Direct dimethyl ether synthesis from syngas on copper–zeolite hybrid catalysts with a wide range of zeolite particle sizes

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

Tandem Reactions over Zeolite-Based Catalysts in Syngas Conversion

Syngas conversion can play a vital role in providing energy and chemical supplies while meeting environmental requirements as the world gradually shifts toward a net-zero. While prospects of this process cannot be doubted, there is a lingering challenge in distinct product selectivity over the bulk transitional metal catalysts. To advance research in this respect, composite catalysts comprising traditional metal catalysts and zeolites have been deployed to distinct product selectivity while suppressing side reactions. Zeolites are common but highly efficient materials used in the chemical industry for hydroprocessing. Combining the advantages of zeolites and some transition metal catalysts has promoted the catalytic production of various hydrocarbons (e.g., light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from syngas. In this outlook, a thorough revelation on recent progress in syngas conversion to various products over metal-zeolite composite catalysts is validated. The strategies adopted to couple the metal species and zeolite material into a composite as well as the consequential morphologies for specific product selectivity are highlighted. The key zeolite descriptors that influence catalytic performance, such as framework topologies, proximity and confinement effects, acidities and cations, pore systems, and particle sizes are discussed to provide a deep understanding of the significance of zeolites in syngas conversion. Finally, an outlook regarding challenges and opportunities for syngas conversion using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

Hybrid monometallic and bimetallic copper-palladium zeolite catalysts for direct synthesis of dimethyl ether from CO2

Nowadays, carbon dioxide is the major reason of the global climate changes. The direct CO2 hydrogenation to dimethyl ether produces an important platform molecule for synthesis of fuels and chemicals...

Validation of a Fixed Bed Reactor Model for Dimethyl Ether Synthesis Using Pilot-Scale Plant Data

The one-dimensional (1D) mathematical model of fixed bed reactor was developed for dimethyl ether (DME) synthesis at pilot-scale (capacity: 25–28 Nm3/h of syngas). The reaction rate, heat, and mass transfer equations were correlated with the effectiveness factor. The simulation results, including the temperature profile, CO conversion, DME selectivity, and DME yield of the outlet, were validated with experimental data. The average error ratios were below 9.3%, 8.1%, 7.8%, and 3.5% for the temperature of the reactor, CO conversion, DME selectivity, and DME yield, respectively. The sensitivity analysis of flow rate, feed pressure, H2:CO ratio, and CO2 mole fraction was investigated to demonstrate the applicability of this model.

Direct Synthesis of Dimethyl Ether from CO2: Recent Advances in Bifunctional/Hybrid Catalytic Systems

Dimethyl ether (DME) is a versatile raw material and an interesting alternative fuel that can be produced by the catalytic direct hydrogenation of CO2. Recently, this process has attracted the attention of the industry due to the environmental benefits of CO2 elimination from the atmosphere and its lower operating costs with respect to the classical, two-step synthesis of DME from syngas (CO + H2). However, due to kinetics and thermodynamic limits, the direct use of CO2 as raw material for DME production requires the development of more effective catalysts. In this context, the objective of this review is to present the latest progress achieved in the synthesis of bifunctional/hybrid catalytic systems for the CO2-to-DME process. For catalyst design, this process is challenging because it should combine metal and acid functionalities in the same catalyst, in a correct ratio and with controlled interaction. The metal catalyst is needed for the activation and transformation of the stable CO2 molecules into methanol, whereas the acid catalyst is needed to dehydrate the methanol into DME. Recent developments in the catalyst design have been discussed and analyzed in this review, presenting the different strategies employed for the preparation of novel bifunctional catalysts (physical/mechanical mixing) and hybrid catalysts (co-precipitation, impregnation, etc.) with improved efficiency toward DME formation. Finally, an outline of future prospects for the research and development of efficient bi-functional/hybrid catalytic systems will be presented.

Sorption enhanced dimethyl ether synthesis under industrially relevant conditions: experimental validation of pressure swing regeneration

High single-pass production of dimethyl ether from CO₂-rich feedstock is demonstrated by pressure swing regeneration, allowing enormous increase in productivity.

The Effect of Zeolite Features on the Dehydration Reaction of Methanol to Dimethyl Ether: Catalytic Behaviour and Kinetics

The synthesis of dimethyl ether (DME) is an important step in the production of chemical intermediate because it is possible to prepare it by direct hydrogenation of CO₂. This paper reports the effect of different zeolitic frameworks (such as: BEA, EUO, FER, MFI, MOR, MTW, TON) on methanol conversion, DME selectivity and catalyst deactivation. The effect of crystal size, Si/Al ratio and acidity of the investigated catalysts have been also studied. Finally, the kinetic parameters (such as: ∆H, ∆S and ∆G) have been evaluated together with pre-exponential factor and activation energy for catalysts with FER and MFI structure topology.

