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Journal of CO₂ Utilization 32 (2019) 299–320

Contents lists available at ScienceDirect

Journal of CO2 Utilization


journal homepage: www.elsevier.com/locate/jcou

Review article

Perspective of dimethyl ether as fuel: Part I. Catalysis T


Ujjal Mondal, Ganapati D. Yadav

Department of Chemical Engineering, Institute of Chemical Technology, Nathalal Parekh Marg, Mumbai 400019, India

ARTICLE INFO ABSTRACT

Keywords: Dimethyl ether (DME) is heralded as the cleanest high-efficiency compression ignition fuel as a substitute for
Dimethyl ether (DME) diesel. DME's autoignition property and high octane number are favorable to use it as a substitute for diesel and
Syngas also LPG as a cooking fuel. DME can be synthesized from different routes such as coal, petroleum and biomass
CO2 including various greenhouse gases. Huge amounts of greenhouse gases (CO and CO2) are generated in coal or
Catalysis
petroleum operated thermal power plants and released in the atmosphere. Roughly 5–10% of total CO2 emission
Multi-metal catalysts
can be utilized for fuel and chemical production. CO2 capture and sequestering (CCS) plants only can be sus-
Fuel
Methanol tainable if supported by DME synthesis plant with a capacity of 3000–7500 TPD. DME can be produced from CO2
LPG using innovative catalysts, reactors and separators. Part I of this review is a representation of the innovative
CCS strategies which have been reported for the production of DME from different sources of raw materials, catalysts
Multi-phase reactors and influence of operational parameters on DME selectivity and yield. The critical gaps are identified and fur-
ther, research potentials are given in Part I. However, the industrial processes using a variety of reactor con-
figurations affect the overall capex and opex. The production of syngas, irrespective of the source, is the first step
in DME synthesis, which is then followed by conversion into DME using a battery of reactors and separators. A
critical analysis is presented and future scope is outlined in Part II.

1. Introduction alternatives, which have to be renewable and can be utilized in the in-
dustry without any major modification of the present infrastructure.
The UN Sustainable Development Goals for the world are indeed The three main characteristics of the energy supply chain which are
challenging and consequently finding reliable and economic resources essential for any type of energy infrastructure are the energy genera-
for energy will depend on the science and technology of converting tion, storage, and distribution and utilization [1]. Dimethyl ether
different waste products, waste energy and finding new resources. The (DME), or methoxymethane (IUPAC name) is the cleanest high-effi-
energy and environment problems are intertwined due to the fast de- ciency compression ignition fuel because of its autoignition property. It
pletion of natural resources and a huge build-up of greenhouse gases in is the simplest and safer aliphatic ether which is known to be far from
the atmosphere. Among different natural energy resources such as crude being toxic, carcinogenic, teratogenic, mutagenic compound and cor-
oil, coal, and natural/shale gases, crude oil is depleting very fast. The rosive. DME is an environmentally benign compound and upon release
transportation industry happens to be the primary cause of oil delpetion; it is photochemically degraded to CO2 and H2O a within few hours and
it consumes roughly 57% of total petroleum production. According to will not deplete the ozone layer or build up greenhouse gas [2]. Apart
some estimates (e.g., BP Energy), the crude oil supply will run out by from its use as fuel, DME is a higher grade propellant used for the
∼2055. Electric cars are introduced to restrain air pollution but the synthesis of many safer healthcare products vis-à-vis conventional
problem is still unsolved as most of the power plants are operating on petroleum-based routes. It is estimated that the total worth of the DME
coal and petroleum as the primary non-renewable energy sources. The industry will be approximately $ 9.7 billion by 2020 [1] which is di-
power plants are releasing a huge amount of greenhouse gases (COX, vided in mainly four categories mainly, (1) LPG blend, (2) diesel re-
SOX, NOX) into the environment. The lifetime of the natural resources has placement as a transportation fuel, (3) gas turbine fuel in power gen-
been reduced dramatically and their overuse will lead to energy supply eration sector, and (4) chemical precursor for different chemicals (for
shortages for future generations. These problems have propelled to re- instance, olefins and petrochemicals). China is the largest DME pro-
search and innovation in the development of new clean energy ducer utilizing 90% of total DME production for LPG blending. Other

DOI of original article: https://doi.org/10.1016/j.jcou.2019.02.006



Corresponding author.
E-mail addresses: gdyadav@yahoo.com, gd.yadav@ictmumbai.edu.in (G.D. Yadav).

https://doi.org/10.1016/j.jcou.2019.02.003
Received 24 January 2019; Accepted 7 February 2019
Available online 23 April 2019
2212-9820/ © 2019 Elsevier Ltd. All rights reserved.
U. Mondal and G.D. Yadav Journal of CO₂ Utilization 32 (2019) 299–320

