Multifunctional Catalyst Combination for the Direct Conversion of CO2 to Propane

Selectivity control by zeolites during methanol-mediated CO2 hydrogenation processes

The thermocatalytic conversion of CO2 with green or blue hydrogen into valuable energy and commodity chemicals such as alcohols, olefins, and aromatics emerges as one of the most promising strategies for mitigating global warming concerns in the future. This process can follow either a CO2-modified Fischer-Tropsch synthesis route or a methanol-mediated route, with the latter being favored for its high product selectivity beyond the Anderson-Schulz-Flory distribution. Despite the progress of the CO2-led methanol-mediated route over bifunctional metal/zeolite catalysts, challenges persist in developing catalysts with both high activity and selectivity due to the complexity of CO2 hydrogenation reaction networks and the difficulty in controlling C-O bond activation and C-C bond coupling on multiple active sites within zeolites. Moreover, the different construction and proximity modes of bifunctionality involving redox-based metallic sites and acidic zeolite sites have been explored, which have not been systematically reviewed to derive reliable structure-reactivity relationships. To bridge this "knowledge gap", in this review, we will provide a comprehensive and critical overview of contemporary research on zeolite-confined metal catalysts for alcohol synthesis and zeolite-based bifunctional tandem/cascade catalytic systems for C2+ hydrocarbons synthesis in CO2 hydrogenation via the methanol-mediated route. Accordingly, special emphasis will be placed on evaluating how confinement and proximity effects within the "redox-acid" bifunctional systems influence the reaction outcomes, particularly regarding product selectivity, which has also been analyzed from the mechanistic standpoint. This review will also examine the synergistic interactions among various catalyst components that govern catalysis, offering valuable insights for the rational design of new or improved catalyst systems. By discussing current challenges and recognizing future opportunities in CO2 hydrogenation using zeolite-based bifunctional catalysis, this review aims to contribute to the advancement of sustainable and efficient processes for CO2 valorization.

Heterogeneous catalysis strategies for polyolefin plastic upcycling: co-reactant-assisted and direct transformation under mild conditions

The large-scale production and inadequate disposal of polyolefin (PO) plastics pose significant environmental challenges. Traditional recycling methods are energy-intensive and often ineffective, prompting a need for more sustainable approaches. In recent years, catalytic upcycling under mild conditions has emerged as a promising strategy to transform PO plastics into valuable products. Co-reactants such as hydrogen, short-chain alkanes or alkenes, oxygen, and CO2 play a crucial role in driving these transformations, influencing reaction mechanisms and broadening the range of possible products. This review categorizes recent advancements in PO plastic upcycling based on the type of co-reactant employed and compares these with direct, co-reactant-free processes. Despite these advances, challenges remain in improving catalytic stability, product selectivity, and overcoming diffusion limitations in viscous plastic feedstocks. This review underscores the catalytic chemistry underpinning the development of efficient PO plastic upcycling processes with co-reactants, offering insights into future directions for sustainable plastic chemical management.

Restructuring of Palladium Nanoparticles during Oxidation by Molecular Oxygen

An interplay between Pd and PdO and their spatial distribution inside the particles are relevant for numerous catalytic reactions. Using in situ time-resolved X-ray absorption spectroscopy (XAS) supported by theoretical simulations, a mechanistic picture of the structural evolution of 2.3 nm palladium nanoparticles upon their exposure to molecular oxygen is provided. XAS analysis revealed the restructuring of the fcc-like palladium surface into the 4-coordinated structure of palladium oxide upon absorption of oxygen from the gas phase and formation of core@shell Pd@PdO structures. The reconstruction starts from the low-coordinated sites at the edges of palladium nanoparticles. Formation of the PdO shell does not affect the average Pd‒Pd coordination numbers, since the decrease of the size of the metallic core is compensated by a more spherical shape of the oxidized nanoparticles due to a weaker interaction with the support. The metallic core is preserved below 200 °C even after continuous exposure to oxygen, with its size decreasing insignificantly upon increasing the temperature, while above 200 °C, bulk oxidation proceeds. The Pd‒Pd distances in the metallic phase progressively decrease upon increasing the fraction of the Pd oxide due to the alignment of the cell parameters of the two phases.

