Catalysts 14 00061 v2
Catalysts 14 00061 v2
Article
Kinetic Modeling of the Direct Dimethyl Ether (DME) Synthesis
over Hybrid Multi-Site Catalysts
Antonio D’Ambrosio 1 , Alice Bertino 1 , Serena Todaro 2 , Mariarita Santoro 2 , Catia Cannilla 2 ,
Francesco Frusteri 2 , Giuseppe Bonura 2, * , Leone Mazzeo 1, * and Vincenzo Piemonte 1
1 Unit of Chemical-Physics Fundamentals in Chemical Engineering, Faculty of Science and Technology for
Sustainable Development and One Health, University Campus Bio-Medico of Rome, Via Alvaro del Portillo
21, 00128 Rome, Italy; [email protected] (A.D.); [email protected] (A.B.);
[email protected] (V.P.)
2 CNR-ITAE, Istituto di Tecnologie Avanzate per l’Energia “Nicola Giordano”, Via S. Lucia sopra Contesse 5,
98126 Messina, Italy; [email protected] (S.T.); [email protected] (M.S.); [email protected] (C.C.);
[email protected] (F.F.)
* Correspondence: [email protected] (G.B.); [email protected] (L.M.)
Abstract: This paper deals with the proposition of a kinetic model for the direct synthesis of DME via
CO2 hydrogenation in view of the necessary optimization of the catalytic system, reactor design, and
process strategy. Despite the fact that DME synthesis is typically treated as a mere combination of
two separated catalytic steps (i.e., methanol synthesis and methanol dehydration), the model analysis
is now proposed by taking into account the improvements related to the process running over a
hybrid catalyst in a rational integration of the two catalytic steps, with boundary conditions properly
assumed from the thermodynamics of direct DME synthesis. Specifically, the CO2 activation step
at the metal–oxide interface in the presence of ZrO2 has been described for the first time through
the introduction of an ad hoc mechanism based on solid assumptions from inherent studies in the
literature. The kinetic modeling was investigated in a tubular fixed-bed reactor operating from 200
to 260 ◦ C between 1 and 50 bar as a function of a gas hourly space velocity ranging from 2500 to
Citation: D’Ambrosio, A.; Bertino, A.;
60,000 NL/kgcat /h, in a stoichiometric CO2 /H2 feed mixture of 1:3 v/v. A well-detailed elementary
Todaro, S.; Santoro, M.; Cannilla, C.;
mechanism was used to predict the CO2 conversion rate and identify the key reaction pathways,
Frusteri, F.; Bonura, G.; Mazzeo, L.;
starting with the analysis of the implicated reactions and corresponding kinetic mechanisms and
Piemonte, V. Kinetic Modeling of the
Direct Dimethyl Ether (DME)
expressions, and finally estimating the main parameters based on an appropriate modeling of
Synthesis over Hybrid Multi-Site test conditions.
Catalysts. Catalysts 2024, 14, 61.
https://doi.org/10.3390/ Keywords: dimethyl ether; CO2 valorization; hydrogen conversion; hybrid catalysts; kinetic modeling;
catal14010061 fixed-bed reactor
However, the real appeal of this compound lies in its potential synthesis reaction
(Equation (1)), since recent research frontiers aim to employ CO2 and H2 as reactants [10,11]:
2CO2 + 6H2 ⇌ CH3 OCH3 + 3H2 O ∆H0 = −122 kJ/mol (1)
Using captured CO2 and green H2 produced via electrolysis, it is, therefore, possible
to configure DME as an e-fuel directly produced in a sustainable CCUS (carbon capture
utilization and storage) technology chain [12,13]. Furthermore, even though this aspect
is still under investigation, DME can be steam-reformed, making it a potential circular
hydrogen carrier [14]. For this to be feasible, however, it is necessary to make the synthesis
process more efficient and cost-effective. Currently, DME is primarily produced from
synthesis gas through an indirect method involving the use of two reactors in a typical
cascade process [15]. In the first reactor, methanol synthesis is performed on a ternary
metal–oxide catalyst (typically CZA, which is CuO-ZnO-Al2 O3 ), while the second reactor
allows the dehydration of the previously formed methanol over an acidic catalytic bed
(usually γ-Al2 O3 or a zeolite sample, such as HZSM-5) [10,16–18]. The real challenge is to
achieve effective process intensification by implementing direct synthesis in a single reactor,
using CO2 as a feedstock, thus allowing the valorization of a thermodynamically “inert”
compound, as well as reducing operating and investment costs [19,20]. Certainly, the
main concern is the development of a multi-functional catalyst wherein a long-range inter-
dispersion among metallic, oxide, and acidic functionalities must be achieved to catalyze
both the methanol synthesis and DME production steps [14,21]. Indeed, by hybridizing
the catalytic system for direct DME synthesis, the thermodynamic limitations behind
the CO2 hydrogenation process stopping the formation of methanol can be overcome,
even if unavoidable water generation is a key contributor to possible catalyst deactivation
mechanisms, such as copper sintering or migration of weak acidic sites [22–24].