DME with the addition of a very little methanol and water is a good
alternative to diesel for transportation sector and small-scale power
generation industry. Based on Lower Heating Value (LHV), 1.2 L of
DME is equivalent to 1 L of diesel. Because of higher octane number
(55–60) with a low boiling point (−25 °C), it requires little modifica-
tion of existing diesel engine to utilize DME as a fuel. Inside diesel
engine, DME burns without sooting which is similar to an oxygenated
fuel additive and it also enhances favorable air/fuel mixture inside the
engine.
DME has a very low vapor pressure and is chemically and physically
stable. Thus, DME can be used as an aerosol propellant and can replace
chlorofluorocarbon (CFC), Freon and R-134, which are the main con-
tributors to ozone layer depletion. DME is used as a feedstock for a
variety of chemicals such as acetic acid [9,10], methyl acetate [11–13],
aromatics [14,15], gasoline [11], light olefins [16–18], higher ethers,
oxygenates, etc. [19,20]. As the fuel cell technology matures, the op-
Fig. 1. The overall trend of papers published in the area of DME synthesis. portunity of DME as fuel in a hybrid vehicle is very high. DME is a
hydrogen carrier and it can be reformed to produce syngas (H2 + CO)
at a lower temperature (120–150 °C) when compared with other fuels
countries such as Egypt, Indonesia, South Korea, Vietnam, and India like diesel, gasoline, and methane (above 650 °C). DME can be cataly-
have also started evaluating or establishing manufacturing DME units. tically converted to other useful chemicals by reacting with syngas such
A number of research articles have been published over the years on as formaldehyde [21], methyl acetate [22], and ethanol [23]. Other
DME synthesis (Fig. 1), particularly during the last two decades. The usages of DME include as solvent, kiln fuel for ceramics, and for
highest number of articles were published in 2011 due to its perceived welding and cutting plus brazing applications.
great potential as a fuel inviting the attention of researchers in academia
and industry. It is thus timely to review the scope of DME and its potential
as a fuel and precursor for a number of chemicals, and industrial processes. 3. History of DME production
The current review is thus written in two parts highlighting all areas
concerning DME synthesis using various catalysts, and the reactor and DME was developed as an aerosol propellant in 1963 by Akzo Nobel.
separation strategies. The scope of Part I is to highlight the recent ad- From 1970 global oil prices started to increase and Amoco was the first
vancement of DME synthesis which includes various innovative reac- company to invest in R and D of DME [24]. Until 1975 DME was pro-
tion systems, catalysts and their synthetic protocols to get high activity, duced as a by-product (3–5%) along with methanol in a high-pressure
and effect of operational parameters on DME selectivity and yield. production process [25]. A German patent filed in 1980 mentioned that
DME was present in methanol based fuel [26]. In 1990 a US patent was
published on the operation of a diesel engine with 95% DME [27].
2. DME properties and applications National Institute for Petroleum and Energy Research laboratories
at Bartlesville in the US was the first to test DME in diesel engines in the
A comparison of the physico-chemical properties of different con- 1980s [5]. In 1995, Haldor Topsoe, Amoco, and Navistar International
ventional fuels which could be replaced by DME is shown in Table 1. Corporation jointly started an investigation on the large-scale synthesis
According to the World LP Gas Association (WLPGA), DME can be of DME and concluded that methanol dehydration is a suitable tech-
used as a mixture or separately as a substitute in the LPG industry [4]. nology for DME production. Amoco consortium was the first to justify
About 15–20 vol.% of DME blending in LPG will not affect the current the use of DME as a non-polluting ultra-clean fuel with diesel engines,
LPG infrastructure for storage, distribution, and usage [5]. DME gas can which can meet the 1995 ULEV (California Ultra Low Emissions Ve-
be liquefied by pressurizing at 0.57 MPa at 20 °C or by cooling to hicle) regulations in the category of medium-duty vehicles. In Europe,
−25 °C at atmospheric pressure. The similar physical properties of LPG Volvo was the first company to carry out trials on buses with bio-DME.
and DME, allow DME to be used as a substitute for propane and butane DME blending in LPG (20% vol./vol.) is more convenient than using
in LPG as a cooking fuel. The well established LPG industry infra- DME as a diesel replacement because for the latter purpose, engines
structure can be also used for DME without difficulty [6,7]. Around the have to be modified accordingly. Enhancement of blending of DME
world, the number of vehicles running on LPG is increasing. Currently, from 20 to 30% does not need any major infrastructure other than the
there are more than 10 million LPG operated cars on the road. DME can storage capacity of LPG industry [5,28].
be synthesized from biomass and, especially bio-DME can be used as a The use of DME as a gas turbine fuel was started by Toyo
blending agent with LPG (15–20 vol.) [8]. Engineering, Haldor Topsoe Chiyoda Corporation and Snamprogetti/

Table 1
Comparison of properties of different fuels (information extracted from [3,4]).
Properties DME MeOH Methane LPG Gasoline Diesel

Chemical formula CH3OCH3 CH3OH CH4 C2-C5 C4-C12 C3-C25


Molecular weight (Da) 46.07 32.04 16.04 44.09 100–105 ≈200
Boiling Point (°C) −24.9 64.6 −161.5 −42 35–200 180–360
Vapour pressure at 20 °C 5.1 – – 8.4 – –
Liquid density at 20 °C g/cm3 0.67 0.79 0.42 0.49 0.71–0.77 0.832
Specific gravity (25 °C/4 °C) 0.661 0.786 0.55 0.51 0.739 0.82–0.95
Flammability limits in Air, Vol% 3.4–17 5.5–36 5–15 0.94–2.1 1.9–8.4 0.6–7.5
Wobbe Index, kJ/m3 46198 – 48530 69560 – –
Cetane No. 55–60 5 0 5 4–20 40–55
Calorific Value LHV, kcal/kg 6925 4800 12000 11950 11110 10800

