From Organometallic Zinc and Copper Complexes to Highly Active Colloidal Catalysts for the Conversion of CO2 to Methanol
- Neil J. Brown ,
- Andrés García-Trenco ,
- Jonathan Weiner ,
- Edward R. White ,
- Matthew Allinson ,
- Yuxin Chen ,
- Peter P. Wells ,
- Emma K. Gibson ,
- Klaus Hellgardt ,
- Milo S. P. Shaffer , and
- Charlotte K. Williams
Abstract

A series of zinc oxide and copper(0) colloidal nanocatalysts, produced by a one-pot synthesis, are shown to catalyze the hydrogenation of carbon dioxide to methanol. The catalysts are produced by the reaction between diethyl zinc and bis(carboxylato/phosphinato)copper(II) precursors. The reaction leads to the formation of a precatalyst solution, characterized using various spectroscopic (NMR, UV–vis spectroscopy) and X-ray diffraction/absorption (powder XRD, EXAFS, XANES) techniques. The combined characterization methods indicate that the precatalyst solution contains copper(0) nanoparticles and a mixture of diethyl zinc and an ethyl zinc stearate cluster compound [Et4Zn5(stearate)6]. The catalysts are applied, at 523 K with a 50 bar total pressure of a 3:1 mixture of H2/CO2, in the solution phase, quasi-homogeneous, hydrogenation of carbon dioxide, and they show high activities (>55 mmol/gZnOCu/h of methanol). The postreaction catalyst solution is characterized using a range of spectroscopies, X-ray diffraction techniques, and transmission electron microscopy (TEM). These analyses show the formation of a mixture of zinc oxide nanoparticles, of size 2–7 nm and small copper nanoparticles. The catalyst composition can be easily adjusted, and the influence of the relative loadings of ZnO/Cu, the precursor complexes and the total catalyst concentration on the catalytic activity are all investigated. The optimum system, comprising a 55:45 loading of ZnO/Cu, shows equivalent activity to a commercial, activated methanol synthesis catalyst. These findings indicate that using diethyl zinc to reduce copper precursors in situ leads to catalysts with excellent activities for the production of methanol from carbon dioxide.
Introduction
Results and Discussion
Precatalyst Synthesis and Characterization
Scheme 1

Figure 1

Figure 1. Normalized XANES spectra of Cu(stearate)2 (black), CuO (red), Cu2O (green), the precatalyst solution (light blue), the post catalysis solution (blue), and Cu foil (yellow).
Figure 2

Figure 2. Normalized XANES spectra of diethyl zinc (black), the precatalyst solution (red), Zn(stearate)2 (green), the post catalysis solution (light blue), ZnO nanoparticles with stearate capping groups (dark blue), and Zn foil (yellow).
Carbon Dioxide Hydrogenation Catalysis
Catalyst Composition
entry | molar ratio precursors: ZnEt2/Cu(stearate)2 | expected weight ratio ZnO/Cu | methanol peak activity, mmol gZnOCu–1 h–1 | methanol activity after 12 h, mmol gZnOCu–1 h–1 |
---|---|---|---|---|
1 | 1:3 | 30:70 | 39 | 39 |
2 | 1:1 | 55:45 | 60 | 58 |
3 | 2:1 | 70:30 | 43 | 37 |
4 | 7:1 | 90:10 | 18 | 13 |
5 | ternary benchmarka (expected weight ratio of ZnO/Cu is 1:2) | 60 | 46 |
Alfa Aesar ternary methanol synthesis catalyst (product code: 45776), comprising (by weight) 24.7% ZnO, 63.5% CuO, 11.4% Al2O3, and MgO; see ESI for catalyst preactivation details and activity calculations. Error for each measurement is ±4.5% as determined by runs in triplicate. Figures S7 and S8 illustrate the stability of the catalysts showing activity vs time.
Reaction conditions: 523 K, 50 bar (3:1, H2/CO2), in a solution of squalane/toluene (90:10) at a fixed total volume of 100 mL, a total gas flow of 166 mL min–1, over 16 h. The total catalyst concentration (ZnO + Cu) was constant at 0.20 g dm–3.
