The role of copper crystallization and segregation toward enhanced methanol synthesis via CO[subscri
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Marcos, Francielle C.F.↗
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A Highly Active Molybdenum Phosphide Catalyst for Methanol Synthesis from CO and CO 2
Methanol is a major fuel and chemical feedstock currently produced from syngas, a CO/CO2/H2 mixture. Herein we identify formate binding strength as a key parameter limiting the activity and stability of known catalysts for methanol synthesis in the presence of CO2. We present a molybdenum phosphide catalyst for CO and CO2 reduction to methanol, which through a weaker interaction with formate, can improve the activity and stability of methanol synthesis catalysts in a wide range of CO/CO2/H2 feeds.
10 SYNTHETIC FUELS↗
Mechanism of methanol synthesis on Ni(110)
Planewave density functional theory (DFT-PW91) calculations are employed to study the methanol synthesis through CO 2 and CO hydrogenation, as well as the two side reactions: the water gas shift (WGS) reaction and formic acid formation, on Ni(110). For the WGS reaction on Ni(110), we find that the redox mechanism is favored over the carboxyl-mediated mechanism. We show that the formate pathway is the dominant one for formic acid formation. For methanol synthesis through CO 2 and CO hydrogenation on Ni(110), our results reveal that the formic-acid- and dioxymethylene-mediated pathways coexist, in contrast to methanol synthesis on Cu(111) where the formic-acid-mediated pathway dominates. We also find that on Ni(110), hydrogenation of CH 2 O* to CH 3 O* and that to CH 2 OH* both contribute to MeOH synthesis. Based on the derived energetics, we ascertain that CH 3 O* hydrogenation to CH 3 OH* is likely the rate-determining step along the CH 3 O* pathway on Ni(110). Remarkably, CH 3 O* hydrogenation can be facilitated by the presence of HCO*, demonstrating the promotional effect of CO. Furthermore, we show that CO also participates in methanol synthesis directly via its hydrogenation to HCO* and further to CH 2 O*. Additional microkinetic modeling by considering feed composition and reaction conditions would provide further mechanistic insights into methanol synthesis on Ni(110).
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
A Highly Active Molybdenum Phosphide Catalyst for Methanol Synthesis from CO and CO 2
Abstract Methanol is a major fuel and chemical feedstock currently produced from syngas, a CO/CO 2 /H 2 mixture. Herein we identify formate binding strength as a key parameter limiting the activity and stability of known catalysts for methanol synthesis in the presence of CO 2 . We present a molybdenum phosphide catalyst for CO and CO 2 reduction to methanol, which through a weaker interaction with formate, can improve the activity and stability of methanol synthesis catalysts in a wide range of CO/CO 2 /H 2 feeds.
Duyar, Melis S.↗
Hydrogenation of CO 2 on ZnO/Cu(100) and ZnO/Cu(111) Catalysts: Role of Copper Structure and Metal–Oxide Interface in Methanol Synthesis
The results of kinetic tests and ambient-pressure X-ray photoelectron spectroscopy (AP-XPS) show the important role played by a ZnO–copper interface in the generation of CO and the synthesis of methanol from CO 2 hydrogenation. The deposition of nanoparticles of ZnO on Cu(100) and Cu(111), θ oxi < 0.3 monolayer, produces highly active catalysts. The catalytic activity of these systems increases in the sequence: Cu(111) < Cu(100) < ZnO/Cu(111) < ZnO/Cu(100). The structure of the copper substrate influences the catalytic performance of a ZnO–copper interface. Furthermore, size and metal–oxide interactions affect the chemical and catalytic properties of the oxide making the supported nanoparticles different from bulk ZnO. The formation of a ZnO–copper interface favors the binding and conversion of CO 2 into a formate intermediate that is stable on the catalyst surface up to temperatures above 500 K. Alloys of Zn with Cu(111) and Cu(100) were not stable at the elevated temperatures (500–600 K) used for the CO 2 hydrogenation reaction. However, reaction with CO 2 oxidized the zinc, enhancing its stability over the copper substrates.