Applications of Zeolites to C1 Chemistry: Recent Advances, Challenges, and Opportunities

C1 chemistry, which is the catalytic transformation of C1 molecules including CO, CO₂ , CH₄ , CH₃ OH, and HCOOH, plays an important role in providing energy and chemical supplies while meeting environmental requirements. Zeolites are highly efficient solid catalysts used in the chemical industry. The design and development of zeolite-based mono-, bi-, and multifunctional catalysts has led to a booming application of zeolite-based catalysts to C1 chemistry. Combining the advantages of zeolites and metallic catalytic species has promoted the catalytic production of various hydrocarbons (e.g., methane, light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from C1 molecules. The key zeolite descriptors that influence catalytic performance, such as framework topologies, nanoconfinement effects, Brønsted acidities, secondary-pore systems, particle sizes, extraframework cations and atoms, hydrophobicity and hydrophilicity, and proximity between acid and metallic sites are discussed to provide a deep understanding of the significance of zeolites to C1 chemistry. An outlook regarding challenges and opportunities for the conversion of C1 resources using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

Direct Synthesis of Dimethyl Ether from Syngas on Bifunctional Hybrid Catalysts Based on Supported H3PW12O40 and Cu-ZnO(Al): Effect of Heteropolyacid Loading on Hybrid Structure and Catalytic Activity

The performance of bifunctional hybrid catalysts based on phosphotungstic acid (H3PW12O40, HPW) supported on TiO2 combined with Cu-ZnO(Al) catalyst in the direct synthesis of dimethyl ether (DME) from syngas has been investigated. We studied the effect of the HPW loading on TiO2 (from 1.4 to 2.7 monolayers) on the dispersion and acid characteristics of the HPW clusters. When the concentration of the heteropoliacid is slightly higher than the monolayer (1.4 monolayers) the acidity of the clusters is perturbed by the surface of titania, while for concentration higher than 1.7 monolayers results in the formation of three-dimensional HPW nanocrystals with acidity similar to the bulk heteropolyacid. Physical hybridization of supported heteropolyacids with the Cu-ZnO(Al) catalyst modifies both the acid characteristics of the supported heteropolyacids and the copper surface area of the Cu-ZnO(Al) catalyst. Hybridization gives rise to a decrease in the copper surface area and the disappearance of the strong acidic sites typical of HPW nanocrystals, showing all hybrids similar acid sites of weak or medium strength. The activity of the hybrids was tested for direct DME synthesis from syngas at 30 bar and 250 °C; only the hybrids with HPW loading higher than 1.4 monolayers showed activity for the direct synthesis of DME, showing that the sample loaded with 2.7 monolayers of heteropolyacid had higher activity than the reference hybrid representative of the most widely applied catalysts based on the combination of Cu-ZnO(Al) with HZSM-5. In spite of the high activity of the hybrids, they show a moderate loss in the DME production with TOS that denotes some kind of deactivation of the acidity function under reaction conditions.

CO2 utilization: Turning greenhouse gas into fuels and valuable products

This study critically reviews the recent developments and future opportunities pertinent to the conversion of CO₂ as a potent greenhouse gas (GHG) to fuels and valuable products. CO₂ emissions have reached an alarming level of around 410 ppm and have become the primary driver of global warming and climate change leading to devastating events such as droughts, hurricanes, torrential rains, floods, tornados and wildfires across the world. These events are responsible for thousands of deaths and have adversely affected the economic development of many countries, loss of billions of dollars, across the globe. One of the promising choices to tackle this issue is carbon sequestration by pre- and post-combustion processes and oxyfuel combustion. The captured CO₂ can be converted into fuels and valuable products, including methanol, dimethyl ether (DME), and methane (CH₄). The efficient use of the sequestered CO₂ for the desalinization might be critical in overcoming water scarcity and energy issues in developing countries. Using the sequestered CO₂ to produce algae in combination with wastewater, and producing biofuels is among the promising strategies. Many methods, like direct combustion, fermentation, transesterification, pyrolysis, anaerobic digestion (AD), and gasification, can be used for the conversion of algae into biofuel. Direct air capturing (DAC) is another productive technique for absorbing CO₂ from the atmosphere and converting it into various useful energy resources like CH₄. These methods can effectively tackle the issues of climate change, water security, and energy crises. However, future research is required to make these conversion methods cost-effective and commercially applicable.

