In industrially relevant Cu/ZnO/Al2 O3 catalysts for methanol synthesis, the strong metal support interaction between Cu and ZnO is known to play a key role. Here we report a detailed chemical transmission electron microscopy study on the nanostructural consequences of the strong metal support interaction in an activated high-performance catalyst. For the first time, clear evidence for the formation of metastable "graphite-like" ZnO layers during reductive activation is provided. The description of this metastable layer might contribute to the understanding of synergistic effects between the components of the Cu/ZnO/Al2 O3 catalysts.

Methanol, an important chemical, fuel additive, and precursor for clean fuels, is produced by hydrogenation of carbon oxides over Cu‐based catalysts. Despite the technological maturity of this process, the understanding of this apparently simple reaction is still incomplete with regard to the reaction mechanism and the active sites. Regarding the latter, recent progress has shown that stepped and ZnOx‐decorated Cu surfaces are crucial for the performance of industrial catalysts. Herein, we integrate this insight with additional experiments into a full microkinetic description of methanol synthesis. In particular, we show how the presence or absence of the Zn promoter dramatically changes not only the activity, but unexpectedly the reaction mechanism itself. The Janus‐faced character of Cu with two different sites for methanol synthesis, Zn‐promoted and unpromoted, resolves the long‐standing controversy regarding the Cu/Zn synergy and adds methanol synthesis to the few major industrial catalytic processes that are described on an atomic level.

The design of solid catalysts for industrial processes remains a major challenge in synthetic materials chemistry. Based on the investigation of the industrial Cu/ZnO/Al₂O₃ catalyst, a modular concept is introduced that helps to develop novel methanol synthesis catalysts that operate in different feed gas mixtures. SA=surface area, SMSI=strong metal–support interaction

The promoting effect of Al, Ga, and Mg on the support in Cu/ZnO catalysts for methanol synthesis has been investigated. Different unpromoted and promoted ZnO supports were synthesized and impregnated with Cu metal in a subsequent step. All materials, supports, and calcined and activated catalysts were characterized by various methods, including contactless (microwave) conductivity measurements under different gas atmospheres. Small amounts of promoters were found to exhibit a significant influence on the properties of the oxide support, concerning textural as well as electronic properties. We found correlations between the conductivity of the ZnO support and the activity of the catalyst in the reverse water-gas shift reaction (rWGS) as well as in methanol synthesis. In rWGS the activation energy and reaction order in H₂ are decreased upon promotion of the ZnO support with the trivalent promoters Al³⁺ and Ga³⁺, indicating an electronic promotion. In methanol synthesis, results point to a structural promotion by Al³⁺ and Ga³⁺. A detrimental effect of Mg²⁺ doping was observed in both reactions. This effect is discussed in the context of the reducibility of ZnO under reaction conditions, which can be tuned by the promoter in different ways. The reducibility is seen as a critical property for the dynamic metal support interaction of the Cu/ZnO system

The complexity of heterogeneous catalysts means that a priori design of new catalytic materials is difficult, but the well-defined nature of single-atom–alloy catalysts has made it feasible to perform unambiguous theoretical modeling and precise surface science experiments. Herein we report the theory-led discovery of a rhodium-copper (RhCu) single-atom–alloy catalyst for propane dehydrogenation to propene. Although Rh is not generally considered for alkane dehydrogenation, first-principles calculations revealed that Rh atoms disperse in Cu and exhibit low carbon-hydrogen bond activation barriers. Surface science experiments confirmed these predictions, and together these results informed the design of a highly active, selective, and coke-resistant RhCu nanoparticle catalyst that enables low-temperature nonoxidative propane dehydrogenation.

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In 2 O 3 has recently emerged as a promising catalyst for methanol synthesis from CO 2 . In this work, we present the promotional effect of Pd on this catalyst and investigate structure−performance relationships using in situ X-ray spectroscopy, ex situ characterization, and microkinetic modeling. Catalysts were synthesized with varying In:Pd ratios (1:0, 2:1, 1:1, 1:2, 0:1) and tested for methanol synthesis from CO 2 /H 2 at 40 bar and 300 °C. In:Pd(2:1)/SiO 2 shows the highest activity (5.1 μmol MeOH/g InPd s) and selectivity toward methanol (61%). While all bimetallic catalysts had enhanced catalytic performance, characterization reveals methanol synthesis was maximized when the catalyst contained both In−Pd intermetallic compounds and an indium oxide phase. Experimental results and density functional theory suggest the active phase arises from a synergy between the indium oxide phase and a bimetallic In−Pd particle with a surface enrichment of indium. We show that the promotion observed in the In−Pd system is extendable to non precious metal containing binary systems, in particular In−Ni, which displayed similar composition−activity trends to the In−Pd system. Both palladium and nickel were found to form bimetallic catalysts with enhanced methanol activity and selectivity relative to that of indium oxide.

Different surface sites of solid catalysts are usually quantified by dedicated chemisorption techniques from the adsorption capacity of probe molecules, assuming they specifically react with unique sites. In case of methanol synthesis catalysts, the Cu surface area is one of the crucial parameters in catalyst design and was for over 25 years commonly determined using diluted N2O. To disentangle the influence of the catalyst components, different model catalysts were prepared and characterized using N2O, temperature programmed desorption of H2, and kinetic experiments. The presence of ZnO dramatically influences the N2O measurements. This effect can be explained by the presence of oxygen defect sites that are generated at the Cu-ZnO interface and can be used to easily quantify the intensity of Cu-Zn interaction. N2O in fact probes the Cu surface plus the oxygen vacancies, whereas the exposed Cu surface area can be accurately determined by H2.