Carbon dioxide is a desired feedstock for platform molecules, such as carbon monoxide or higher hydrocarbons, from which we will be able to make many different useful, value-added chemicals. Its catalytic hydrogenation over abundant metals requires the amalgamation of theoretical knowledge with materials design. Here we leverage a theoretical understanding of structure sensitivity, along with a library of different supports, to tune the selectivity of methanation in the Power-to-Gas concept over nickel. For example, we show that carbon dioxide hydrogenation over nickel can and does form propane, and that activity and selectivity can be tuned by supporting different nickel particle sizes on various oxides. This theoretical and experimental toolbox is not only useful for the highly selective production of methane, but also provides new insights for carbon dioxide activation and subsequent carbon–carbon coupling towards value-added products thereby reducing the deleterious effects of this environmentally harmful molecule.

Transforming carbon dioxide into valuable chemicals and fuels, is a promising tool for environmental and industrial purposes. Here, we present catalysts comprising of cobalt (oxide) nanoparticles stabilized on various support oxides for hydrocarbon production from carbon dioxide. We demonstrate that the activity and selectivity can be tuned by selection of the support oxide and cobalt oxidation state. Modulated excitation (ME) diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) reveals that cobalt oxide catalysts follows the hydrogen-assisted pathway, whereas metallic cobalt catalysts mainly follows the direct dissociation pathway. Contrary to the commonly considered metallic active phase of cobalt-based catalysts, cobalt oxide on titania support is the most active catalyst in this study and produces 11% C2+ hydrocarbons. The C2+ selectivity increases to 39% (yielding 104 mmol h−1 gcat−1 C2+ hydrocarbons) upon co-feeding CO and CO2 at a ratio of 1:2 at 250 °C and 20 bar, thus outperforming the majority of typical cobalt-based catalysts.

Nickel metal nanoparticles are intensively researched for the catalytic conversion of carbon dioxide. They are commercially explored in the so-called power-to-methane application in which renewably resourced H2 reacts with CO2 to produce CH4, which is better known as the Sabatier reaction. Previous work has shown that this reaction is structure-sensitive. For instance, Ni/SiO2 catalysts reveal a maximum performance when nickel metal nanoparticles of ∼2–3 nm are used. Particularly important to a better understanding of the structure sensitivity of the Sabatier reaction over nickel-based catalysts is to understand all relevant elementary reaction steps over various nickel metal facets because this will tell as to which type of nickel facets and which elementary reaction steps are crucial for designing an efficient nickel-based methanation catalyst. In this work, we have determined by density functional theory (DFT) calculations and micro-kinetics modeling (MKM) simulations that the two terrace facets Ni(111) and Ni(100) and the stepped facet Ni(211) barely show any activity in CO2 methanation. The stepped facet Ni(110) turned out to be the most effective in CO2 methanation. Herein, it was found that the dominant kinetic route corresponds to a combination of the carbide and formate reaction pathways. It was found that the dissociation of H2CO* toward CH2* and O* is the most critical elementary reaction step on this Ni(110) facet. The calculated activity of a range of Wulff-constructed nickel metal nanoparticles, accounting for varying ratios of the different facets and undercoordinated atoms exposed, reveals the same trend of activity-versus-nanoparticle size, as was observed in previous experimental work from our research group, thereby providing an explanation for the structure-sensitive nature of the Sabatier reaction.