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ENI [8,24], and also due to a joint effort of three major institutions, On the contrary according to Gates and Johanson [35], methanol
namely, Electric Power Development Corporation of Japan (EPDC), BP molecules are absorbed on the two adjacent acid sites of the catalyst.
Amoco and General Electric Co. of US [29]. In Japan, a 1.15 MW DME Kiviranta-Paakkonen et al. proposed Eley–Rideal (ER) model for the
fueled diesel power plant was established by FE Holdings, Daihatsu and methanol dehydrogenation reaction, where one molecule of methanol
Iwatani Corporation [30]. Haldor Topsoe has developed advanced solid is absorbed on the acidic site of catalyst while other reacting molecule
oxide fuel cell technology which can use DME directly which eventually remains in the bulk phase [32].
increases the thermal efficiency of small-scale power generation plant Ha et al. [36] studied a number of methanol dehydration reactions
[8]. Chinese companies are converting coal into olefins such as ethylene and concluded that at the beginning of the reaction two methanol
and propylene via methanol to olefins (MTO) process. Others include molecules are non-dissociatively adsorbed on two acidic sites of an
Lurgi's methanol to propylene (MTP) process and Honeywell's advanced acidic catalyst (m-ZSM-5). Then those two adsorbed methanol mole-
MTO process. Both processes utilize coal gas as a raw material to pro- cules form an intermediate which instantly rearranges itself to form
duce methanol followed by DME production and finally, DME is reacted methyl carboxyneum ion and carbenium ion or two methyl carbox-
to produce olefins. In 2001 International DME Association was estab- yneum ions. The second step was regarded as the rate determining step
lished followed subsequently by China DME Association (CDA), Japan [36]. DME formation from methanol is also demonstrated by associa-
DME Forum (JDF) and Korea DME Forum (KDF). In 2016 Shenhuya tive and dissociative pathways and both the reactions are proposed to
group and Dow Chemical Company of China announced to invest US carry out on the Brønsted acid site [37–39]. Methanol to dimethyl ether
$10 billion to produce olefins from MTO process. Amoco along with (MTD) reaction with ZSM-22 catalyst has been studied on the basis of
Indian Oil Corporation Limited (IOCL) and Gas Authority of India density function theory (DFT) by Moses and Nørskov [40] who pro-
Limited (GAIL) formed a joint venture in 1998 to promote DME in the posed that both the associative and dissociative pathways are re-
Indian power market which was less competitive and less risky for in- sponsible for methanol conversion but the dissociative pathway is faster
vestment at that time. Biomass derived catalytic DME synthesis is being than the former with similar dependency on acidic site. They have es-
pursued by Indian researchers. tablished a linear correlation between the strength of acidic site and
activation energy and proposed that weaker acid sites produce higher
4. DME synthesis activation energies. In the case of two-step dissociative pathway, DME
synthesis step is a bit slower than the water releasing step. Hence, DME
Coal or petroleum operated thermal power plants generate huge formation is the rate determining step for the dissociative pathway.
quantities of CO and CO2 greenhouse gases and technologies must be Cassone et al. [41] have done computational analysis based on ab initio
developed for CO2 capture and sequestering (CCS) facility. The molecular dynamics method to study a novel electrochemical pathway
economy of the CCS plant only could be sustainable when it is sup- to produce DME from methanol.
ported by DME synthesis plant with a capacity of 3000–7500 TPD [28]. The indirect process of DME synthesis from CO2 is shown in Fig. 3.
DME can be synthesized via two synthesis routes: (1) indirect For the methanol synthesis process, matured methanol-synthesis cata-
synthesis or two-step process, (2) direct synthesis or single step process. lysts are used and a majority of them are copper based catalysts. While
The direct synthesis process comprises a single reactor process for the methanol dehydration process, acidic catalysts like zeolite,
where both reactions occur over a bifunctional catalyst. Linde/Lurgi, alumina and sulphuric acid have been used. Thus with the existing
Haldor Tospoe, Uhde, Toyo Engineering, and Mitsubishi Gas Chemical catalyst technology setting up a DME plant is rather cheap but the
Company are holding the licenses for the single-step DME synthesis output is a mixture of methanol, water, and DME which has to be
technology. distilled for purification, separation, and recycling. Methanol cost is one
of the deciding factors for DME price which it is generally double the
4.1. Indirect method cost of methanol [3,42].
Despite disadvantages, most of the DME plants operate with indirect
The indirect process is a dual-step catalytic process in which me- synthesis process where a solid acid catalyst (usually alumina) is used
thanol is synthesized from syngas or CO2 in the first reactor and then it for vapour phase dehydration of methanol. H2SO4 is also used as an
is dehydrated to produces DME in the second reactor. MGC, Toyo, acid catalyst by some industries, e.g. Jiutai Energy Group of China. and
Udhe, and Lurgi are the companies which are developing DME pro- the reaction mechanism is shown below (Eqs. (5) and (6)). The ad-
duction technology by indirect synthesis [28]. vantages of this process are that the sulphuric acid can be recycled
In the presence of an acidic catalyst, methanol is dehydrated to DME several times and the weakened acid is used as a raw material in the
wherein the by product water acts as a reaction inhibitor by competing fertilizer industry; this liquid phase catalytic dehydration process can
with methanol for protons (Fig. 2). Kinetic modeling of methanol de- reduce the process cost by one-third of actual cost [43].
hydration has been reported in the literature and a majority concludes
CH3OH + H2SO4 → CH3HSO4+H2O (5)
that the methanol dehydration reaction (Eq. (1)) follows either
Eley–Rideal kinetic model or Langmuir–Hinshelwood [31–33]. CH3HSO4 + CH3OH → CH3OCH3+H2SO4 (6)

2CH3 OH CH3 OCH3 + H2 O °


H298 = 23.5 kJ/mol (1)
According to Bandiera and Naccache [34], the mechanism of DME 4.2. Direct method
formation by methanol dehydration involves two adjacent sites on the
catalyst surface, i.e., one acidic site (H+) and another adjacent basic Though the direct or one-pot synthesis of DME from syngas is a one-
site (O2−). Methanol is protonated on the acidic site to form step process, it involves three reactions, i.e. methanol formation by
[CH3·OH2]+ which is instantly converted to CH3+ and H2O (Eq. (2)). syngas hydration, methanol dehydration and water-gas shift (WGS)
One methanol molecule is converted to CH3O− and OH− on the ad- reaction (Eqs. (7)–(9)). Hydrogen produced in the WGS reaction is used
jacent basic site (Eq. (3)). Finally, DME is formed by combining two in the methanol synthesis reaction and methanol (Eq. (7)) is thereafter
activated species (CH3+ and CH3O−) (Eq. (4)). dehydrated to DME. These reactions are conducted in a single reactor
packed with a bifunctional catalyst for the simultaneous occurrence of
CH3OH + H+ ↔ [CH3·OH2]+ → CH3+ + H2O (2) the reactions. The overall reaction of the syngas to dimethyl ether (STD)
2− − − process can be expressed as Eq. (10).
CH3OH + O ↔ CH3O + OH (3)

CH3+ −
+ CH3O ↔ CH3OCH3 (4) CO + 2H2 CH3 OH °
H298 = 90.6 kJ/mol (7)

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Fig. 2. Indirect method of DME synthesis via methanol dehydration reaction [32,35].