36 MATERIALS SCIENCE↗
Phase change material integrated core–shell catalyst for in situ thermal control in methanol synthesis from syngas
A model-guided core–shell catalyst design is presented for methanol synthesis, featuring a phase change material (PCM) core encapsulated by a Cu–Zn–Al 2 O 3 (CZA) catalytic shell. The PCM enables in situ thermal management by absorbing reaction heat at its melting point, mitigates the kinetic decline at high temperatures and therefore avoids low conversion, prevents hot spots, and stabilizes the reaction temperature. A two-dimensional axisymmetric, non-isothermal packed-bed reactor model (COMSOL 6.3) was developed for a 10 g system. Simulations evaluate three PCM candidates, that is, LiNO 3 , 9 wt% LiCl + 91 wt% LiNO 3 , and commercial H250, with melting points near 244–250°C. Results indicate that CO conversion can increase from 34.4% to 52.4%, and methanol production can improve by 69% compared to a conventional packed-bed reactor. Beyond methanol synthesis, the PCM-integrated core–shell concept provides a scalable approach for thermal control in exothermic reactions, improving reactor efficiency and safety.
core–shell catalyst↗
Modular Integrated System for Carbon-Neutral Methanol Synthesis Using Direct Air Capture and Carbon-Free Hydrogen Production
This study investigates the development and economic analysis of a modular integrated system for carbon-neutral methanol synthesis, leveraging direct air capture (DAC) and solid oxide electrolysis cells (SOEC) for carbon dioxide and hydrogen production, respectively. The proposed system integrates a novel building-based DAC process, functionalized solid sorbents, and low-energy SOEC technology, aiming to minimize operational and capital costs. A comparison between the base case system (1,000 t methanol/year) and a scaled-up model (14,758 t methanol/year) reveals significant improvements in efficiency and economic feasibility. The scaled-up system achieves a levelized cost of methanol (LCOM) of $740/t, a 7.5% reduction compared to that of conventional DAC-based systems, while utilizing existing building HVAC infrastructure for air handling. Detailed sensitivity analyses were conducted, evaluating the effects of plant capacity and air flow rate on the LCOM, demonstrating the scalability of the building-based DAC system. The cradle-to-gate life cycle analysis shows that the proposed process using renewable-sourced electricity achieves a 38% reduction in greenhouse gas (GHG) emission compared to reported values of green methanol production technologies that use a conventional DAC and a conventional methanol synthesis catalyst. When fossil-sourced electricity is used in the proposed process, it leads to about a 37.5% reduction in GHG emission in comparison to reported values for conventional methanol production technologies using steam methane reforming technology and fossil-sourced electricity.
alcohols↗
A Comparative Techno-Economic Analysis of Renewable Methanol Synthesis Pathways from Biomass and CO2: Preprint
Global demand for methanol as both a chemical precursor and a fuel additive is rising. At the same time, numerous sustainable methanol production pathways are under development which, if commercialized, could present significant environmental benefits over traditional methanol synthesis pathways. There is a need to harmonize the analyses of sustainable pathways using a consistent techno-economic approach to evaluate the potential for commercialization of various pathways. This analysis considers economic and environmental factors critical to market acceptance of three sustainable pathways versus a commercial baseline. We suggest that biomass gasification to methanol represents a near-term viable pathway with high technology readiness level and commercially competitive market price. However, long-term solutions should consider CO2 electrolysis pathways which offer further improvements in sustainability metrics to support global decarbonization efforts.
biomass↗
Simulation of methanol synthesis in a membrane-contactor reactor
In a recent paper we investigated experimentally in the laboratory the methanol synthesis (MeS) reaction in a novel high-pressure membrane reactor (MR) using tetraethylene glycol dimethyl ether (TGDE) and an ionic liquid (IL) as the sweep liquids. We reported significantly higher carbon conversion (per single-pass) compared to a traditional packed-bed reactor (PBR), as a result of the in-situ removal of methanol by the sweep liquid. Here, in this paper, a steady-state model is developed to simulate the MR behavior during MeS and is validated by the experimental data. The model is then used to study the reactor behavior for a broader range of operating conditions beyond those that can be accessed and studied experimentally in the laboratory-scale reactor. Converting the model equations into their dimensionless form helps to identify the key dimensionless groups determining reactor performance, enables one to better evaluate the efficacy of the MR system, and guides further process design and scale-up.