In situ photodeposition of ultra-small palladium particles on TiO2

In situ and operando investigation of photocatalysts plays a fundamental role in understanding the processes of active phase formation and the mechanisms of catalytic reactions, which is crucial for the rational design of more efficient materials. Using a custom-made operando photocatalytic cell, an in situ procedure to follow the formation steps of Pd/TiO2 photocatalyst by synchrotron-based X-ray absorption spectroscopy (XAS) is proposed. The procedure resulted in the formation of ∼1 nm Pd particles with a much narrower size distribution and homogeneous spreading over TiO2 support compared with the samples generated in a conventional batch reactor. The combination of in situ XAS spectroscopy with high-angle annular dark-field scanning transmission electron microscopy demonstrated the formation of single-atom Pd(0) sites on TiO2 as the initial step of the photodeposition process. Palladium hydride particles were observed for all investigated samples upon exposure to formic acid solutions.

Deciphering Local Structural Complexity in Zn/Ga-ZrO2 CO2 Hydrogenation Catalysts

In the last few decades, massive effort has been expended in heterogeneous catalysis to develop new materials presenting high conversion, selectivity, and stability even under high-temperature and high-pressure conditions. In this context, CO2 hydrogenation is an interesting reaction where the catalyst local structure is strongly related to the development of an active and stable material under hydrothermal conditions at T/P > 300 °C/30 bar. In order to clarify the relationship between catalyst local ordering and its activity/stability, we herein report a combined laboratory and synchrotron investigation of aliovalent element (Ce/Zn/Ga)-containing ZrO2 matrixes. The results reveal the influence of similar average structures with different short-range orderings on the catalyst properties. Moreover, a further step toward the comprehension of the oxygen vacancy formation mechanism in Ce- and Ga-ZrO2 catalysts is reported. Finally, the reported results illustrate a robust method to guide local structure determination and ultimately help to avoid overuse of the "solid solution" definition.

Transitioning from Methanol to Olefins (MTO) toward a Tandem CO2 Hydrogenation Process: On the Role and Fate of Heteroatoms (Mg, Si) in MAPO-18 Zeotypes

The tandem CO2 hydrogenation to hydrocarbons over mixed metal oxide/zeolite catalysts (OXZEO) is an efficient way of producing value-added hydrocarbons (platform chemicals and fuels) directly from CO2via methanol intermediate in a single reactor. In this contribution, two MAPO-18 zeotypes (M = Mg, Si) were tested and their performance was compared under methanol-to-olefins (MTO) conditions (350 °C, PCH3OH = 0.04 bar, 6.5 gCH3OH h-1 g-1), methanol/CO/H2 cofeed conditions (350 °C, PCH3OH/PCO/PH2 = 1:7.3:21.7 bar, 2.5 gCH3OH h-1 g-1), and tandem CO2 hydrogenation-to-olefin conditions (350 °C, PCO2/PH2 = 7.5:22.5 bar, 1.4-12.0 gMAPO-18 h molCO2-1). In the latter case, the zeotypes were mixed with a fixed amount of ZnO:ZrO2 catalyst, well-known for the conversion of CO2/H2 to methanol. Focus was set on the methanol conversion activity, product selectivity, and performance stability with time-on-stream. In situ and ex situ Fourier transform infrared spectroscopy (FT-IR), X-ray diffraction (XRD), solid-state nuclear magnetic resonance (NMR), sorption experiments, and ab initio molecular dynamics (AIMD) calculations were performed to correlate material performance with material characteristics. The catalytic tests demonstrated the better performance of MgAPO-18 versus SAPO-18 at MTO conditions, the much superior performance of MgAPO-18 under methanol/CO/H2 cofeeds, and yet the increasingly similar performance of the two materials under tandem conditions upon increasing the zeotype-to-oxide ratio in the tandem catalyst bed. In situ FT-IR measurements coupled with AIMD calculations revealed differences in the MTO initiation mechanism between the two materials. SAPO-18 promoted initial CO2 formation, indicative of a formaldehyde-based decarboxylation mechanism, while CO and ketene were the main constituents of the initiation pool in MgAPO-18, suggesting a decarbonylation mechanism. Under tandem CO2 hydrogenation conditions, the presence of high water concentrations and low methanol partial pressure in the reaction medium led to lower, and increasingly similar, methanol turnover frequencies for the zeotypes. Despite both MAPO-18 zeotypes showing signs of activity loss upon storage due to the interaction of the sites with ambient humidity, they presented a remarkable stability after reaching steady state under tandem reaction conditions and after steaming and regeneration cycles at high temperatures. Water adsorption experiments at room temperature confirmed this observation. The faster activity loss observed in the Mg version is assigned to its harder Mg2+-ion character and the higher concentration of CHA defects in the AEI structure, identified by solid-state NMR and XRD. The low stability of a MgAPO-34 zeotype (CHA structure) upon storage corroborated the relationship between CHA defects and instability.