Given the potential and critical issues associated with the direct synthesis of dimethyl
ether from hydrogen and carbon dioxide, this work aims at investigating the performance,
on a laboratory scale, of a previously optimized hybrid CuO-ZnO-ZrO2 /HZSM-5 catalytic
system [22] by developing a kinetic model suitable to predict its experimental behavior in a
wide set of operating conditions. Particularly, the exchange of alumina (a key component in
the benchmark catalyst for methanol synthesis) with zirconia to enhance CO2 adsorption,
water tolerance, and heat management [25] has been limitedly studied from a microkinetic
point of view [26,27]. Therefore, this knowledge gap inspired an ad hoc 18-parameter model
based on three cascade steps (i.e., CO2 hydrogenation to methanol, methanol dehydration,
and rWGS) occurring in one pot over a hybrid catalytic system. This model aims at
explaining a dual-site mechanism on two different adsorption sites by claiming that the CO2
activation step at the metal–oxide interface is crucial prior to undergoing hydrogenation to
methanol. Acidic functionality is then necessary for the subsequent dehydration into DME.
As a consequence, the corresponding kinetic expressions were derived and appropriately
integrated with all the reactions involved in the process. This resulted in a comprehensive
model for the direct synthesis of DME, which led to the assessment of new mechanistic
clues about the activity–selectivity pattern of the catalyst under investigation as necessary
for further optimization of its design.
2. Experimental Section
This section is divided into two parts: synthesis of the hybrid catalyst and validation
of its performance through a fixed-bed reactor.
constant mode, to a vigorously stirred ethanolic solution containing oxalic acid (20 wt.%
in excess with respect to the stoichiometric amount necessary to precipitate the metal
precursors) and the finely dispersed HZSM-5 zeolite (Si/Al = 23 mol/mol) in a weight
ratio of 1:1 with respect to the final oxide composition of the catalyst. The precipitate was
stirred for 3 h, then aged overnight. The catalyst was filtered, dried at 90 ◦ C for 16 h, and
then calcined at 350 ◦ C for 4 h.
out
FDME
YDME = in
(3)
FCO 2
out
FDME
SDME = out out + F out
(4)
FDME + FMeth CO
out
FCO
SCO = out + F out + F out
(5)
FDME Meth CO
In Equations (2)–(5), Fiin and Fiout are the inlet and the outlet molar flow rates of
component i, respectively. Conversion and selectivity data were determined by both
internal standard and mass-balance methods, averaging three independent measurements
with an accuracy of ±3%.
3. Kinetic Modeling
The development of a kinetic model for direct CO2 -to-DME hydrogenation was carried
out in two steps:
1. Analysis of the implicated reactions and corresponding kinetic mechanisms and
expressions.
2. Estimation of missing parameters based on appropriate modeling of test conditions.
CO hydrogenation to DME is not considered since it can be obtained from the linear
combination of Equations (7) and (8), and is also significantly inhibited by the production
of formate, an intermediate that strongly binds copper active sites [32,33]. For each reaction,
the kinetic mechanism was reconstructed, identifying the rate-determining step (r.d.s.) [34].
As for methanol dehydration and rWGS, previously elaborated mechanisms from the
literature were adopted due to the conventional nature of the employed catalyst (HZSM-
5 and Cu-based systems, respectively) [35,36], while an ad hoc kinetic mechanism was
developed for CO2 hydrogenation, based on experimental evidence [37]. Finally, the
kinetic expression of the reaction rate was derived for each mechanism, assuming that all
elementary steps, except the r.d.s., were at thermodynamic equilibrium and adopting the
Langmuir–Hinshelwood–Hougen–Watson (LHHW) model [38]. In light of the moderate
operating conditions in terms of pressure and temperature, the gas phase was assumed
to be ideal, with a unitary fugacity coefficient (see Appendix A). A “dual site” model is
thus proposed, distinguishing two different active
sites on the hybrid catalyst [37,39]: the
∼
metal–oxide site (σ ) and the zeolitic acid site σ .