36 MATERIALS SCIENCE↗
Elucidating the factors controlling the methanol synthesis from CO 2 on ZnPd-ZnO/TiO 2 catalysts prepared by direct/inverse impregnation
The direct hydrogenation of CO 2 to methanol over supported ZnPd intermetallic catalysts remains a challenge due to the complex nature of the active sites, which are highly dependent on both the dispersion of ZnPd intermetallics and their proximity to ZnO. This study investigates the effect of the Pd and Zn incorporation order on methanol synthesis over TiO 2 -supported ZnPd catalysts. Catalysts were prepared via direct (Pd/Zn), inverse (Zn/Pd), and co-impregnation (Pd+Zn) methods using anatase TiO 2 as the support. Comprehensive characterization by XRD, HRTEM, CO-DRIFTS and XPS revealed that the formation of small and crystalline intermetallic β-ZnPd particles and their interaction with ZnO/ZnO x depends on the sequence of Pd and Zn incorporation. It was found that, under the reaction conditions, the ZnO x species plays a critical role in facilitating the formation of the intermetallic ZnPd through the interactions between Pd and ZnO x . In addition, ZnO x species have also been shown to modulate key catalytic properties, such as CO 2 activation and methanol selectivity. Specifically, the ZnPd/Pd surface ratio, determined by Pd dispersion and proximity to ZnO/ZnO x , was shown to determine the methanol production from CO 2 directly or via a CO intermediate. The Pd/Zn catalyst showed superior selectivity due to the in-situ formation of intermetallic species facilitated by Pd-ZnO x interactions.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Novel inverse oxide/metal catalysts for methanol synthesis: impact of oxide–metal interactions and reversible morphological changes
Inverse oxide/metal catalysts have proved to be excellent systems for the generation of methanol by CO 2 hydrogenation or the partial oxidation of methane. These systems can exhibit unique structural and chemical properties due to the nano size of the oxide component and strong oxide–metal interactions. Recent studies for ZnO/Cu, CeO 2 /Cu, TiO 2/ Cu, MgO/Cu, In 2 O 3 /Cu, and In 2 O 3 /Au catalysts have shown large variations in the composition and morphology of the oxide overlayer as a function of temperature and chemical environment. These oxide–metal interfaces are able to react with CO 2 and CH 4 at room temperature, and both reactants have a strong influence on the physical and chemical properties of the catalysts. Under reaction conditions, switches between oxide–metal and metal–metal interfaces can take in the catalyst surface. A dynamic behavior that can be linked to a high selectivity for methanol production over systems such as ZnO/Cu, CeO 2 /Cu and In 2 O 3 /Au. Finally, this type of correlation deserves additional systematic studies since it could be a powerful tool for designing highly efficient catalysts for methanol synthesis.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Exploiting electricity market dynamics using flexible electrolysis units for retrofitting methanol synthesis
Here we investigate the economic viability of integrating flexible electrolysis units to produce hydrogen in methanol synthesis processes. Specifically, we investigate whether this approach can help reduce methanol production costs by strategically exploiting dynamics of electricity markets. Our study integrates high-fidelity process simulations, optimization tools, and microkinetic modeling (informed by density functional theory) to conduct detailed techno-economic analyses and to compare performance against traditional processes that use hydrogen produced via steam-methane reforming (SMR). We also use this approach to estimate the levelized cost of hydrogen (LCOH) as a function of time-varying electricity prices (from day-ahead and real-time prices) and of key techno-economic parameters. Our results show that the proposed electrification framework is cost-competitive under certain electricity market conditions. Specifically, we find that, when the electrolysis system is operated in flexible mode (and can respond to dynamics of electricity markets), the associated electricity cost nearly collapses to zero. Conversely, when the unit is not flexible (and cannot respond to markets), the electricity cost comprises 60% of the total cost. Our results also reveal that the LCOH of the flexible electrolysis system participating in real-time electricity markets is 31% lower than the LCOH obtained from SMR. Overall, this indicates that exploiting the dynamics of electricity markets can make hydrogen production cost-competitive and this can lead to viable alternatives to electrify methanol production and other hydrogen-based processes.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Low-pressure methanol synthesis from CO 2 over metal-promoted Ni-Ga intermetallic catalysts