2CH3 OH CH3 OCH3 + H2 O °


H298 = 23.4 kJ/mol (8) is produced via syngas hydration. The single step conversion method is
getting more attention in the industry because of the higher one pass
H2 O + CO H2 + CO2 °
H298 = 23.4 kJ/mol (9) conversion of syngas and it requires a lower supply of hydrogen to
produce DME in comparison to dual step process. Thermodynamic
3CO + 3H2 CH3 OCH3 + CO2 °
H298 = 245.8 kJ/mol (10) analysis of direct DME synthesis from syngas and CO2 reaction has been
CO2 is hydrogenated to produce DME and like in the STD process, done by Moradi et al. [44] and Ateka et al. [45]. By comparing the heat
methanol is formed as an intermediate product followed by DME generation between Eqs. (9) and (14), it can be concluded that the use
synthesis through methanol dehydration. Both methanol synthesis and of CO2 in the direct synthesis process produces less heat and thus the
methanol etherification reactions occur in parallel (Eqs. (11) and (12)) reaction is more thermodynamically stable and the catalyst bed over-
along with the reverse water-gas shift (rWGS) reaction as a side reaction heating problem with syngas can be avoided. However, H2O formation
(Eq. (13)). The overall reaction of CO2 hydrogenation to produce DME during the reaction promotes the catalyst deactivation and reduces
is given by Eq. (14). DME yield. Another advantage of using CO2 is its higher oxidation
power compared to syngas and the presence of CO2 in the supplied
CO2 + 3H2 CH3 OH + H2 O °
H298 = 49.4 kJ/mol (11) reaction gas mixture influences the active site of catalyst to produce
more methanol [46].
2CH3 OH CH3 OCH3 + H2 O °
H298 = 23.4 kJ/mol (12) Commercialization of DME production from syngas is not econom-
ically viable as it requires a higher amount of energy and releases
H2 + CO2 H2 O + CO °
H298 = 41.4 kJ/mol (13) greenhouse gases into the atmosphere via water-gas shift reaction. DME
production has to adopt new technologies to be more energy efficient
2CO2 + 6H2 CH3 OCH3 + H2 O °
H298 = 122.2 kJ/mol (14)
and environment-friendly. Utilization of CO2 for the purpose of DME
The direct method of DME synthesis is more practical as both the production can be a noble way to prevent accumulation of greenhouse
reactions are performed in a single reactor and thus the operational cost gas in the environment. The present technology is not mature enough to
will be less (Fig. 4). Integration of methanol formation and methanol convert CO2 into DME with higher conversion rate and selectivity. This is
esterification reaction makes the whole process more thermo- an equilibrium limited reaction and if the produced water can be with-
dynamically favorable as the methanol formation from syngas hydro- drawn from the reactor, the equilibrium can shift toward DME synthesis.
genation is exothermic and reversible (Eq. (1)). The formation of water
molecules during methanol dehydration reaction (Eq. (8)) is also ben- 4.3. Other routes
eficial for hydrogen generation in WGR reaction (Eq. (9)). The reactions
(Equations (7), (8) and (9)) produce a synergic effect on reaction Methane has a high potential to be used as a precursor for DME
equilibrium and as more methanol is converted to DME, more methanol production via a dual-step synthesis process. Firstly methane is

Fig. 3. The indirect process of DME synthesis from the gaseous mixture of CO2 and H2.

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Fig. 4. the Direct process of DME synthesis from the gaseous mixture of CO2 and H2.

transformed into methyl halide (such as CH3Cl, CH3Br) by reacting with 5.1. Methanol formation reaction
hydrogen halide via oxidative halogenation reaction and then methyl
halide is converted to higher hydrocarbons including DME via hydro- 5.1.1. Copper based catalysts
lysis and carbonylation reactions [47–52]. Yang et al. [47] have re- BASF was the first company to commercially produce methanol from
ported the conversion of methane into methyl bromide by reacting with syngas containing CO2 by using ZnO-Cr2O3 as a hydrogenation catalyst.
oxygen and hydrogen bromide over Rh/SiO2 catalyst. One of the pro- In 1960 ICI introduced copper zinc oxide alumina catalyst for selective
blems associated with this reaction is that ony ∼10% methane is production of methanol from naphtha/natural gas under milder reaction
converted to CO and CO2. You et al. [48] co-fed CO and CO2 along with conditions. Thereafter a lot of research was done on Cu-ZnO based cat-
methane and HBr/H2O in the oxidative halogenation reactor to produce alyst combined with other metals. Among them Cu-ZnO based catalysts
CH3Br and avoided generation of CO2.Then the produced methyl bro- prepared by co-precipitation method have shown higher conversion and
mide was hydrolyzed to produce DME over a metal chloride catalyst selectivity. The metallic Cu clusters in Cu-ZnO-Al2O3 are the active sites
supported on silica (ZnCl2/SiO2). Corrosion of the reactor is a common for methanol synthesis and WSG reactions; and the conversion and se-
