The amount of greenhouse gases in the atmosphere increases leading to adverse effects on environment and climate. Currently, the amount of carbon dioxide (CO2) emission exceeds the levels adopted in the Paris Agreement. To reduce the negative effects of greenhouse gases on the environment, more efficient utilization of fossil fuels as well as CO2 capture and utilization need to be addressed. Carbon capture, utilization, and storage is an emissions reduction technology that has attracted a great attention in recent years due to its high efficiency [1]. One of the carbon utilization methods is the catalytic hydrogenation of CO2 which converts CO2 into energy products, such as methanol. Methanol has a wide range of applications: it can be used to produce a variety of chemicals and it is also an alternative fuel. Today, methanol is mainly synthesized in an industrial process from fossil sources using Cu/ZnO/Al2O3 catalysts, that converts synthesis gas (H2/CO/CO2) into methanol under rather harsh conditions (at a pressure of 50–100 bar and a temperature of 200–300°C). In recent years the interest of direct hydrogenation to methanol has increased significantly. The catalytic hydrogenation of CO2 is green and environmentally-friendly method, especially if the cost-effective and safe conditions are applied [2].
Effective catalyst is a key parameter to CO2 hydrogenation performance. The most efficient catalysts for CO2 hydrogenation to methanol are multi-component catalytic systems consisting of intermixed metal and metal oxides nanoparticles.
The most effective/promising catalytic systems for CO2 hydrogenation to methanol reported in the literature are copper-zinc oxide based catalysts, indium oxide-palladium based catalysts [2] and iron-potassium based catalysts [3]. The complexity of the multi-component catalytic systems and challenges in elucidating the active sites are the main stumbling blocks in developing rational catalyst design strategies [2].
The main role of ZnO in Cu/Zn catalyst has been proposed to increase Cu dispersion, the exposure of more active Cu sites. ZnO prevents the agglomeration of Cu particles, thus leading to the large Cu surface area needed for methanol synthesis[4]. A large Cu surface area is important to obtain high activity, but there are differences in intrinsic activity between Cu/ZnO-based catalysts with different preparation history. Additionally, the fact that the migration of Zn species to Cu surface generates active sites, oxygen vacancies or Cu-Zn surface alloy may facilitate CO2 hydrogenation to methanol [5].
Recently, In2O3-based catalysts with oxygen vacancies have been reported to possess higher methanol selectivity than Cu/Zn based catalysts [6,7,8]. Over the last decade, indium-based catalysts have gained significant interest for CO2 hydrogenation to methanol, based on low activity for the reverse water–gas shift reaction, which results in high methanol selectivity over a wide temperature range. Ye et al. predicted that methanol formation is favorable on the defective In2O3(110) surface containing oxygen vacancies [9]. In Jiang et al. work it was shown that the addition of Pd enhanced the number of oxygen vacancies on the surface of In2O3 and facilitated the CO2 activation through interaction with In2O3 [6].
The synergistic effects of K (and Na) in the iron catalyst are responsible for the excellent higher alcohol synthesis [10,11]. As limited progress has been made in the hydrogenation of CO2 to alcohols with iron catalysts, in this study Fe/K on SBA-15 was used to determine the activity in reactions. Xi et al. reported that well-dispersed Fe2O3 and In2O3 phases with oxygen vacancies can be observed on Ce-ZrO2 support [3]. Potassium can greatly affect CO2 and H2 activation, thus regulating CO2 conversion and product selectivity [11].
The thermodynamics of CO2 conversion also limits methanol synthesis due to the competing reverse water-gas shift reaction. Furthermore the by-product water can have negative effects on the activity and stability of the catalyst during CO2 hydrogenation to methanol [2]. The effective solution for the stabilization of the active phase/nanoparticles and improvement of catalytic and mechanical properties is the dispersion of the active phase onto a suitable, high-surface area support, such as SBA-15 (Santa Barbara Amorphous mesoporous silica). It is well-known that supports can increase active metal surface area and stabilize the particles from sintering thus improving the catalytic and mechanical properties [5]. SBA-15 ordered mesoporous structure allows the formation of active nanophases with narrow particle size distribution, the wall thickness ensures the thermal stability of the support, and the size of pores allows the easy diffusion of the gaseous molecules [4].
It was found in recent years that metal-support interaction and creation of interfacial sites promotes metal dispersion, and changes concentration of acid sites, basic sites, and oxygen vacancies on the catalyst surface [5]. Mureddu et al. studied CO2 hydrogenation to methanol using Cu/Zn/Zr/SBA-15 catalyst and showed that strong metal–support interaction could prevent the restructuring effects of copper particles like particle agglomeration during the reaction [4]. The study revealed that better results can be achieved when a thin amorphous homogeneous layer of the active phase is formed, rather than larger particles located at the external surface, leading to improved activity and selectivity of the catalyst [4].
In this study SBA-15 was applied as carrier material providing large surface to disperse the active components and to ensure the thermal stability during the reaction. SBA-15 has abundant mesopores beneficial to mass transferwhich makes it a promising catalyst support for industrial applications [12]. Besides, our previous study reveals that methanol yield obtained using Cu/ZnO/SBA-15 catalyst is comparable to the yield obtained with the commercial catalyst [13]. Three different promising catalytic systems for the CO2 hydrogenation process were studied and the influence of metal – support interaction on the structure of catalysts and the activity of CO2 hydrogenation reaction was investigated using mesoporous SBA-15 as a support material. These catalytic systems are: copper-based catalyst (with Zn), indium-based catalyst (with Pd) and iron-based catalyst (with K). These catalytic systems were compared at the same reaction conditions to find the most effective one providing the maximal methanol yield and selectivity.
Direct comparison of these catalysts with identical metal content under identical reaction conditions (fixed-bed tubular micro-activity reactor, 20 bar and the temperature 250°C) is performed for the first time for the development of more effective catalysts, which can promote commercialization of the CO2 hydrogenation process.