Catalyst Concentration
Figure 3

Figure 3. Influence of the overall catalyst concentration (ZnO + Cu in gZnOCu/L) on the methanol synthesis activity (mmol gZnOCu–1 h–1). The error for each measurement is ±4.5% as determined by runs in triplicate. The complete data set is presented in Table S3, and plots for each concentration of activity vs time are presented in Figure S9.
Influence of the Organometallic Precursor Complexes
copper precursor | zinc precursor | methanol peak activity, mmol gZnOCu–1h–1 |
---|---|---|
Cu(stearate)2 | ZnEt2 | 42 |
Cu(stearate)2 | ZnPh2 | 32 |
Cu(laurate)2 | ZnEt2 | 43 |
Cu(octanoate)2 | ZnEt2 | 44 |
Cu(2-ethyl hexanoate)2 | ZnEt2 | 39 |
Cu(dioctyl phosphinate)2 | ZnEt2 | 50 |
Reaction conditions: 523 K, 50 bar (3:1, H2/CO2), in squalane/toluene (90:10) at a fixed total volume of 100 mL, a total gas flow of 166 mL min–1, over 16 h. The weight ratio of ZnO/Cu was fixed at 55:45, assuming complete conversion of the precursor complexes, and the overall catalyst concentration (ZnO + Cu) was fixed at 0.4 gZnOCu/L. Error for each measurement is 4.5% as determined by runs in triplicate. Figure S10 shows the activity vs time data for all catalysts.
Characterization
Figure 4

Figure 4. TEM images of the catalyst postreaction. (left) Low-resolution TEM image of discrete nanostructures. (right) High-resolution image of a nanoparticle cluster containing ZnO, Cu, and Cu2O; colors indicate the phase where unambiguously identified by lattice analysis. Catalysis conditions: 1:1 ZnEt2/Cu(stearate)2 at fixed concentration (0.2 g dm–3), 523 K, 50 bar (3:1, H2/CO2), in squalane at a fixed total volume of 100 mL, a total gas flow of 166 mLmin–1, over 16 h.
Figure 5

Figure 5. XRD of postcatalysis material for 55:45 ZnO/Cu (Table 1, entry 2). The spectrum is referenced to Cu (PDF no. 01-0851326 ICDD), Cu2O (PDF no. 034-1354 ICDD), CuO (PDF no. 045-0937 ICDD), and ZnO (PDF no. 36-1451, ICDD).
Conclusions
Supporting Information
The following file is available free of charge on the ACS Publications website at DOI: 10.1021/cs502038y.
Experimental details, 15 figures, 4 tables of results; additional references (PDF)
Terms & Conditions
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Acknowledgment
At Imperial College London, the EPSRC are acknowledged for funding (EP/H046380, EP/K035274/1), as well as the Energy Futures Lab, the Alan Howard Studentship (Y.W.), and the EPSRC Centre for Doctoral Training in Plastic Electronics (M.A.). Dr Peter Wells and Emma Gibson acknowledge EPSRC funding for the XAFS measurements (EP/I019693/1, EP/K014714/1) and Diamond Light Source for provision of beamtime (SP8071-8). The RCaH are also acknowledged for use of facilities and support of their staff.
References
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Abstract
Scheme 1
Scheme 1. Representation of the Formation of the Ligand-Stabilized Cu and ZnO Nanoparticles from Diethyl Zinc and Bis(stearate)copper(II) Precursor Using the One-Pot Synthesis MethodFigure 1
Figure 1. Normalized XANES spectra of Cu(stearate)2 (black), CuO (red), Cu2O (green), the precatalyst solution (light blue), the post catalysis solution (blue), and Cu foil (yellow).
Figure 2
Figure 2. Normalized XANES spectra of diethyl zinc (black), the precatalyst solution (red), Zn(stearate)2 (green), the post catalysis solution (light blue), ZnO nanoparticles with stearate capping groups (dark blue), and Zn foil (yellow).