Ni-Ga and M-Ni-Ga (M = Au, Co, Cu) catalysts were evaluated for methanol synthesis from CO 2 at 10 bar and 200-270°C. The following trend in turnover frequency (TOF) for CO 2 hydrogenation was observed: AuNiGa > CuNiGa > NiGa > CoNiGa, where TOF increased with decreasing catalyst affinity for CO. The presence of a third metal was found to influence both the formation of the Ni-Ga intermetallic phase as well as the number of available sites for CO chemisorption. Phase formation, catalyst composition and stability were evaluated using therm ogravimetric analysis (TGA), X-ray diffraction (XRD), X-ray fluorescence (XRF), scanning transmission electron microscopy and energy dispersive X-ray spectroscopy (STEM-EDX). Au-Ni-Ga, which showed a nearly 4-fold improvement in TOF at 263°C and 10 bar compared to Ni-Ga, consisted of Ni 3 Ga particles decorated with Au, as evidenced by post catalysis characterization.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
A comparative techno-economic analysis of renewable methanol synthesis from biomass and CO 2 : Opportunities and barriers to commercialization
Global demand for methanol as both a chemical precursor and a fuel additive is rising. At the same time, numerous renewable methanol production pathways are under development, which, if commercialized, could provide significant environmental benefits over traditional methanol synthesis pathways. However, it is difficult to compare technologies at different maturity levels, with differing feedstocks, and with significant differences in overall process design. Thus, there is a need to harmonize the analyses of renewable pathways using a consistent techno-economic approach to evaluate the potential for commercialization of various pathways. This analysis uses a novel cross-comparison method to assess near-term and long-term viability of both low- and high-maturity level technologies. Furthermore, the techno-economic assessment considers cost factors critical to market acceptance combined with carbon- and energy-efficiency assessments of three renewable pathways compared with a commercial baseline. We find that biomass gasification to methanol represents a near-term viable pathway with a high technology readiness level and commercially competitive market price. If cost-reducing technological improvements can be realized and scaled up in the CO 2 electrolysis pathways, the potential for higher carbon efficiencies may help drive market adoption of these more modular, direct conversion pathways in future markets as they present an opportunity to better support global decarbonization efforts through efficient waste carbon utilization.
09 BIOMASS FUELS↗
IR-Spectroscopic Study on the Interface of Cu-Based Methanol Synthesis Catalysts: Evidence for the Formation of a ZnO Overlayer
Carbon monoxide was applied as probe molecule to compare the surface of a ZnO-containing (Cu/ZnO:Al) and a ZnO-free (Cu/MgO) methanol synthesis catalyst (copper content 70 atomic %) after reduction in hydrogen at 523 K by DRIFT spectroscopy. Nano-structured, mainly metallic copper was detected on the surface of the Cu/MgO catalyst. In contrast, the high energy of the main peak in the spectrum of CO adsorbed on reduced Cu/ZnO:Al (2125 cm -1 ) proves that metallic copper is largely absent on the surface of this catalyst. The band is assigned to Zn δ+ –CO. The presence of not completely reduced Cu δ+ –CO species cannot be excluded. The results are interpreted in terms of a partial coverage of the copper nano-particles in the Cu/ZnO:Al catalyst by a thin layer of metastable, defective zinc oxide. Minor contributions in the spectrum at 2090 and 2112 cm -1 due to nano-structured Cu 0 –CO and CO adsorbed on highly defective Cu 0 , respectively, indicate that the coverage of metallic copper is not complete.