problem when methyl halide is used as a precursor. This issue was re- lectivity are dependent on copper dispersion and metal surface area
solved by Prakash et al. [49] who utilized poly(4-vinyl pyridine) as a [58–60]. A typical example of the commercial catalyst is Cu-ZnO-Al2O3,
catalyst in the place of liquid amines. Methyl halide is also used to which is usually composed of 50–70 mol% of CuO, 20–50 mol% of ZnO
synthesize DME and methyl acetate as a by-product via oxidative car- and 5–20 mol% Al2O3. According to Chinchen et al. [61], ZnO is the best-
bonylation reaction by reacting with CO and Cu2O in the presence of performing oxide among MnO, Cr2O3, and SiO2 in terms of various
SbF5/graphite as a catalyst [50]. Methanol and DME were produced functionalities and it shows a good promoting effect for methanol
when the mixed oxide was used as a catalyst for the oxidative carbo- synthesis but not for rWSR reaction [62]. The primary role of ZnO is to
nylation of methyl bromide [51,52]. provide an optimum dispersion of metallic Cu, by acting as a geometric
spacer between the Cu nanoparticles which leads to higher number of
active sites on which syngas conversion to methanol takes place [55].
5. Catalysts for DME synthesis The other functions of zinc oxide are to hinder sintering of copper par-
ticles as well as to disperse catalyst poison such as Cl and S to reduce
Many challenges still exist for DME production despite several ef- poisoning. The ratio of Cu+/Cu° is also appropriately maintained by ZnO
forts during the last few years. The development of a highly active and by creating Cu+-O-Zn active sites, as both the Cu states are important in
efficient catalyst for CO and CO2 hydrogenation is still a distant dream. methanol formation. da Silva et al. [63] concluded that ZnO is re-
One pot DME synthesis (direct method) from either syngas or CO2 in- sponsible for the strong metal-support interaction with Cu nanoparticles,
volves two separate reactions (methanol formation and methanol de- which were referred to as “methanol active copper”. The size of the
hydrogenation). The catalyst should perform as a redox function which copper particle and its dispersion over the support material are greatly
first turns gases into alcohol which is dehydrated to the ether on an acid varied with the type of precipitant, Cu/Zn molar ratio, calcination tem-
site. As stated earlier the indirect method of DME synthesis involves perature, etc. although excessive ZnO is responsible for deactivation of
both the reactions in separate reactors whereas the direct method is the catalyst. Thorhauge et al. [64] have demonstrated the role of Zn
more attractive since it alleviates the thermodynamic constraints of particles on Cu dispersion and its influence on syngas to methanol con-
methanol synthesis from CO2 or CO and leads to higher conversion as version. Le Valent et al. [65] have developed a mathematical model of
well as selectivity [53–55]. It is highly recommended by the industry to methanol synthesis reaction on core-shell Cu-ZnO catalyst to correlate
use a single pot synthesis technique for DME synthesis to reduce pro- successfully the number of Cu-ZnO contact points with observed catalytic
duction cost [55,56]. activity. Further addition of trivalent ions (M3+) such as Al3+ in Cu/ZnO
Other than the metal function and acid function of the of bi-func- catalyst leads to the enhanced thermal and chemical stability of the
tional catalyst, some other important factors also influence the pro- catalyst, higher Cu dispersion and metal surface area [66]. Based on
ductivity of the one-pot process, such as (i) preparation method of the previous studies Sugawa et al. [67] have proposed the following order of
catalyst, (ii) sintering of the copper particle, and (iii) catalyst deacti- activity of different metals for methanol formation from CO2:
vation. It is very important to know that the product distribution of
Cu ≫ Co = Pd = Re > Ni > Fe ≫ Ru = Pt > Os > Ir = Ag = Rh >
direct DME synthesis reaction does not only depend on the thermo-
Au
dynamics of the reaction but also on the reaction kinetics. The heat
conduction properties of the bi-functional catalyst are very low and the Water generation during hydrogenation of CO2 for methanol pro-
reaction process is carried out in the range of 523–673 K and pressure of duction leads to the unsatisfactory performance of Cu-ZnO-Al2O3, since
10–50 bar [57,58]. In the case of the indirect process, irrespective of the alumina possesses strong hydrophilic property; and in order to solve
process followed, the productivity is highly dependent on the catalyst this problem, lower hydrophilic promoters have been adopted such as
properties. In the following section, the effect of metal function and ZrO2 [68,69]. Various Cu based zirconia catalysts have been reviewed
acid function on the DME synthesis is discussed. by Raudaskoski et al. [70] who have described how Zr promoted high