According to this route, one molecule of CO2 activated on a partially oxidized Cu(δ+)
site (9b) initially reacts with one atom of hydrogen previously activated on a metallic site
(9a), giving rise to a formate species (9c). The latter then reacts with other activated hydro-
gen atoms in a cascade sequence to produce dioxomethylene species (9d), formaldehyde
(9f), methoxy species (9f), and finally methanol (9i) in the last hydrogenation step.
H2 O + σ ⇌ H2 Oσ (11a)
particular, it should be noted that the adsorption of CO2 can even occur on bare oxides,
while the dissociation of H2 more efficiently takes place on metallic surfaces; however, a
possible activation over metal–oxide surfaces is not ruled out [40,41]. Therefore, this model
proposes the use of a unique metal–oxide site for both CO2 and H2 adsorption, assumed to
be the active center in CO2 hydrogenation to methanol and in rWGS reaction. Accordingly,
the rate equations proposed for this dual-site LHHW mechanism are summarized in
Equations (12)–(14):
1/2 PCH3 OH PH2 O
KcinCHM PCO2 PH2 − 5/2
KeqCHM PH
2
rCHM = p 2 (12)
1 + KCO PCO + KCO2 PCO2 + KCH3 OH PCH3 OH + K H2 O PH2 O + K H2 PH2
Gi (z = 0) = yin in
i GTOT (16)
In Equation (15), L represents the reactor length, r j is the rate of reaction j
(Equations (12)–(14)) and νij is the stoichiometric coefficient of compound i in reaction
j. In Equation (16), yin in
i is the inlet molar fraction of component i and GTOT is the total inlet
gas hourly space velocity. The balances are, indeed, expressed in terms of space velocity
of each compound, noted as Gi , which is here defined as the ratio between the molar flow
rate Fi and the total weight of the catalyst Mc (Equation (17)):
Fi
Gi = (17)
Mc
dependence and were reparametrized (see Equations (18) and (19)) to improve numerical
stability in fitting and decrease numerical correlation between estimated parameters [49,50]:
Tri f
Kcin j = k cin j exp − E A j −1 (18)
TR
Tri f
Ki = k i exp −∆Hadsi −1 (19)
TR
E∗A j
EAj = (20)
Tri f R
∗
∆Hads
∆Hadsi = i
(21)
Tri f R
Both pre-exponential factor and energetic terms were estimated by minimizing the
weighted sum ϕ of square relative errors between experimental molar fractions Yik and
model outputs Ŷik (Equation (22)) [52]:
!2
Np
Yik − Ŷik
ϕ= ∑ ∑ wi · Yik
(22)
k =1 i
Figure 1. Influence of temperature and pressure on CO2 conversion (a), DME yield (b), DME
Figure 1. Influence of temperature and pressure on CO2 conversion (a), DME yield (b), DME selec-
selectivity (c), CO
tivity (c), and andselectivity
CO selectivity (d), evaluated
(d), evaluated withwith an inlet
an inlet flow flow rate
rate of of 8800
8800 NL/(kg
NL/(kg cat h). cat
h).
On the whole, the results are consistent with the thermodynamic analysis of the sys-
On the whole, the results are consistent with the thermodynamic analysis of the sys-
tem [10,31,53]. High pressure is preferable during the DME synthesis reaction as it leads
tem [10,31,53]. High pressure is preferable during the DME synthesis reaction as it leads
to a decrease in the number of moles. On the other hand, an increase in temperature
to a decrease in the number of moles. On the other hand, an increase in temperature favors
favors CO2 conversion due to its positive kinetic effect on the reaction rate. However,
CO2 conversion due to its positive kinetic effect on the reaction rate. However, it simulta-
it simultaneously decreases DME selectivity while raising CO selectivity, in agreement
neously decreases DME selectivity while raising CO selectivity, in agreement with the
with the thermal tonality both of DME synthesis (exo-) and rWGS (endo-). Although a
thermal tonality both of DME synthesis (exo-) and rWGS (endo-). Although a plateau in
plateau in DME and CO selectivity was observed above 240 ◦ C for runs performed both
DME and CO selectivity was observed above 240 °C for runs performed both at 30 and 50
at 30 and 50 bar, a further increase in reaction temperature unfortunately triggers severe
bar, a further
catalyst increase Indeed,
deactivation. in reaction temperature
a larger amountunfortunately
of water formed triggers
abovesevere
thosecatalyst de-
conditions
activation. Indeed, a larger amount of water formed above those conditions
dramatically determines morphological changes in the catalyst surface, prompting a drastic dramatically
determines
activity decaymorphological
(ca. 20% withchanges
respect tointhe
theinitial
catalyst surface,
activity) in aprompting
few hours ofa drastic
time onactivity
stream
decay (ca. 20% with respect to the initial activity) in a few hours of time on
(<20 h) [17,22]. Therefore, these findings not only indicate that the process performance stream (<20 h)
[17,22].