Figure 3
Figure 3. Influence of the overall catalyst concentration (ZnO + Cu in gZnOCu/L) on the methanol synthesis activity (mmol gZnOCu–1 h–1). The error for each measurement is ±4.5% as determined by runs in triplicate. The complete data set is presented in Table S3, and plots for each concentration of activity vs time are presented in Figure S9.
Figure 4
Figure 4. TEM images of the catalyst postreaction. (left) Low-resolution TEM image of discrete nanostructures. (right) High-resolution image of a nanoparticle cluster containing ZnO, Cu, and Cu2O; colors indicate the phase where unambiguously identified by lattice analysis. Catalysis conditions: 1:1 ZnEt2/Cu(stearate)2 at fixed concentration (0.2 g dm–3), 523 K, 50 bar (3:1, H2/CO2), in squalane at a fixed total volume of 100 mL, a total gas flow of 166 mLmin–1, over 16 h.
Figure 5
Figure 5. XRD of postcatalysis material for 55:45 ZnO/Cu (Table 1, entry 2). The spectrum is referenced to Cu (PDF no. 01-0851326 ICDD), Cu2O (PDF no. 034-1354 ICDD), CuO (PDF no. 045-0937 ICDD), and ZnO (PDF no. 36-1451, ICDD).
References
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(John Wiley & Sons Ltd.)NIRE and RITE have jointly performed a national R&D project on MeOH synthesis from CO2 and H to contribute to CO2 mitigation. In the first step, many attempts were made at developing high-performance catalysts for MeOH synthesis. The roles of metal oxides contained in Cu/ZnO-based catalysts were classified into 2 categories: (1) Al2O3 or ZrO2 improves the dispersion of Cu particles in the catalyst; (2) Ga2O3 or Cr2O3 increases the activity per unit Cu surface area of the catalyst. The long-term stability of Cu/ZnO-based catalysts during MeOH synthesis from CO2 and H was improved by adding a small amt. of silica to the catalysts, and then calcining the catalysts at high temps. around 873 K. Silica added to the catalysts suppressed the crystn. of ZnO contained in the catalysts, which was probably caused by the action of water produced together with MeOH. Based on those 2 important findings, high-performance Cu/ZnO-based multicomponent catalysts (Cu/ZnO/ZrO2/Al2O3/SiO2 and Cu/ZnO/ZrO2/Al2O3/Ga2O3/SiO2) were developed. The catalysts developed were highly active and extremely stable in MeOH synthesis from CO2 and H. In the next step, a bench plant with a capacity of 50 kg day-1 of CH3OH, which was equipped with facilities for recycling unreacted gases and gaseous products, was successfully operated. The activity of the Cu/ZnO/ZrO2/Al2O3/SiO2 catalyst was 580 g h-1 of CH3OH per L of catalyst under the reaction conditions of 523 K, 5 MPa and SV = 10,000 h-1 in 1000 h on stream. The selectivity to MeOH synthesis was as high as 99.7%, and the purity of crude MeOH produced was 99.9 wt.-%, whereas the purity of crude MeOH produced from syngas in a present-day com. plant was reported as 99.6 wt.-%.(c) Wang, W.; Wang, S. P.; Ma, X. B.; Gong, J. L. Chem. Soc. Rev. 2011, 40, 3703– 3727 DOI: 10.1039/c1cs15008a(d) Wu, J. 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On the other hand, the catalysts both with and without silica were only slightly deactivated during methanol synthesis from a CO-rich feed contg. a higher concn. of CO, because only a small amt. of water was produced during the reaction, so no remarkable crystn. of Cu and ZnO contained in the catalyst occurred.