36 MATERIALS SCIENCE↗
Inverse ZrO 2 /Cu as a highly efficient methanol synthesis catalyst from CO 2 hydrogenation
Enhancing the intrinsic activity and space time yield of Cu based heterogeneous methanol synthesis catalysts through CO 2 hydrogenation is one of the major topics in CO 2 conversion into value-added liquid fuels and chemicals. Here we report inverse ZrO 2 /Cu catalysts with a tunable Zr/Cu ratio have been prepared via an oxalate co-precipitation method, showing excellent performance for CO 2 hydrogenation to methanol. Under optimal condition, the catalyst composed by 10% of ZrO 2 supported over 90% of Cu exhibits the highest mass-specific methanol formation rate of 524 g MeOH kg cat -1 h -1 at 220°C, 3.3 times higher than the activity of traditional Cu/ZrO 2 catalysts (159 g MeOH kg cat -1 h -1 ). In situ XRD-PDF, XAFS and AP-XPS structural studies reveal that the inverse ZrO 2 /Cu catalysts are composed of islands of partially reduced 1–2 nm amorphous ZrO 2 supported over metallic Cu particles. The ZrO 2 islands are highly active for the CO 2 activation. Meanwhile, an intermediate of formate adsorbed on the Cu at 1350 cm -1 is discovered by the in situ DRIFTS. This formate intermediate exhibits fast hydrogenation conversion to methoxy. The activation of CO 2 and hydrogenation of all the surface oxygenate intermediates are significantly accelerated over the inverse ZrO 2 /Cu configuration, accounting for the excellent methanol formation activity observed.
36 MATERIALS SCIENCE↗
An experimental and modeling study of the application of membrane contactor reactors to methanol synthesis using pure CO 2 feeds
We describe here a post-combustion CO 2 capture and utilization (CCU) technology that converts the CO 2 into methanol (MeOH), a valuable chemical, thus providing a way to monetize the carbon captured to offset process costs. Methanol synthesis (MeS) has been discussed recently for application to CCU, but thermodynamic limitations make it difficult to convert in a single pass a large CO 2 fraction. Conventional catalysts show slow kinetics in converting CO 2 -rich syngas (or pure CO 2 ) into MeOH. Our Group developed a novel MeS process, employing a membrane contactor reactor (MCR) system that attains carbon conversions significantly higher than equilibrium. Our focus here is to process pure CO 2 streams by combining the MCR with a separate reactor, which converts the CO 2 into a syngas via the reverse water gas shift (RWGS) reaction. In this preliminary effort, the RWGS reactor (RWGSR) is assumed to reach equilibrium. Additional MeS kinetic rate data are generated validating experimentally the ability of the MeS-MCR to process as a feed the RWGSR exit stream. The performance of the combined (RWGSR/MeS-MCR) system is then simulated using a recently developed MeS-MCR model. In conclusion, the findings are encouraging, and research is currently ongoing to experimentally validate the RWGSR/MeS-MCR system performance.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Room‐Temperature Formate Ester Transfer Hydrogenation Enables an Electrochemical/Thermal Organometallic Cascade for Methanol Synthesis from CO 2
Abstract The reduction of CO 2 to synthetic fuels is a valuable strategy for energy storage. However, the formation of energy‐dense liquid fuels such as methanol remains rare, particularly under low‐temperature and low‐pressure conditions that can be coupled to renewable electricity sources via electrochemistry. Here, a multicatalyst system pairing an electrocatalyst with a thermal organometallic catalyst is introduced, which enables the reduction of CO 2 to methanol at ambient temperature and pressure. The cascade methanol synthesis proceeds via CO 2 reduction to formate by electrocatalyst [Cp*Ir(bpy)Cl] + (Cp*=pentamethylcyclopentadienyl, bpy=2,2′‐bipyridine), Fischer esterification of formate to isopropyl formate catalyzed by trifluoromethanesulfonic acid (HOTf), and thermal transfer hydrogenation of isopropyl formate to methanol facilitated by the organometallic catalyst (H‐PNP)Ir(H) 3 (H‐PNP=HN(C 2 H 4 P i Pr 2 ) 2 ). The isopropanol solvent plays several crucial roles: activating formate ion as isopropyl formate, donating hydrogen for the reduction of formate ester to methanol via transfer hydrogenation, and lowering the barrier for transfer hydrogenation through hydrogen bonding interactions. In addition to reporting a method for room‐temperature reduction of challenging ester substrates, this work provides a prototype for pairing electrochemical and thermal organometallic reactions that will guide the design and development of multicatalyst cascades.
Fernández, Sergio [Department of Chemistry Univers↗