is Therefore,
governed these[15],
by kinetics findings not suggest
but also only indicate that the
an optimal process performance
compromise between CO is gov-
2 con-
erned by kinetics [15], but also suggest an optimal compromise between
version and DME selectivity at moderately high pressures (30 or 50 bar) and intermediateCO 2 conversion
Table 2. Estimated parameters for the proposed kinetic model and corresponding confidence interval
with a level of significance equal to 0.05.
The model provided satisfactory results in calculating the molar fractions of CO2 and
H2 , with an average relative error of 1.5%, which is comparable to the chromatographic
tolerance. Moreover, despite an average relative error of around 40%, the model suitably
also works in the prediction of the molar fractions of DME and CO, considering a minimal
absolute error in the order of 0.001. Only in the case of the other compounds (i.e., CH3 OH
or H2 O), the large number of estimated parameters (which is equal to 18) cannot determine
a lower discrepancy in the model fitting, so that a relatively small error in absolute terms
has a strong impact in relative terms.
In any case, even the highest deviation recorded for large methanol concentrations
(see Figure 2f) cannot be considered a relevant issue since the simulation model targets
the one-pot synthesis of DME and the methanol selectivity always attains relatively low
values (below 10%) under all the experimental conditions applied. More importantly, these
results evidently confirmed previous mechanistic clues on the catalytic behavior, with
positive effects on the process performance played by an increase in space velocity or
reaction pressure. However, further optimization of the hybrid catalyst design is required
for higher CO2 conversion rates below 220 ◦ C, where CO formation can be minimized.
Finally, not only the catalyst formulation but also the reactor configuration should be
Catalysts 2024, 14, x FOR PEER REVIEW 10 of 15
properly designed in order to tackle the issues related to water formed during the process,
dramatically affecting catalyst lifetime and process performance.
Figure 2. Cont.
Catalysts 2024, 14, 61 10 of 15
Figure
Figure 2. 2. Comparisonofofexperimental
Comparison experimental data
data (along
(alongthe
thex-axis) and
x-axis) andmodel results
model (along
results the y-axis)
(along for
the y-axis)
the mole fractions of CO
for the mole fractions of CO (a), H (b), DME (c), CO (d), H O (e), and methanol (f).
2 2 (a), 2H2 (b), DME (c), CO (d),2 H2O (e), and methanol (f).
5. Conclusions
A comprehensive 18-parameter kinetic model was developed for the direct hydrogena-
tion of CO2 to DME over a hybrid CuO-ZnO-ZrO2 /HZSM-5 catalytic system, previously
optimized in terms of composition, preparation method, and tuning of physico-chemical
properties. The model was validated in a wide set of reaction pressure, temperature, and
space velocity, clearly showing a reliable fitting of the estimated parameters, within an
average absolute error of 10−4 , both for the process reactants (i.e., CO2 , H2 ) and the target
product (i.e., DME), with the correspondent experimental values. The accuracy of the
model confirmed previous findings on the multi-site nature of the studied process, mainly
following the formate route, according to which carbon dioxide is activated at the metal–
oxide interface, then reacting with activated hydrogen migrating via spillover from metallic
copper sites. Afterwards, formate species are hydrogenated to methanol, which, in line with
an associative pathway, quickly turns into DME by condensation with another adsorbed
methanol molecule over the acidic sites of the zeolite. Overall, the adequate accuracy in the
prediction of the compositions related to the most abundant process compounds makes
the model promising for further implementation within a plant simulation, prompting an
Catalysts 2024, 14, 61 11 of 15
estimation of the costs associated with the direct DME synthesis process for an assessment
of its actual convenience on an industrial scale.
Author Contributions: Conceptualization, L.M., V.P. and F.F.; methodology, A.D., A.B. and L.M.;
software, A.D.; validation, A.D., A.B. and L.M.; formal analysis, A.D.; investigation, S.T., M.S. and
C.C.; resources, V.P. and G.B.; data curation, A.D.; writing—original draft preparation, A.D.; writing—
review and editing, A.D., A.B., L.M. and G.B.; supervision, G.B.; project administration, V.P.; funding
acquisition, G.B. All authors have read and agreed to the published version of the manuscript.