Atomically synergistic Zn-Cr catalyst for iso-stoichiometric co-conversion of ethane and CO2 to ethylene and CO

Developing atomically synergistic bifunctional catalysts relies on the creation of colocalized active atoms to facilitate distinct elementary steps in catalytic cycles. Herein, we show that the atomically-synergistic binuclear-site catalyst (ABC) consisting of [Formula: see text]-O-Cr6+ on zeolite SSZ-13 displays unique catalytic properties for iso-stoichiometric co-conversion of ethane and CO2. Ethylene selectivity and utilization of converted CO2 can reach 100 % and 99.0% under 500  °C at ethane conversion of 9.6%, respectively. In-situ/ex-situ spectroscopic studies and DFT calculations reveal atomic synergies between acidic Zn and redox Cr sites. [Formula: see text] ([Formula: see text]) sites facilitate β-C-H bond cleavage in ethane and the formation of Zn-Hδ- hydride, thereby the enhanced basicity promotes CO2 adsorption/activation and prevents ethane C-C bond scission. The redox Cr site accelerates CO2 dissociation by replenishing lattice oxygen and facilitates H2O formation/desorption. This study presents the advantages of the ABC concept, paving the way for the rational design of novel advanced catalysts.

Kinetic Model for the Direct Conversion of CO2/CO into Light Olefins over an In2O3-ZrO2/SAPO-34 Tandem Catalyst

An original kinetic model is proposed for the direct production of light olefins by hydrogenation of CO2/CO (COx) mixtures over an In2O3-ZrO2/SAPO-34 tandem catalyst, quantifying deactivation by coke. The reaction network comprises 12 individual reactions, and deactivation is quantified with expressions dependent on the concentration of methanol (as coke precursor) and H2O and H2 (as agents attenuating coke formation). The experimental results were obtained in a fixed-bed reactor under the following conditions: In2O3-ZrO2/SAPO-34 mass ratio, 0/1-1/0; 350-425 °C; 20-50 bar; H2/COx ratio, 1-3; CO2/COx ratio, 0-1; space time, 0-10 gIn2O3-ZrO2 h molC-1, 0-20 gSAPO-34 h molC-1; time, up to 500 h; H2O and CH3OH in the feed, up to 5% vol. The utility of the model for further scale-up studies is demonstrated by its application in optimizing the process variables (temperature, pressure, and CO2/COx ratio). The model predicts an olefin yield higher than 7% (selectivity above 60%), a COx conversion of 12% and a CO2 conversion of 16% at 415 °C and 50 bar, for a CO2/COx = 0.5 in the feed. Additionally, an analysis of the effect of In2O3-ZrO2 and SAPO-34 loading in the configuration of the tandem catalyst is conducted, yielding 17% olefins and complete conversion of CO2 under full water removal conditions.