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Cu dispersion results in higher conversion and more methanol se- η-Al2O3 > γ-Al2O3 ≫ θ-Al2O3 ≫ (χ + γ)-Al2O3 ≫ δ-Al2O3 > α-
lectivity. To further enhance the performance of ZrO2 containing Cu Al2O3 ≈ κ-Al2O3
based ternary catalyst, additional promoters have been incorporated
γ-Al2O3 forms Lewis acid site during the calcination process and al-
such as Ti [68]. Cu-ZnO-ZrO2-TiO2 quaternary catalyst prepared by
though it is very active, it strongly binds to water molecules and gets
oxalate precipitation method led to higher conversion and selectivity
deactivated instantly. Xu et al. [96] studied the effect of water content,
due to the presence of both the promoters Zr and Ti. The addition of Zr
reaction temperature, and catalyst acidity on methanol conversion and
and Ti in the catalyst structure led to a decrease in crystallite size of
in this regard, a number of catalysts with different acidity (different
CuO, ZnO and increased CuO-ZnO interaction [68]. Angelo et al. [71]
silica content) such as γ-Al2O3, amorphous alumina-silica, titania
have studied the effect of CeO2 as a promoter in Cu-ZnO-Al2O3 catalyst
modified zirconia, and HZSM-5 have been considered. Water molecules
and found that CeO2 addition decreases the Cu crystalline size and does
block the active sites of the catalyst, and it was reported that γ-Al2O3
not benefit the reaction in any way. Garciani et al. [72] have introduced
was the most affected whereas HZSM-5 the least. More acidic catalyst
a new site for CO2 activation and hydrogenation on the ceria-copper
shows an increase in the activity of the catalyst. γ-Al2O3 is affected by
interface. They have shown that the hydrogenation reaction on CeOx/
water content because it possesses the most number of strong Lewis
Cu (100) is 200 times higher than Cu (100) and 14 times higher than
acid sites to adsorb water molecules [97].
Cu-ZnO. Fornero et al. [73] have shown that Cu-Ga2O3-ZrO2 catalyst
performed better than Cu-Ga2O3 and Cu-ZrO2 catalysts.
Other than the foregoing metal promoters, various other metal and 5.2.2. Zeolites and modified zeolies
non-metal promoters have been added in to the Cu-ZnO bi-metallic Considerable attention is focused on the use of zeolites as a solid
system for methanol synthesis; these include Mn [74], Cr [75], Au [76], acid catalyst for methanol dehydration reaction. Zeolites are crystalline
La [77], Ce [77], V [78], graphene [79], carbon [74,80] or mixture aluminosilicates which are widely studied for their shape selectivity
[77,81,82] among them. It was observed that Zr, Al, and Ga showed the which comes from their well-defined microporous structure. The shape
maximum activity in terms of conversion and selectivity [83]. Among a selectivity can be further tuned as per the reaction by turning the
number of catalysts studied, LaCr0.5Cu0.5O3 and Cu-ZnO-Ga2O3/SiO2 opening and special orientation of the channels, size, and location of
have shown better methanol formation rate with high selectivity (as the cases. Zeolites possess both Brosted and Lewis acid sites and the
high as 99.5%), but their stability and scalability have not been tested distribution, number, position and strength of these acid sites are the
[84]. Martin et al. [85] have studied the activity of In2O3/ZrO2 catalyst main deciding factors for catalytic activity [98]. The main advantage of
for methanol synthesis from CO2 hydrogenation at very low pressure zeolite is the stronger acid sites, which allows the reaction to be carried
compared to conventional system. They have achieved 100% methanol out at low reaction temperature [99,100] Vishwanathan et al. [99]
selectivity compared to Cu-ZnO catalyst and shown 1000 h time on reported 80% conversion of methanol to DME at 230 °C by HZSM-5
stream (TOS) stability. catalyst, while γ-Al2O3 required a higher temperature of 320 °C to reach
the same conversion [99]. Olefins and coke formed through some un-
5.1.2. Palladium-based catalysts desired side reactions at the high strength acid sites of zeolites and
A number of Pd based catalysts have also been developed for me- blocking of pore structure by coke molecules were the main reasons for
thanol synthesis by hydrogenation of CO and CO2 such as Cu/SiO2 [86], deactivation of zeolites [101].
Li-Pd and Na-Pd [87], Pd-Ga2O3 [88], Pd-βGa2O3 [89], Ga2O3 pro- Catizzone et al. [102] have investigated several types of zeolites for
moted Pd-SiO2 [90,91], Pd-Cu/SiO2 [69], and Pd-ZnO [92]. Koizumi methanol dehydration reaction based on the channel openings (8–12
et al. [93] have reported that methanol synthesis from CO2 by Pd cat- membered rings) and channel orientation (1-,2- and 3-dimensional
alyst can be further improved by adopting two strategies such as (i) channel orientations). One dimensional zeolite such as MTW or MOR
using uniform mesoporous support for the catalyst (SBA-15, MCM-41), have shown high DME selectivity at 240 °C but deposition of coke leads
and (ii) use of alkali/alkaline earth metal additives. to early deactivation of the catalyst. With medium pore opening the 1-D
zeolite turn over number (TON) was better and it showed good re-
sistance to coke deposition. SAPO-34, MFI, and BEA are 3-D channel
5.2. Methanol Dehydration to DME
zeolites which have been investigated by the same research group who
found that despite the small channel openings (3.8 Å) of SAPO-34, it
5.2.1. Alumina
showed high DME selectivity, but it rapidly got deactivated by coke
The second step of indirect DME synthesis is the dehydration of
deposition [102,103]. When channel intersection and channel openings
methanol for which generally solid acid catalysts are employed, and the
have a similar size such as MFI and BAE structure, higher stability was
most desired properties of the solid acid catalyst require them to be
observed with coke deposition [104]. Tang et al. [105] have studied
hydrophobic, stable at high temperature, highly active and selective for
ZSM-5-MCM-41 composite catalyst which is both microporous and
the desired product. One of the earliest studies reported that DME was
macroporous, having a better activity for methanol dehydration [106].
formed by methanol dehydration using alumina as a catalyst at the
Several studies on FER zeolites for the methanol dehydration reaction
temperature range of 300–400 °C [94]. Methanol dehydration process
have shown high DME yield. Catizzone et al. [107] have investigated
has several licensors around the globe such as Linde/Lurgi, Haldor
FER zeolites with different acidity (governed by Si/Al ratio) for me-
Tospoe, Toyo Engineering, Mitsubishi Gas Chemical Company (Japan),
thanol dehydration reaction. Higher aluminum content increases me-
Uhde, China Southwestern Research Institute of Chemical Industry and
thanol conversion and Lewis acid sites are more active at a lower
China Energy. This reaction can be carried out in either the liquid or
temperature (240–160 °C) than Bronsted acid sites [108].
vapor phase, depending on the catalyst used, at suitable reaction tem-
The activity of zeolites can be further improved by decreasing sur-
perature (100–300 °C) and pressure (1–20 bar). Among the solid acid
face acid strength or decreasing total number of acid sites of the cata-
catalysts applied for methanol dehydration, alumina and zeolites are the
lyst. The strength of acidic sites of the solid acid catalyst is of great
most popular as they are stable at high temperature and pressure, having
importance, as DME formation occurs at the low acidic side (Lewis acid)
a high surface area, low cost and most of the acid sites have lower acidity
and DME is further converted to olefins on strong acid sites. Several
(Lewis acid site). Sung et al. [95] have investigated different crystalline
reports have appeared on Na, Mg, Zn, Zr impregnated HZSM-5 catalyst
phases of alumina for the methanol dehydration reaction and concluded
for DME synthesis from methanol and it was demonstrated that with
that γ-Al2O3 showed the second highest catalytic activity among other
these metal impregnation strong acidity was decreased which reduced
phases and the order of activity of different phases was as follows:
coke deposition [109]. Khandan et al. [110] have shown with