(e) Li, C.; Yuan, X.; Fujimoto, K. Appl. Catal., A 2014, 469, 306– 311 DOI: 10.1016/j.apcata.2013.10.010[Crossref], [CAS], Google Scholar6ehttps://chemport.cas.org/services/resolver?origin=ACS&resolution=options&coi=1%3ACAS%3A528%3ADC%252BC3sXhvFWqur%252FI&md5=2c1b3b2c31564283200a2e8dc8109459Development of highly stable catalyst for methanol synthesis from carbon dioxideLi, Congming; Yuan, Xingdong; Fujimoto, KaoruApplied Catalysis, A: General (2014), 469 (), 306-311CODEN: ACAGE4; ISSN:0926-860X. (Elsevier B.V.)Zr-doped Cu-Zn-Zr-Al (CZZA) catalyst showed excellent performances for the methanol synthesis from carbon dioxide and hydrogen such as activity, selectivity and esp. stability under mild conditions (such as 230° and 3.0 MPa). The catalyst showed excellent tolerance against water vapor. It was found that added alumina promoted the dispersion of Cu whereas it suppressed the redn. of copper oxide. On the other hand, added Zr promoted the catalytic activity of methanol synthesis from CO2 and suppressed the inhibitive effect of water for the reaction as well as the catalyst deactivation. It was concluded that the methanol formation from CO2 proceeds through two routes: one is the direct hydrogenation of CO2 to methanol and another is the one which pass through the CO formation. The Zr-promoted catalyst gave methanol and CO at the selectivity ratio of 0.4 to 0.6, whereas the un-promoted catalyst gave only CO at the initial stage of the reaction. It was claimed that the doped Zr promote the in-situ redn. of oxidized Cu (which should be caused by the reaction with the co-product H2O) by H2 to increase the content of reduced Cu (active site) and thus the catalyst activity. The promoted reductivity of the Zr-contg. catalyst prevents the crystal growth of CuOx which cause the irreversible deactivation of catalyst.(f) Natesakhawat, S.; Lekse, J. W.; Baltrus, J. P.; Ohodnicki, P. R.; Howard, B. H.; Deng, X. Y.; Matranga, C. ACS Catal. 2012, 2, 1667– 1676 DOI: 10.1021/cs300008g[ACS Full Text
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6fhttps://chemport.cas.org/services/resolver?origin=ACS&resolution=options&coi=1%3ACAS%3A528%3ADC%252BC38XovFaqsLc%253D&md5=5a92b555dde13d88836fefaaf80c9b7eActive Sites and Structure-Activity Relationships of Copper-Based Catalysts for Carbon Dioxide Hydrogenation to MethanolNatesakhawat, Sittichai; Lekse, Jonathan W.; Baltrus, John P.; Ohodnicki, Paul R.; Howard, Bret H.; Deng, Xingyi; Matranga, ChristopherACS Catalysis (2012), 2 (8), 1667-1676CODEN: ACCACS; ISSN:2155-5435. (American Chemical Society)Active sites and structure-activity relations for MeOH synthesis from a stoichiometric mixt. of CO2 and H2 were studied for copptd. Cu-based catalysts with temp.-programmed redn. (TPR), XRD, TEM, XPS, and N2O decompn. Expts. in a reaction chamber attached to an XPS instrument show that metallic Cu exists on the surface of both reduced and spent catalysts and there is no evidence of monovalent Cu+ species. This finding confirms the active oxidn. state of Cu in MeOH synthesis catalysts because it is obsd. with 6 compns. possessing different metal oxide additives, Cu particle sizes, and varying degrees of ZnO crystallinity. Smaller Cu particles demonstrate larger turnover frequencies (TOF) for MeOH formation, confirming the structure sensitivity of this reaction. No correlation between TOF and lattice strain in Cu crystallites is obsd. suggesting this structural parameter is not responsible for the activity. Also, changes in the obsd. rates may be ascribed to relative distribution of different Cu facets as more open and low-index surfaces are present on the catalysts contg. small Cu particles and amorphous or well-dispersed ZnO. In general, the activity of these systems results from large Cu surface area, high Cu dispersion, and synergistic interactions between Cu and metal oxide support components, illustrating that these are key parameters for developing fundamental mechanistic insight into the performance of Cu-based MeOH synthesis catalysts.