MCM-41-supported tungstophosphoric acid as an acid function for dimethyl ether synthesis from CO2 hydrogenation

We mixed an MCM-41-supported tungstophosphoric acid (TPA) catalyst with a commercial CuO–ZnO–Al2O3 methanol synthesis catalyst (MSC) and optimized the mixing ratios/reaction conditions towards high performance in dimethyl ether (DME) synthesis by CO2 hydrogenation. First, a series of TPA/MCM-41 catalysts were synthesized at a TPA loading of 30, 40, 60, and 80 wt% and characterized by combining various techniques. The results of X-ray fluorescence spectroscopy confirmed the loading of stoichiometric TPA amounts in each TPA/MCM-41 catalyst, while the N2 adsorption-desorption measurements and the scanning transmission electron microscopy images were showing the decoration of MCM-41 pores with TPA clusters. X-ray diffraction and infrared spectroscopy results identified some structural distortions in TPA clusters especially at relatively low loadings and the results of temperature programmed desorption of ammonia measurements quantified the consequences of these changes in TPA structure on the acid properties. The optimized TPA loading in TPA/MCM-41 was 60 wt% with CuO–ZnO–Al2O3:TPA/MCM-41 = 4:1 at 40 000 mL CO2 gcat−1 h−1 and H2:CO2 = 3:1 at 250 °C and 45 bar. At these conditions, the rate was 1551.5 gDME kgcat−1 h−1, to the best of our knowledge, the highest rate for the direct DME synthesis from CO2 hydrogenation in a single-pass reactor. This performance was originated from the high density of acid sites in TPA/MCM-41 owing to exceptionally high surface area of MCM-41 offering a monolayer dispersion of TPA even at a TPA loading of 60 wt%. These results present a broad potential of TPA/MCM-41 as an acid function in the catalyst mixture for the single-pass DME synthesis from CO2 hydrogenation, especially if used together with an MSC specifically designed for CO2 hydrogenation.