Optimization of the Pd/Cu ratio in Pd-Cu-Zn/SiC catalysts for the CO 2 hydrogenation to methanol at atmospheric pressure

A Review on Green Hydrogen Valorization by Heterogeneous Catalytic Hydrogenation of Captured CO2 into Value-Added Products

The catalytic hydrogenation of captured CO2 by different industrial processes allows obtaining liquid biofuels and some chemical products that not only present the interest of being obtained from a very low-cost raw material (CO2) that indeed constitutes an environmental pollution problem but also constitute an energy vector, which can facilitate the storage and transport of very diverse renewable energies. Thus, the combined use of green H2 and captured CO2 to obtain chemical products and biofuels has become attractive for different processes such as power-to-liquids (P2L) and power-to-gas (P2G), which use any renewable power to convert carbon dioxide and water into value-added, synthetic renewable E-fuels and renewable platform molecules, also contributing in an important way to CO2 mitigation. In this regard, there has been an extraordinary increase in the study of supported metal catalysts capable of converting CO2 into synthetic natural gas, according to the Sabatier reaction, or in dimethyl ether, as in power-to-gas processes, as well as in liquid hydrocarbons by the Fischer-Tropsch process, and especially in producing methanol by P2L processes. As a result, the current review aims to provide an overall picture of the most recent research, focusing on the last five years, when research in this field has increased dramatically.

Recent Advances in Carbon Dioxide Adsorption, Activation and Hydrogenation to Methanol using Transition Metal Carbides

The inevitable emission of carbon dioxide (CO₂ ) due to the burning of a substantial amount of fossil fuels has led to serious energy and environmental challenges. Metal-based catalytic CO₂ transformations into commodity chemicals are a favorable approach in the CO₂ mitigation strategy. Among these transformations, selective hydrogenation of CO₂ to methanol is the most promising process that not only fulfils the energy demands but also re-balances the carbon cycle. The investigation of CO₂ adsorption on the surface of heterogeneous catalyst is highly important because the formation of various intermediates which determines the selectivity of product. Transition metal carbides (TMCs) have received considerable attention in recent years because of their noble metal-like reactivity, ceramic-like properties, high chemical and thermal stability. These features make them excellent catalytic materials for a variety of transformations such as CO₂ adsorption and its conversion into value-added chemicals. Herein, the catalytic properties of TMCs are summarize along with synthetic methods, CO₂ binding modes, mechanistic studies, effects of dopant on CO₂ adsorption, and carbon/metal ratio in the CO₂ hydrogenation reaction to methanol using computational as well as experimental studies. Additionally, this Review provides an outline of the challenges and opportunities for the development of potential TMCs in CO₂ hydrogenation reactions.

A computational study of direct CO2 hydrogenation to methanol on Pd surfaces

The reaction mechanism of direct CO₂ hydrogenation to methanol is investigated in detail on Pd (111), (100) and (110) surfaces using density functional theory (DFT), supporting investigations into emergent Pd-based catalysts. Hydrogen adsorption and surface mobility are firstly considered, with high-coordination surface sites having the largest adsorption energy and being connected by diffusion channels with low energy barriers. Surface chemisorption of CO₂, forming a partially charged CO₂^δ-, is weakly endothermic on a Pd (111) whilst slightly exothermic on Pd (100) and (110), with adsorption enthalpies of 0.09, -0.09 and -0.19 eV, respectively; the low stability of CO₂^δ- on the Pd (111) surface is attributed to negative charge accumulating on the surface Pd atoms that interact directly with the CO₂^δ- adsorbate. Detailed consideration for sequential hydrogenation of the CO₂ shows that HCOOH hydrogenation to H₂COOH would be the rate determining step in the conversion to methanol, for all surfaces, with activation barriers of 1.41, 1.51, and 0.84 eV on Pd (111), (100) and (110) facets, respectively. The Pd (110) surface exhibits overall lower activation energies than the most studied Pd (111) and (100) surfaces, and therefore should be considered in more detail in future Pd catalytic studies.