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incorporation Zr in HZSM-5 framework DME yield increases from 53 to an industrially applied mature catalyst which is well researched. Like
92%. Kim et al. [111] have studied γ-Al2O3 impregnated HZSM-5 cat- syngas, CO2 is also converted to DME by a physical mixture of CZA and
alyst for methanol dehydration reaction and obtained 50% conversion γ-Al2O3 catalysts [124–126]. Takeguchi et al. [127] have studied DME
with 99% DME selectivity. synthesis from a mixture of CO and H2 by physically mixed Cu/ZnO/
Al2O3/Cr2O3/Ga2O3 and silica-modified γ-Al2O3 catalysts. Silica
5.2.3. Heteropolyacid (HPA) loading increases the Bronsted sites and catalyst surface area. Other
Heteroplyacids (HPAs) are also used as catalysts in methanol de- studies have reported that when γ-Al2O3 was modified with niobium
hydration reaction. Keggin-type HPAs, which are represented as sulfate (Nb2(SO4)3) and treated with 0.1 mol NH4F solution, both the
H8−n[Xn+M12O40], where “X” is heteroatom (such as Al3+, P5+, Si4+, surface area and acidity of the catalyst increased [128]. Joo et al. [129]
etc.), “n” is the oxidation state and “M” is the metal ion, are the most have suggested that strong acidic sites on γ-Al2O3 converted methanol
commonly used. The heteroatom in the HPAs possesses highly acidic and DME into CO through reforming reaction and thus prior treatment
Bronsted acid site. Thus HPA performs better at lower reaction tem- of γ-Al2O3 and HZSM-5 with sodium carbonate and formaldehyde
perature compared to zeolites. Carr et al. [38] have done methanol would increase the number of weak acid sites.
dehydration reaction over Keggin type HPA clusters with different A huge number of studies have been reported on the effect of dif-
heteroatoms (X = P5+, Si4+, Al3+, and Co2+) and proposed that the ferent promoters on the Cu-metal functions in the hybrid bi-metal
reaction mechanism follows associative reaction pathway. Alharbi et al. catalyst such as Ga [130], Mn [131], Pd [132], La [133], Zr [82–84], Y
[112] have studied the activity of HPA in methanol dehydration reac- [134], magnesia [130], as well as carbon nanotubes [135], etc. and the
tion and compared results with zeolite with different acidity (Si/ effect of different promoters on Cu dispersion, activity, and selectivity
Al = 10–120) in terms of the turn over reaction frequency (TOF) and of DME have been discussed. According to Venugopal et al. [134]
acid strength of the catalyst. HPA containing tungsten/phosphorus among the different promoters (Ga, Zr, La, Y) in CZA catalyst, yttrium
(HPW) showed TOF of 53 h−1 whereas the most active zeolite, HZSM5 (Y) showed the highest CO conversion (70%) and DME selectivity of
had TOF of 1 h−1. Ladera et al. [113] have proposed that the activity of 47.7% which was due to Cu particle grain growth and surface area.
HPAs can be further enhanced by using TiO2 as support as it enhances Different functionalities of various promoters enhance the catalyst ac-
the accessibility of the methanol molecules to the proton site of HPAs. tivity of CZA catalyst; for instance, Ga increases the inverse spillover of
hydrogen [130], and Zr increases the crystalline size of Cu [136], etc.
5.2.4. Ion exchange resin (IER) MgO modified γ-Al2O3 dehydration catalysts in hybrid form also have
Ion exchange resins (IER) are also employed for methanol dehy- been studied to witness better CO conversion and DME activity [130].
dration reaction. IER is a copolymer of divinyl benzene/styrene and When alumina content is more than 50 wt% in Cu/ZrO2 and calcination
sulfonic acid is present in the IER structure. The main advantage of temperature is more than 500 °C, CZA catalyst itself can be used as a
using IER as an acid catalyst is the use of low reaction temperature in hybrid catalyst [137]. Gel type slurry catalyst made up of CZA with
the range of 30–150 °C [114,115]. The activity can be further improved AlOOH binder showed good catalytic activity for DME synthesis as
by incorporation of Lewis acid site through reaction with aluminum AlOOH acts as methanol dehydration catalyst [138].
chloride or boron trifluoride [116]. Hosseininejad et al. [117] have Various mesoporous catalysts also have been extensively reported
shown that Amberlyst 35 has the highest catalytic activity among other for the one-pot synthesis of DME from CO and CO2. Jiang et al. [139]
IERs, γ-alumina, and zeolites (HY, HZSM5, HM zeolites) at the tem- prepared a mesoporous Cu-γ-Al2O3 catalyst with different Cu mol ratio
perature range of 110–135 °C. by evaporation induced self-assembly method and it showed excellent
CO conversion (72%) and DME selectivity (69%) at 310 °C and 50 bar
5.2.5. SBA-15 and HMS supported catalysts pressure. Wang et al. [140] prepared mesoporous Al2O with highly
Tokey et al. [118] have synthesized alumina impregnated SBA-15, a dispersed Cu by combustion synthesis method and it showed good ac-
mesoporous structure aluminosilicate, by one-pot hydrothermal synth- tivity with high DME selectivity for 56 h time on stream (TOS).
esis and used it for DME production by the methanol dehydration re- Zeolite-based catalysts have been used as an acid function in a bi-
action demonstrating methanol conversion value close to equilibrium functional catalyst as the hydrophobic nature of zeolite is responsible
conversion with 100% DME selectivity. Al-HMS with different Si/Al for the higher activity at the lower reaction temperature, which makes
ratio has been synthesized by Sabour et al. [119] and tested for DME the methanol formation step thermodynamically more favorable
production by methanol dehydration reaction. Al-HMS with Si/Al ratio [141–143]. Zeolites of proton and non-proton form (HZSM-5 and ZSM-
of 10 showed the best catalytic activity with methanol conversion of 5), ferrierite, zeolite-Y, and mordenite are among the most famous
89% with 100% DME selectivity. When the Si/Al ratio was increased, zeolites used as an acid function in DME synthesis. Ramos et al. [144]
the conversion increased but DME selectivity decreased. investigated different solid acid catalysts mixed with a commercially
available methanol synthesis catalysts such as porous alumina (alu-
5.3. Direct method of DME production mina-C), non-porous alumina (alumina-D), tungstated zirconia (W-
ZrO2), sulfated zirconia (S-ZrO2), and HZSM-5. HZSM-5 was the most
One pot conversion of CO and CO2 to DME is challenging and en- active catalyst among the rest when employed for DME synthesis from
ergetically unfavorable. Suitable reaction conditions and efficient cat- CO, which was due to the higher number of Bronsted acid sites present
alyst are required to carry out such reactions. During DME synthesis on HZSM-5. Cu-Mn-Zn supported on HY zeolites, modified via ion ex-
reaction from CO2, CO and water are produced by reverse water gas change with rear earth (Nd, La, Ce, Sm, Pr, and Eu) [145] and transition
shift (rWGS) reaction and other hydrocarbons are also formed from (Ni, Co, Fe, Cr, and Zr) [145] metals, as hybrid catalysts have been
methanol. A large quantity of water formation which is a big problem utilized for DME synthesis. The effect of Si/Al (30, 80, 280) ratio of
during DME synthesis from CO2, as it creates a thermodynamic lim- HZSM-5 and HY catalyst in CZA-zeolite on CO conversation and DME
itation for methanol formation and methanol dehydration reaction, and selectivity has been studied by Xie et al. [146]. In their case, the lowest
thus the DME yield is lower when CO2 is used as compared to CO. CO conversion of 46.7% and the highest DME selectivity 70.4% were
Many reports can be found on syngas to DME (STD) reactions with observed with HZSM-5 (Si/Al = 280) whereas the highest CO conver-
physical mixtures of catalysts used for methanol synthesis and me- sion of 87.7% and the lowest DME selectivity of 65.9% was achieved
thanol dehydration (e.g. Cu/ZnO/Al2O3 and γ-Al2O3). It was reported with HZSM-5(Si/Al = 30). García-Trenco et al. [147] and others have
that CO conversion increased from 50 to 93% and DME selectivity from shown that CZA-zeolite catalysts are deactivated due to Cu sintering as
34 to 52% when the reaction temperature was elevated to 240–290 °C Cu2+ ions (and sometimes Zn ions also) migrate to the HZSM-5 and
with CO: H2 mole ratio of 2 [120–123]. Cu/ZnO/Al2O3 (CZA) catalyst is increase the number of Lewis acid sites. In order to modify and study