Morphology-Dependent Catalytic Performance of Mordenite in Carbonylation of Dimethyl Ether: Enhanced Activity with High c/b Ratio

The morphology of zeolite often plays an important role in catalytic performance. Controllable synthesis of zeolite with special morphology and elucidating the structure-performance relationship of microporous zeolite are significant to its application. In this work, rod-assembled H-MOR with a controllable c/b ratio was successfully fabricated via template-free hydrothermal methods. NH₃ adsorption IR and pyridine-adsorbed IR were employed to quantify the amount of acid sites in 8-MR and 12-MR of MOR. By excluding the influence of acidic properties on activity, the rate of methyl acetate formation via dimethyl ether carbonylation has been proved proportionally dependent on c/b ratio. Pressure-composition-temperature measurements revealed that the reactant, CO, readily enriches in the longer channels in the c-axis direction, resulting in an enhanced methyl acetate formation. Meanwhile, a higher concentration of CO in channels as well as severer diffusion limitation in the H-MOR with a higher c/b ratio results in a faster deactivation rate.

Direct coating copper–zinc–aluminum oxalate with H-ZSM-5 to fabricate a highly efficient capsule-structured bifunctional catalyst for dimethyl ether production from syngas

This work reports a facile strategy for preparing a highly efficient capsule bifunctional catalyst by direct coating copper–zinc–aluminum oxalate with H-ZSM-5, showing outstanding catalytic properties for dimethyl ether production from syngas.

In Situ FT-IR Characterization of CuZnZr/Ferrierite Hybrid Catalysts for One-Pot CO₂-to-DME Conversion

CO₂ hydrogenation to dimethyl ether (DME) is a promising strategy to drive the current chemical industry towards a low-carbon scenario since DME can be used as an eco-friendly fuel as well as a platform molecule for chemical production. A Cu‒ZnO‒ZrO₂/ferrierite (CZZ/FER) hybrid grain was recently proposed as a catalyst for CO₂-to-DME one-pot conversion exhibiting high DME productivity thanks to the unique shape-selectivity offered by ferrierite zeolite. Nevertheless, such a catalyst deactivates but no direct evidence has been reported of activity loss over time. In this work, CZZ/FER catalysts with different acidity levels were characterized with the FTIR technique before and after reactions, aiming to give new insights about catalyst deactivation. Results show that activity loss can be related to both (i) copper particle sintering, which decreases CO₂ activation towards methanol, and (ii) acidity loss due to H⁺/Cu²⁺ ion exchange.

Status and prospects in higher alcohols synthesis from syngas

Higher alcohols are important compounds with widespread applications in the chemical, pharmaceutical and energy sectors. Currently, they are mainly produced by sugar fermentation (ethanol and isobutanol) or hydration of petroleum-derived alkenes (heavier alcohols), but their direct synthesis from syngas (CO + H₂) would comprise a more environmentally-friendly, versatile and economical alternative. Research efforts in this reaction, initiated in the 1930s, have fluctuated along with the oil price and have considerably increased in the last decade due to the interest to exploit shale gas and renewable resources to obtain the gaseous feedstock. Nevertheless, no catalytic system reported to date has performed sufficiently well to justify an industrial implementation. Since the design of an efficient catalyst would strongly benefit from the establishment of synthesis-structure-function relationships and a deeper understanding of the reaction mechanism, this review comprehensively overviews syngas-based higher alcohols synthesis in three main sections, highlighting the advances recently made and the challenges that remain open and stimulate upcoming research activities. The first part critically summarises the formulations and methods applied in the preparation of the four main classes of materials, i.e., Rh-based, Mo-based, modified Fischer-Tropsch and modified methanol synthesis catalysts. The second overviews the molecular-level insights derived from microkinetic and theoretical studies, drawing links to the mechanisms of Fischer-Tropsch and methanol syntheses. Finally, concepts proposed to improve the efficiency of reactors and separation units as well as to utilise CO₂ and recycle side-products in the process are described in the third section.

One-pass selective conversion of syngas to para-xylene

The finite petroleum resources and environmental crisis compel the development of non-petroleum carbon resources by chemical transformation routes. Syngas (CO + H2) is a crucial junction point that exclusively bridges the non-petroleum carbon resources and other basic chemicals like alcohols, alkane/alkenes, etc. However, the one-pass conversion of syngas to value-added aromatics, especially para-xylene, is still a big challenge. Here we presented a promising hybrid catalyst, named Cr/Zn-Zn/Z5@S1, to effectively realize the one-pass conversion of syngas to para-xylene. This hybrid catalyst exhibited enhanced activity on syngas conversion (CO conversion of 55.0%), good stability of catalyst lifetime and considerable selectivity of para-xylene (27.6% in the total products and 77.3% in xylene). The characterization and catalytic performance evaluation revealed that the well-designed core-shell Zn/Z5@S1 zeolite, as a vital part of this Cr/Zn-Zn/Z5@S1 hybrid catalyst, substantially contributed to its extreme performance for the para-xylene one-pass precise synthesis from syngas. The concerted combination of two components in this hybrid catalyst can effectively depress the formation of unwanted by-products and facilitate the oriented synthesis of para-xylene from syngas with unprecedented efficiency at the same time.