Heterogeneous Trimetallic Nanoparticles as Catalysts

The development and application of trimetallic nanoparticles continues to accelerate rapidly as a result of advances in materials design, synthetic control, and reaction characterization. Following the technological successes of multicomponent materials in automotive exhausts and photovoltaics, synergistic effects are now accessible through the careful preparation of multielement particles, presenting exciting opportunities in the field of catalysis. In this review, we explore the methods currently used in the design, synthesis, analysis, and application of trimetallic nanoparticles across both the experimental and computational realms and provide a critical perspective on the emergent field of trimetallic nanocatalysts. Trimetallic nanoparticles are typically supported on high-surface-area metal oxides for catalytic applications, synthesized via preparative conditions that are comparable to those applied for mono- and bimetallic nanoparticles. However, controlled elemental segregation and subsequent characterization remain challenging because of the heterogeneous nature of the systems. The multielement composition exhibits beneficial synergy for important oxidation, dehydrogenation, and hydrogenation reactions; in some cases, this is realized through higher selectivity, while activity improvements are also observed. However, challenges related to identifying and harnessing influential characteristics for maximum productivity remain. Computation provides support for the experimental endeavors, for example in electrocatalysis, and a clear need is identified for the marriage of simulation, with respect to both combinatorial element screening and optimal reaction design, to experiment in order to maximize productivity from this nascent field. Clear challenges remain with respect to identifying, making, and applying trimetallic catalysts efficiently, but the foundations are now visible, and the outlook is strong for this exciting chemical field.

Porous Silicon Carbide (SiC): A Chance for Improving Catalysts or Just Another Active-Phase Carrier?

There is an obvious gap between efforts dedicated to the control of chemicophysical and morphological properties of catalyst active phases and the attention paid to the search of new materials to be employed as functional carriers in the upgrading of heterogeneous catalysts. Economic constraints and common habits in preparing heterogeneous catalysts have narrowed the selection of active-phase carriers to a handful of materials: oxide-based ceramics (e.g. Al₂O₃, SiO₂, TiO₂, and aluminosilicates-zeolites) and carbon. However, these carriers occasionally face chemicophysical constraints that limit their application in catalysis. For instance, oxides are easily corroded by acids or bases, and carbon is not resistant to oxidation. Therefore, these carriers cannot be recycled. Moreover, the poor thermal conductivity of metal oxide carriers often translates into permanent alterations of the catalyst active sites (i.e. metal active-phase sintering) that compromise the catalyst performance and its lifetime on run. Therefore, the development of new carriers for the design and synthesis of advanced functional catalytic materials and processes is an urgent priority for the heterogeneous catalysis of the future. Silicon carbide (SiC) is a non-oxide semiconductor with unique chemicophysical properties that make it highly attractive in several branches of catalysis. Accordingly, the past decade has witnessed a large increase of reports dedicated to the design of SiC-based catalysts, also in light of a steadily growing portfolio of porous SiC materials covering a wide range of well-controlled pore structure and surface properties. This review article provides a comprehensive overview on the synthesis and use of macro/mesoporous SiC materials in catalysis, stressing their unique features for the design of efficient, cost-effective, and easy to scale-up heterogeneous catalysts, outlining their success where other and more classical oxide-based supports failed. All applications of SiC in catalysis will be reviewed from the perspective of a given chemical reaction, highlighting all improvements rising from the use of SiC in terms of activity, selectivity, and process sustainability. We feel that the experienced viewpoint of SiC-based catalyst producers and end users (these authors) and their critical presentation of a comprehensive overview on the applications of SiC in catalysis will help the readership to create its own opinion on the central role of SiC for the future of heterogeneous catalysis.

CO2 hydrogenation over functional nanoporous polymers and metal-organic frameworks

CO₂ is one of the major environmental pollutants and its mitigation is attracting huge attention over the years due to continuous increase in this greenhouse gas emission in the atmosphere. Being environmentally hazardous and plentiful presence in nature, CO₂ utilization as C1 resource into fuels and feedstock is very demanding from the green chemistry perspectives. To accomplish this CO₂ utilization issue, functional organic materials like porous organic polymers (POPs), covalent organic frameworks (COFs) as well as organic-inorganic hybrid materials like metal-organic frameworks (MOFs), having characteristics of large surface area, high thermal stability and tunability in the porous nanostructures play significant role in designing the suitable catalyst for the CO₂ hydrogenation reactions. Although CO₂ hydrogenation is a widely studied and emerging area of research, till date review exclusively focused on designing POPs, COFs and MOFs bearing reactive functional groups is very limited. A thorough literature review on this matter will enrich our knowledge over the CO₂ hydrogenation processes and the catalytic sites responsible for carrying out these chemical transformations. We emphasize recent state-of-the art developments in POPs/COFs/MOFs having unique functionalities and topologies in stabilizing metallic NPs and molecular complexes for the CO₂ reduction reactions. The major differences between MOFs and porous organics are critically summarized in the outlook section with the aim of the future benefit in mitigating CO₂ emission from ambient air.

