New insights about coke deposition in methanol-to-DME reaction over MOR-, MFI- and FER-type zeolites

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.

Steam Reforming of Bioethanol Using Metallic Catalysts on Zeolitic Supports: An Overview

Hydrogen is considered one of the energy carriers of the future due to its high mass-based calorific value. Hydrogen combustion generates only water, and it can be used directly as a fuel for electricity/heat generation. Nowadays, about 95% of the hydrogen is produced via conversion of fossil fuels. One of the future challenges is to find processes based on a renewable source to produce hydrogen in a sustainable way. Bioethanol is a promising candidate, since it can be obtained from the fermentation of biomasses, and easily converted into hydrogen via steam catalytic reforming. The correct design of catalysts and catalytic supports plays a crucial role in the optimization of this reaction. The best results have to date been achieved by noble metals, but their high costs make them unsuitable for industrial application. Very satisfactory results have also been achieved by using nickel and cobalt as active metals. Furthermore, it has been found that the support physical and chemical properties strongly affect the catalytic performance. In this review, zeolitic materials used for the ethanol steam reforming reaction are overviewed. We discuss thermodynamics, reaction mechanisms and the role of active metal, as well as the main noble and non-noble active compounds involved in ethanol steam reforming reaction. Finally, an overview of the zeolitic supports reported in the literature that can be profitably used to produce hydrogen through ethanol steam reforming is presented.

A Carbonylation Zeolite with Specific Nanosheet Structure for Efficient Catalysis

Up to now, the member of zeolite family has expanded to more than 230. However, only little part of them have been reported as catalysts used in reactions. Discovering potential zeolites for reactions is significantly important, especially in industrial applications. A carbonylation zeolite catalyst Al-RUB-41 has special morphology and channel orientation. The 8-MR channel of Al-RUB-41 is just perpendicular to its thin sheet, making a very short mass-transfer distance along 8-MR. This specific nature endows Al-RUB-41 with efficient catalytic ability to dimethyl ether carbonylation reaction with beyond 95% methyl acetate selectivity. Compared with the most widely accepted carbonylation zeolite catalysts, Al-RUB-41 behaves a much better catalytic stability than H-MOR and a greatly enhanced catalytic activity than H-ZSM-35. A space-confined deactivation mechanism over Al-RUB-41 is proposed. By erasing the acid sites on outer surface, Al-RUB-41@SiO₂ catalyst achieves a long-time and high-efficiency activity without any deactivation trend.

Towards the Circular Economy of Rare Earth Elements: Lanthanum Leaching from Spent FCC Catalyst by Acids

Rare earth elements (REEs) are strategic materials widely used in different applications from Information and Communication Technologies (ICT) to catalysis, which are expected to grow more in the future. In order to reduce the impact of market price and reduce the environmental effect from soil extraction, recovery/purification strategies should be exploited. This paper presents a combined acid-leaching/oxalate precipitation process to recover lanthanum from spent FCC catalyst using nitric acid. Preferred to hydrochloric and sulphuric acid (preliminary assessed), HNO3 showed a good capability to completely leach lanthanum. The combination with an oxalate precipitation step allowed demonstrating that a highly pure (>98% w/w) lanthanum solid can be recovered, with a neglectable amount of poisoning metals (Ni, V) contained into the spent catalyst. This could open a reliable industrial perspective to recover and purify REE in the view of a sustainable recycling strategy.

Silica-Related Catalysts for CO2 Transformation into Methanol and Dimethyl Ether

The climate situation that the planet is experiencing, mainly due to the emission of greenhouse gases, poses great challenges to mitigate it. Since CO2 is the most abundant greenhouse gas, it is essential to reduce its emissions or, failing that, to use it to obtain chemicals of industrial interest. In recent years, much research have focused on the use of CO2 to obtain methanol, which is a raw material for the synthesis of several important chemicals, and dimethyl ether, which is advertised as the cleanest and highest efficiency diesel substitute fuel. Given that the bibliography on these catalytic reactions is already beginning to be extensive, and due to the great variety of catalysts studied by the different research groups, this review aims to expose the most important catalytic characteristics to take into account in the design of silica-based catalysts for the conversion of carbon dioxide to methanol and dimethyl ether.

Techno-Economic Assessment of Bio-Syngas Production for Methanol Synthesis: A Focus on the Water-Gas Shift and Carbon Capture Sections

The biomass-to-methanol process may play an important role in introducing renewables in the industry chain for chemical and fuel production. Gasification is a thermochemical process to produce syngas from biomass, but additional steps are requested to obtain a syngas composition suitable for methanol synthesis. The aim of this work is to perform a computer-aided process simulation to produce methanol starting from a syngas produced by oxygen-steam biomass gasification, whose details are reported in the literature. Syngas from biomass gasification was compressed to 80 bar, which may be considered an optimal pressure for methanol synthesis. The simulation was mainly focused on the water-gas shift/carbon capture sections requested to obtain a syngas with a (H₂ - CO₂)/(CO + CO₂) molar ratio of about 2, which is optimal for methanol synthesis. Both capital and operating costs were calculated as a function of the CO conversion in the water-gas shift (WGS) step and CO₂ absorption level in the carbon capture (CC) unit (by Selexol^® process). The obtained results show the optimal CO conversion is 40% with CO₂ capture from the syngas equal to 95%. The effect of the WGS conversion level on methanol production cost was also assessed. For the optimal case, a methanol production cost equal to 0.540 €/kg was calculated.