Enabling the Methanol Economy: Opportunities and Challenges for Heterogeneous Catalysis in the Production of Liquid Fuels via Methanol

ConspectusThirty years ago, George A. Olah proposed the concept of the methanol economy, where methanol replaces fossil fuels as a means of energy storage, ground transportation fuel, and raw material for the manufacture of other carbon-based products. Over the years, with rising global warming concerns, the concept has evolved. A special interest is devoted to the development of catalytic processes that allow the transformation of carbon dioxide, via methanol, into CO2 neutral liquid hydrocarbons. These products could replace the oil-based fuels currently used by combustion engines. The rapid depletion of such fuels would avoid a considerable amount of CO2 emissions during the current energy transition.Over the past decade, we have focused on different key processes that should allow for maximal atom efficiency and, therefore, minimal energy consumption in a field, CO2 valorization, that can easily become a zero-sum game. In this Account, we highlight the importance of catalyst design to overcome the process challenges in the production of liquid fuels from methanol. Additionally, progress in multifunctional catalysts able to directly convert, in one single reactor, CO2 to liquid fuels is also discussed in detail. This integrated option is of particular interest since it allows an important decrease in operational units while increasing throughput by converting, in situ, a thermodynamically limited intermediate.

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.

Polythiophene as a Double-Electrostatic Template for Zinc Oxide and Gold: Multicomponent Nano-Objects for Enhanced Photocatalysis

Using electrostatic self-assembly and electrostatic nanotemplating, a quaternary nanostructured system consisting of zinc oxide nanoparticles, gold nanoparticles, poly[3-(potassium-4-butanoate)thiophene-2,5-diyl] (PT), and methyltrioctylammonium chloride (MTOA) (PT-MTOA-ZnO-Au) was designed for aqueous photocatalysis. The PT-MTOA hollow sphere aggregates served as an electrostatic template for both individual inorganic nanoparticles controlling their morphology, stabilizing the nanoparticles, and acting as a photosensitizer. The hybrid structures included spherical ZnO nanoparticles with a diameter of d = 2.6 nm and spherical Au nanoparticles with d = 6.0 nm embedded in PT-MTOA hollow spheres with a hydrodynamic radius of R_H = 100 nm. The ZnO nanoparticles acted as the main catalyst, while the Au nanoparticles acted as the cocatalyst. As a photocatalytic model reaction, the dye degradation of methylene blue in aqueous solution using the full spectral range from UV to visible light was tested. The photocatalytic activity was optimized by varying the Zn and Au loading ratios and was substantially enhanced regarding the components; for example, it was increased by about 61% using PT-MTOA-ZnO-Au compared to the composite without gold particles. A photocatalytic mechanism of the methylene blue degradation was proposed when catalyzed by these multicomponent nano-objects. Thus, a simple procedure of templating two different nanoparticle species within the same cocatalytically active template has been demonstrated, which can be extended to other inorganic particles, making a variety of task-specific catalysts accessible.

From Lab to Technical CO2 Hydrogenation Catalysts: Understanding PdZn Decomposition

The valorization of CO₂ to produce high-value chemicals, such as methanol and hydrocarbons, represents key technology in the future net-zero society. Herein, we report further investigation of a PdZn/ZrO₂ + SAPO-34 catalyst for conversion of CO₂ and H₂ into propane, already presented in a previous work. The focus of this contribution is on the scale up of this catalyst. In particular, we explored the effect of mixing (1:1 mass ratio) and shaping the two catalyst functions into tablets and extrudates using an alumina binder. Their catalytic performance was correlated with structural and spectroscopic characteristics using methods such as FT-IR and X-ray absorption spectroscopy. The two scaled-up bifunctional catalysts demonstrated worse performance than a 1:1 mass physical mixture of the two individual components. Indeed, we demonstrated that the preparation negatively affects the element distribution. The physical mixture is featured by the presence of a PdZn alloy, as demonstrated by our previous work on this sample and high hydrocarbon selectivity among products. For both tablets and extrudates, the characterization showed Zn migration to produce Zn aluminates from the alumina binder phase upon reduction. Moreover, the extrudates showed a remarkable higher amount of Zn aluminates before the activation rather than the tablets. Comparing tablets and extrudates with the physical mixture, no PdZn alloy was observed after activation and only the extrudates showed the presence of metallic Pd. Due to the Zn migration, SAPO-34 poisoning and subsequent deactivation of the catalyst could not be excluded. These findings corroborated the catalytic results: Zn aluminate formation and Pd⁰ separation could be responsible for the decrease of the catalytic activity of the extrudates, featured by high methane selectivity and unconverted methanol, while tablets displayed reduced methanol conversion to hydrocarbons mainly attributed to the partial deactivation of the SAPO-34.