ with 1% copper chromite at 181 C and 77% linolenate hydrogenation with 0.025% nickel. Without ultrasonic energy, only 59% linolenate hydrogenation was obtained in 240 sec with copper chromite at 198 C and 500 psig H₂ and 68% linolenate hydrogenation in 480 sec with nickel at 200 C and 115 psig H₂. This innovation may offer an important advantage in increasing the activity of commercial catalysts, particularly copper chromite, for fats and oil hydrogenation.     

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.     

Low Temperature Water–Gas Shift/Methanol Steam Reforming: Alkali Doping to Facilitate the Scission of Formate and Methoxy C–H Bonds over Pt/ceria Catalyst

Doping Pt/ceria catalysts with the Group 1 alkali metals was found to lead to an important weakening of the C–H bond of formate and methoxy species. This was demonstrated by a shift to lower wavenumbers of the formate and methoxy ν(CH) vibrational modes by DRIFTS spectroscopy. Li and Na-doped Pt/ceria catalysts were tested relative to the undoped catalyst for low temperature water–gas shift and methanol steam reforming using a fixed bed reactor and exhibited higher catalytic activity. Steaming of formate and methoxy species pre-adsorbed on the catalyst surface during in-situ DRIFTS spectroscopy suggested that the species were more reactive for dehydrogenation steps in the catalytic cycle for the Li and Na-doped catalysts relative to undoped Pt/ceria. However, with increasing atomic number over the series of alkali-doped catalysts, the stability of a fraction of the carbonate species was found to increase. This was observed during TPD-MS measurements of the adsorbed CO₂ probe molecule by a systematic increase of a high temperature peak for a fraction of the CO₂ desorbed. This result indicates that alkali-doping is an optimization problem—that is, while improving the dehydrogenation rates of methoxy and formate species, the carbonate intermediate stability increases, making it difficult to liberate the CO₂. Infrared spectroscopy results of CO adsorbed on Pt and ceria suggest that the alkali dopant is located on, and electronically modifies, both the Pt and ceria components. The results not only lend further support to the role that methoxy and formate species play as intermediates in the catalytic mechanisms, but also provide a path forward for improving rates by means other than resorting to higher noble metal loadings.