CuZnZr-Zeolite Hybrid Grains for DME Synthesis: New Evidence on the Role of Metal-Acidic Features on the Methanol Conversion Step

The assessment of the catalytic performance of “hybrid” metal/zeolite catalysts (based on FER or MFI structure and CuZnZr metal complexes) in the methanol dehydration step to DME has been studied in this work. The results clearly show that there is an important effect of the interaction between metal and acid sites affecting the acid catalyst performances. Additionally, deactivation, studied by means of a Timo-on-Stream (TOS) test, was affected by the type of zeolite structure used for hybrid catalyst preparation. The decrease in DME selectivity can be attributed to the cooperation of metal and acid sites in the production of different compounds (mainly methyl formate and dimethoxy methane) converting methanol and DME. The presence of these compounds (indicating different reaction pathways active) was found to be dependent on the zeolite structure and on the type of co-precipitation medium (water or ethanol) used to prepare the hybrid catalyst.

Valorization of OFMSW Digestate-Derived Syngas toward Methanol, Hydrogen, or Electricity: Process Simulation and Carbon Footprint Calculation

This paper explores a possible waste-based economy transition strategy. Digestate from the organic fraction of municipal solid waste (OFMSW) is considered, as well as a low-added value product to be properly valorized. In this regard, air gasification may be used to produce syngas. In this work, the production of methanol, hydrogen, or electricity from digestate-derived syngas was assessed by ChemCAD process simulation software. The process scheme of methanol production comprises the following parts: water gas shift (WGS) with carbon capture and storage units (CCS), methanol synthesis, and methanol purification. In the case of hydrogen production, after WGS-CCS, hydrogen was purified from residual nitrogen by pressure swing absorption (PSA). Finally, for electricity production, the digestate-derived syngas was used as fuel in an internal combustion engine. The main objective of this work is to compare the proposed scenarios in terms of CO2 emission intensity and the effect of CO2 storage. In particular, CCS units were used for methanol or hydrogen production with the aim of obtaining high equilibrium yield toward these products. On the basis of 100 kt/year of digestate, results show that the global CO2 savings were 80, 71, and 69 ktCO2eq/year for electricity, methanol, and hydrogen production, respectively. If carbon storage was considered, savings of about 105 and 99 ktCO2eq/year were achieved with methanol and hydrogen production, respectively. The proposed scenarios may provide an attractive option for transitioning into methanol or hydrogen economy of the future.

Deoxygenation of Stearic Acid over Cobalt-Based NaX Zeolite Catalysts

For the production of sustainable biofuels from lipid biomass it is essential to develop non-noble metal catalysts with high conversion and selectivity under inert gas atmospheres. Herein, we report a novel cobalt-based catalyst supported on zeolite NaX via ion-exchange synthesis. The resultant bifunctional cobalt-based NaX zeolite catalyst displayed high conversion of stearic acid to liquid fuels. In addition, the effect of reaction temperature and catalyst loading was studied to evaluate the order of reaction and activation energy. Decarboxylation and decarbonylation were the dominant deoxygenation pathways. Stearic acid was successfully deoxygenated in N2 atmospheres using Co/NaX catalysts with a conversion as high as 83.7% and a yield to heptadecane up to ~28%. Furthermore, we demonstrate that higher reaction temperatures resulted in competing pathways of decarboxylation and decarbonylation. Finally, the fresh and recycled catalysts were characterized showing modest recyclability with a ~12.5% loss in catalytic activity.

Hierarchical Low Si/Al Ratio Ferrierite Zeolite by Sequential Postsynthesis Treatment: Catalytic Assessment in Dehydration Reaction of Methanol

In contrast to high silica zeolites, it is difficult to obtain mesoporosity in zeolites with low Si/Al ratio (e.g., <20) via conventional NaOH-based treatment, making the obtainment of hierarchical zeolites with high acidity a challenging target. In this paper, we report the preparation of hierarchical FER-type zeolite at low Si/Al molar ratio (about 10) by postsynthesis etching involving a sequence of three treatments with NaAlO2, HCl, and NaOH solutions and investigate the effect of both NaAlO2 solution concentration and time of treatment on the textural properties. The obtained materials exhibit a mesoporous volume higher than the parent ferrierite with no significant effect on the sample acidity. The catalytic activity of some samples was investigated in vapour-phase methanol dehydration to dimethyl ether, revealing the superiority of hierarchical zeolites in terms of methanol conversion, although the presence of mesopores causes formation of light hydrocarbons at high temperatures.

Distinguishing external and internal coke depositions on micron-sized HZSM-5 via catalyst-assisted temperature-programmed oxidation

The general idea of CatA-TPO for distinguishing external coke from internal coke on HZSM-5.

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.