Crystallographic Orientation Dependence of Surface Segregation and Alloying on PdCu Catalysts for CO2 Hydrogenation

The influence of the crystallographic orientation on surface segregation and alloy formation in model PdCu methanol synthesis catalysts was investigated in situ using near-ambient pressure X-ray photoelectron spectroscopy under CO₂ hydrogenation conditions. Combined with scanning tunneling microscopy and density functional theory calculations, the study showed that submonolayers of Pd undergo spontaneous alloy formation on Cu(110) and Cu(100) surfaces in vacuum, whereas they do not form an alloy on Cu(111). Upon heating in H₂, inward diffusion of Pd into the Cu lattice is favored, facilitating alloying on all Cu surfaces. Under CO₂ hydrogenation reaction conditions, the alloying trend becomes stronger, promoted by the reaction intermediate HCOO*, especially on Pd/Cu(110). This work demonstrates that surface alloying may be a key factor in the enhancement of the catalytic activity of PdCu catalysts as compared to their monometallic counterparts. Furthermore, it sheds light on the hydrogen activation mechanism during catalytic hydrogenation on copper-based catalysts.

Multi-Scale Analysis of Integrated C1 (CH4 and CO2) Utilization Catalytic Processes: Impacts of Catalysts Characteristics up to Industrial-Scale Process Flowsheeting, Part I: Experimental Analysis of Catalytic Low-Pressure CO2 to Methanol Conversion

A multi-aspect analysis of low-pressure catalytic hydrogenation of CO2 for methanol production is reported in the first part (part I) of this paper. This includes an extensive review of distinguished low-pressure catalytic CO2-hydrogenation systems. Specifically, the results of the conducted systematic experimental investigation on the impacts of synthesis and micro-scale characteristics of the selected Cu/ZnO/Al2O3 model-catalysts on their activity and stability are discussed. The performance of the investigated Cu/ZnO/Al2O3 catalysts, synthesized via different methods, were tested under a targeted range of operating conditions in this research. Specifically, the performances of these tested Cu/ZnO/Al2O3 catalysts with regard to the impacts of the main operating parameters, namely H2/CO2 ratio (at stoichiometric -3-, average -6- and high -9- ratios), temperature (in the range of 160–260 °C) and the lower and upper values of physically achievable gas hourly space velocity (GHSV) (corresponding to 200 h−1 and 684 h−1, respectively), were analyzed. It was found that the catalyst prepared by the hydrolysis co-precipitation method, with a homogenously distributed copper content over its entire surface, provides a promising methanol yield of 21% at a reaction temperature of 200 °C, lowest tested GHSV, highest tested H2/CO2 ratio (9) and operating pressure (10 bar). This is in line with other promising results so far reported for this catalytic system even in pilot-plant scale, highlighting its potential for large-scale methanol production. To analyze the findings in more details, the thermal-reaction performance of the system, specifically with regard to the impact of GHSV on the CO2-conversion and methanol selectivity, and yield were experimentally investigated. Moreover, the stability of the selected catalysts, as another crucial factor for potential industrial operation of this system, was tested under continual long-term operation for 150 h, the reaction-reductive shifting-atmospheres and also even after introducing oxygen to the catalyst surface followed by hydrogen reduction-reaction tests. Only the latter state was found to affect the stable performance of the screened catalysts in this research. In addition, the reported experimental reactor performances have been analyzed in the light of equilibrium-based calculated achievable performance of this reaction system. In the performed multi-scale analysis in this research, the requirements for establishing a selective-stable catalytic performance based on the catalyst- and reactor-scale analyses have been identified. This will be combined with the techno–economic performance analysis of the industrial-scale novel integrated process, utilizing the selected catalyst in this research, in the form of an add-on catalytic system under 10 bar pressure and H2/CO2 ratio (3), for efficiently reducing the overall CO2-emission from oxidative coupling of methane reactors, as reported in the second part (part II) of this paper.

State of the art and perspectives in heterogeneous catalysis of CO2 hydrogenation to methanol

The ever-increasing amount of anthropogenic carbon dioxide (CO₂) emissions has resulted in great environmental impacts, the heterogeneous catalysis of CO₂ hydrogenation to methanol is of great significance.