(g) Saito, M.; Fujitani, T.; Takeuchi, M.; Watanabe, T. Appl. Catal., A 1996, 138, 311– 318 DOI: 10.1016/0926-860X(95)00305-3[Crossref], [CAS], Google Scholar6ghttps://chemport.cas.org/services/resolver?origin=ACS&resolution=options&coi=1%3ACAS%3A528%3ADyaK28XjtFSmu7w%253D&md5=5ba633891aa34406bcfc4f3541f7ef36Development of copper/zinc oxide-based multicomponent catalysts for methanol synthesis from carbon dioxide and hydrogenSaito, M.; Fujitani, T.; Takeuchi, M.; Watanabe, T.Applied Catalysis, A: General (1996), 138 (2), 311-318CODEN: ACAGE4; ISSN:0926-860X. (Elsevier)The role of metal oxides such as Ga2O3, Al2O3, ZrO2 and Cr2O3 contained in Cu/ZnO-based ternary catalysts for methanol synthesis from CO2 and H2 was classified into two categories: to improve the Cu dispersion and to increase the specific activity. The Cu/ZnO-based multicomponent catalysts developed on the basis of the role of metal oxides were highly active and stable for a long period in a continuous methanol synthesis operation.(h) Fisher, I. A.; Bell, A. T. J. Catal. 1997, 172, 222– 237 DOI: 10.1006/jcat.1997.1870(i) Liu, X. M.; Lu, G. Q.; Yan, Z. F.; Beltramini, J. Ind. Eng. Chem. Res. 2003, 42, 6518– 6530 DOI: 10.1021/ie020979s[ACS Full Text], [CAS], Google Scholar
6ihttps://chemport.cas.org/services/resolver?origin=ACS&resolution=options&coi=1%3ACAS%3A528%3ADC%252BD3sXovVClsbc%253D&md5=cf007e18d3fca7a11f9756f028cc9e77Recent advances in catalysts for methanol synthesis via hydrogenation of CO and CO2Liu, Xin-Mei; Lu, G. Q.; Yan, Zi-Feng; Beltramini, JorgeIndustrial & Engineering Chemistry Research (2003), 42 (25), 6518-6530CODEN: IECRED; ISSN:0888-5885. (American Chemical Society)In this review, recent progress in catalyst innovation, optimization of the reaction conditions, reaction mechanism, and catalyst performance in methanol synthesis is comprehensively discussed. Since the start of last century, methanol synthesis has attracted great interests because of its importance in chem. industries and its potential as an environmentally friendly energy carrier. The catalyst for the methanol synthesis has been a key area of research in order to optimize the reaction process. In the literature, the nature of the active site and the effects of the promoter and support have been extensively investigated. Key issues of catalyst improvement are highlighted, and areas of priority in R&D are identified in the conclusions.(j) Fujita, S.; Usui, M.; Ito, H.; Takezawa, N. J. Catal. 1995, 157, 403– 413 DOI: 10.1006/jcat.1995.1306(k) Koeppel, R. A.; Baiker, A.; Wokaun, A. Appl. Catal., A 1992, 84, 77– 102 DOI: 10.1016/0926-860X(92)80340-I[Crossref], [CAS], Google Scholar6khttps://chemport.cas.org/services/resolver?origin=ACS&resolution=options&coi=1%3ACAS%3A528%3ADyaK38Xkt12itbc%253D&md5=993dc5079a26bad2ff2b3ab013d946aeCopper/zirconia catalysts for the synthesis of methanol from carbon dioxide. Influence of preparation variables on structural and catalytic properties of catalystsKoeppel, R. A.; Baiker, A.; Wokaun, A.Applied Catalysis, A: General (1992), 84 (1), 77-102CODEN: ACAGE4; ISSN:0926-860X.The effect of the prepn. method on the catalytic behavior of Cu/ZrO2 catalysts for the synthesis of MeOH from CO2 was investigated. Conventional pptn., ion exchange, and impregnation methods were used in addn. to the methods of deposition pptn. and co-pptn. in the presence of reducing agents. Pptn. reactions at const. pH were an interesting route for the prepn. of highly active and selective Cu/ZrO2 catalysts. Efficient catalysts consisted of microcryst. Cu particles stabilized through interaction with an amorphous ZrO2, resulting in a high interfacial area. Detn. of the Cu surface area by N2O titrn. revealed that the MeOH synthesis activity did not exhibit a general correlation with the sp. Cu surface area of the catalysts; such a correlation was found only within families of similarly prepd. catalysts. The influence of the residence time on the relative selectivity γ (MeOH/CO) was investigated at 473-533 K and 1.7 MPa. MeOH and desorbing CO were probably formed from CO2 via parallel reaction pathways. The activation energies were 47.9 ± 1.4 kJ mol-1 for the MeOH synthesis reaction and 93.2 ± 2.9 kJ mol-1 for CO formation.