Funding: This research was financially supported by the European Union’s Horizon Europe research
and innovation program under grant agreement No. 101058540 (project PLASTICE).
Data Availability Statement: Data is contained within the article.
Acknowledgments: The authors also acknowledge Francesco Arena from the University of Messina,
Dip. Ingegneria, for the fruitful discussion about the boundary conditions of the kinetic model.
Conflicts of Interest: The authors declare no conflicts of interest.
In Equation (A1), yi denotes the molar fraction of compound i, while νm was computed
through the two-term virial equation of state (Equations (A2)) [55]:
Bm P
lnνm = (A2)
RT
In Equation (A2), P is the reaction pressure, T is the reaction temperature, and R is
the universal gas constant, whereas Bm denotes the second virial coefficient of the mixture,
which can be evaluated from binary coefficients Bij , as in Equation (A3):
7 7
Bm = ∑ ∑ yi y j Bij (A3)
i =1 j =1
Bij PCij T
= f (0) TRij + ωij f (1) TRij + f (2) TRij where TRij = (A4)
RTCij TCij
0.33 0.1385 0.0121 0.000607
f (0) TRij = 0.1445 − − − − (A5)
TRij TR2 TR3 TR8
ij ij ij
0.331 0.423 0.008
f (1) TRij = 0.0637 + 2 − 3 − 8 (A6)
TR TR TR
ij ij ij
aij bij
f (2) TRij = 6 − 8 (A7)
TR TR
ij ij
The terms f (0) , f (1) and f (2) represent the impact of intermolecular forces from spher-
ically symmetrical molecules, molecular orientation, and polarity, respectively. All the
Catalysts 2024, 14, 61 12 of 15
critical binary properties figuring in Equation (A4) are evaluated from the critical properties
(i.e., critical volume vC , critical temperature TC , and critical pressure PC ) and acentric factors
ω of pure components, as detailed in Equations (A8)–(A11) [57]:
1 1
3
3 3
vC + vC
i j
vCij = (A8)
8
q
TCij = TCi TCj (A9)
!
TCij PCi vCi PCj vCj
PCij = + (A10)
2vCij TCi TCj
ωi + ω j
ωij = (A11)
2
The aij and bij parameters in Equation (A7) measure polar interactions and are exclu-
sively non-zero for pairs of polar fluids. In such instances, they are assumed to be equal to the
average of the constants of pure components, as outlined in Equations (A12) and (A13) [55]:
ai + a j
aij = (A12)
2
bi + b j
bij = (A13)
2
In the specific case analyzed, the only polar fluids considered are water, methanol,
and dimethyl ether, whose parameters are listed in Table A1.
Table A1. a and b parameters for Equations (A12) and (A13) [55].
Compound a b
Water 0.0279 0.0229
Methanol 0.0878 0.0560
Dimethyl Ether −0.01513 0
Based on the above, in Table A2 are reported the fugacity coefficients as determined
under the most severe operating conditions (i.e., 200 ◦ C and 50 bar). The analysis indicates
that, in nearly all cases, these coefficients are very close to one, resulting in a negligible
correction to the partial pressure. Moreover, although nitrogen shows a measurable de-
viation from its ideal behavior, its fugacity is not present in the kinetic expressions of the
reaction rates (Equations (12)–(14)). Therefore, it was preferred to maintain the validity of
the ideal gas hypothesis against a relatively modest enhancement in the model accuracy
only achievable behind an increased computational complexity.
Table A2. Fugacity coefficients for different compositions, evaluated at 200 ◦ C and 50 bar.
yCO2 yH2 yDME yCO yMeth yH2 O yN2 ϕCO2 ϕH2 ϕDME ϕCO ϕMeth ϕH2 O ϕN2
0.23 0.69 - - - - 0.08 0.97 1.03 - - - - 0.24
0.21 0.67 - 0.02 - 0.02 0.08 0.97 1.03 - 1.02 - 0.96 0.24
0.21 0.67 0.005 0.007 0.002 0.016 0.09 0.97 1.03 0.98 1.01 0.95 0.96 0.24
0.20 0.63 0.01 0.03 0.01 0.03 0.09 0.97 1.03 0.97 1.01 0.94 0.95 0.24
0.19 0.62 0.02 0.02 0.01 0.06 0.08 0.96 1.04 0.97 1.02 0.93 0.94 0.24
Catalysts 2024, 14, 61 13 of 15
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