(l) Dutta, G.; Sokol, A. A.; Catlow, C. R. A.; Keal, T. W.; Sherwood, P. ChemPhysChem 2012, 13, 3453– 3456 DOI: 10.1002/cphc.201200517(m) Grabow, L. C.; Mavrikakis, M. ACS Catal. 2011, 1, 365– 384 DOI: 10.1021/cs200055d[ACS Full Text], [CAS], Google Scholar
6mhttps://chemport.cas.org/services/resolver?origin=ACS&resolution=options&coi=1%3ACAS%3A528%3ADC%252BC3MXislGlt7o%253D&md5=5638970e8c4da4dc8ed344f681ad4c3cMechanism of Methanol Synthesis on Cu through CO2 and CO HydrogenationGrabow, L. C.; Mavrikakis, M.ACS Catalysis (2011), 1 (4), 365-384CODEN: ACCACS; ISSN:2155-5435. (American Chemical Society)We present a comprehensive mean-field microkinetic model for the methanol synthesis and water-gas-shift (WGS) reactions that includes novel reaction intermediates, such as formic acid (HCOOH) and hydroxymethoxy (CH3O2) and allows for the formation of formic acid (HCOOH), formaldehyde (CH2O), and Me formate (HCOOCH3) as byproducts. All input model parameters were initially derived from periodic, self-consistent, GGA-PW91 d. functional theory calcns. on the Cu(111) surface and subsequently fitted to published exptl. methanol synthesis rate data, which were collected under realistic conditions on a com. Cu/ZnO/Al2O3 catalyst. We find that the WGS reaction follows the carboxyl (COOH)-mediated path and that both CO and CO2 hydrogenation pathways are active for methanol synthesis. Under typical industrial methanol synthesis conditions, CO2 hydrogenation is responsible for ∼2/3 of the methanol produced. The intermediates of the CO2 pathway for methanol synthesis include HCOO*, HCOOH*, CH3O2*, CH2O*, and CH3O*. The formation of formate (HCOO*) from CO2* and H* on Cu(111) does not involve an intermediate carbonate (CO3*) species, and hydrogenation of HCOO* leads to HCOOH* instead of dioxymethylene (H2CO2*). The effect of CO is not only promotional; CO* is also hydrogenated in significant amts. to HCO*, CH2O*, CH3O*, and CH3OH*. We considered two possibilities for CO promotion: (a) removal of OH* via COOH* to form CO2 and hydrogen (WGS), and (b) CO-assisted hydrogenation of various surface intermediates, with HCO* being the H-donor. Only the former mechanism contributes to methanol formation, but its effect is small compared with that of direct CO hydrogenation to methanol. Overall, methanol synthesis rates are limited by methoxy (CH3O*) formation at low CO2/(CO + CO2) ratios and by CH3O* hydrogenation in CO2-rich feeds. CH3O* hydrogenation is the common slow step for both the CO and the CO2 methanol synthesis routes; the relative contribution of each route is detd. by their resp. slow steps HCO* + H* → CH2O* + * and HCOOH* + H* → CH3O2* + * as well as by feed compn. and reaction conditions. An anal. of the fitted parameters for a com. Cu/ZnO/Al2O3 catalyst suggests that a more open Cu surface, for example, Cu(110), Cu(100), and Cu(211) partially covered by oxygen, may provide a better model for the active site of methanol synthesis, but our studies cannot exclude a synergistic effect with the ZnO support. - 7Behrens, M.; Schloegl, R. Z. Anorg. Allg. Chem. 2013, 639, 2683– 2695 DOI: 10.1002/zaac.201300356
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