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the influence of acid sites of zeolites, modification of HZSM-5 catalyst 6. Effect of catalyst preparation method
with a number of basic oxides (i.e., MgO, ZnO, CaO, and Sb2O3) and
transition metals (Zr and Fe) was carried out and it was found that due A number of methods for synthesizing hybrid catalysts have been
to acid sites being shifted to weaker strength, DME selectivity was reported in the literature such as co-precipitation [131,161], sol–gel
improved [148,149]. Pure and modified ferrierite has become quite [137], precipitating sedimentation [162], impregnation [163], and wet
popular for the direct DME synthesis from CO, as modified ferrierite is chemical methods [164]. Among them, the co-precipitation and phy-
highly DME selective and stable at high reaction temperature. Mon- sical mixing methods are the most widely used preparation methods for
tesano et al. [150] studied the influence of zeolite structure and to- hybrid catalysts. Co-precipitation method involves the co-precipitation
pology on DME yield and concluded that the main reason for ferrierite of active functions of methanol synthesis catalyst (MSC) over an aqu-
activity was that it provides a path for small molecule diffusion (i.e. eous or organic solution of precursors of methanol dehydration catalyst
MeOH and DME). Prasad et al. [151] also reported higher activity and (MDC). The physical mixing of both the MSC and MDC functions is the
stability of CZA/HFER catalyst for DME synthesis compared to HZSM-5, other method. There are a few drawbacks of this method however such
HY, and NaY. Many studies have shown that CZA/Zr incorporated as the uncontrolled size distribution of the particles, random active site
HFER catalyst showed higher catalytic activity than HZSM-5 and Y- distribution on the catalyst surface and aggregation of catalyst particles
zeolites. Zr modification of FER has resulted in low Cu surface area with during precipitation. Ahmad et al. [164] have compared the hybrid
presence of a required number of acid sites for DME synthesis catalyst preparation method for STD reaction including impregnation,
[123,152]. co-precipitation, co-precipitation-impregnation, co-precipitation sedi-
Naik et al. [124] compared the catalytic activity of γ-Al2O3 and mentation, and oxalate methods. According to their study oxalate, co-
HZSM-5 (Si/Al = 60) by mixing with CZA catalyst for direct conversion precipitation and co-precipitation sedimentation are better performing
of CO2 to DME in a fixed bed reactor at 260 °C and 5 MPa. HZSM-5 was methods of hybrid catalyst preparation among the rest. In recent years,
more active in terms of CO2 conversion (30% vs 20%) and DME se- a number of innovative STD catalyst preparation methods have been
lectivity (75% vs 5%) and it also possessed better catalyst stability. So it proposed and developed; among them, sonochemical assisted, physical
was concluded that the use of γ-Al2O3 acid function in the hybrid cat- sputtering, and core-shell catalyst are the most popular. When the co-
alyst is very disadvantageous when single pot CO2 to DME conversion precipitation method is coupled with the ultrasound irradiation, the
reaction is considered. Ge et al. [153] observed that for good conver- ultrasound waves lead to a high nucleation rate limiting particle growth
sion and yield of DME, both the active sites of catalyst should be in and enhance the interaction between particles and fragments of ag-
close proximity. Frusteri et al. have investigated the function of an acid gregates of the catalyst [165]. Allahyari et al. [166] have prepared
catalyst in the hybrid catalytic system, which was prepared via gel- CuO-ZnO-Al2O3/HZSM-5 nanocatalyst by the sonochemical method
oxalate precipitation of CuZnZr precursors on HZSM-5 (Si/ and it was reported that longer irradiation time led to bigger CuO
Al = 27–127) [154]. It was found out that acidity of zeolite has to be crystals, higher surface area along with smaller particle aggregates and
tuned accordingly to achieve highest DME selectivity along with good uniform active site distribution. Khosbin et al. [167] compared the
resistance to water deactivation. HZSM-5 with Si/Al ratio of 127 gave activity of STD nanocatalyst prepared by co-precipitation-ultrasound
the highest methanol conversion but poor resistance to water deacti- and co-precipitation- physical mixing method. It was found that catalyst
vation. HZSM-5 with Si/Al of 27 offered poor methanol conversion but prepared by the former method showed better catalytic activity (50.5%
good water resistance and that HZSM-5 with Si/Al ratio 38 was the best CO conversion and 55% DME selectivity) in comparison to the latter
for one step CO2 to DME conversion and water resistance [154]. method (CO conversion 16.5% and DME selectivity of 38%) at identical
Other than the acidic property, the textual properties of zeolites also reaction conditions. Hosseini et al. [168] prepared nanocrystalline γ-
influence the catalytic activity for CO2 conversion. Therefore Frusteri Al2O3 by sol–gel method and found that catalyst prepared by the sol–gel
et al. [155] prepared hybrid grains of the catalyst by co-precipitating method showed higher activity than that prepared with precipitation
CuZnZr on different zeolites with different channel supports (FER, method. The non-aqueous sol–gel method showed even better activity
MOR, MFI) for direct synthesis of DME from CO2. During the catalyst than aqueous sol–gel one. Some other advantages of the sol–gel method
testing, the following trend of catalyst activity was observed, include low-temperature preparation method, a high degree of purity,
ability to control pore volume and pore size distribution.
CuZnZr/FER > CuZnZr/MOR > CuZnZr/MFI
Irrespective of the catalyst preparation method adopted, the cata-
Lower mass transfer limitation was offered by FER as metal oxide lytic activity decreases with TOS due to the migration of copper par-
anchored on the lamellar crystals of the FER zeolite generates more ticle, sintering [169], oxidation, coke deposition [144,170], the strong
number of Lewis acid and CO2 gets activated on those sites. There are interaction between the CZA and methanol dehydration catalyst [171]
several other reasons for the deactivation of zeolite catalysts, among and partially with the impurities present in syngas [172]. Therefore,
which the most common mechanisms are: (i) coke deposition on the many scientists have proposed a different approach to maximizing the
active site of the catalyst, and (ii) pore blockage inside the zeolite stability of the Cu-based catalyst. Garciá-Trenco et al. [173] confined
channels by carbonaceous compounds. It is experimentally proved that Cu nanoparticles inside the pores of zeolite to improve the stability of
coke deposition in zeolite is very much dependent on the shape of the catalyst in DME synthesis. In a different approach, Cu-ZnO particles
channels [156] and zeolites with large pores are more prone to coke were confined inside the pores of mesoporous silica (SBA-15) to avoid
formation compared to medium pore size zeolites [157]. Deactivation direct contact between CZA and SBA-15 surface [174]. This approach
of zeolite can be controlled by incorporation of Na into the zeolite eliminated any kind of detrimental interaction, as well as sintering of
structure; it leads to moderate number of Bronsted acid sites and de- Cu particles from the catalyst structure and further analysis with
creases the acid strength of the HZSM-5 [121]. One of the other HRTEM, showed the presence of Cu nanoparticles size of 5–6 nm. This
methods for enhancing the resistance to carbon formation is by creating catalyst preparation approach has been proved to be more effective
a silicalite shell around the HZSM-5 [158,159]. Ateka et al. [160] have than physical grinding or mixing method.
established a kinetic model of direct synthesis of DME from syngas and Millimeter size capsule catalyst is also employed for STD reaction
CO2 using CuO-ZnO-MnO/SAPO-18 bifunctional catalyst in a fixed bed where CZA core is covered by a thin layer of acidic zeolite shell [175].
isothermal reactor. The kinetics was established by considering that all This method is advantageous as very less amount of by-product is
reactions occurred during both methanol synthesis and methanol de- formed and high DME selectivity achieved, because the active sites on
hydration reaction. the surface of CZA catalyst and the acid sites of MDC do not much

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interact. Methanol produced on CZA catalyst has to diffuse through the deposition occurs on the catalyst surface. Some other studies have
acidic sites of HZSM-5 on the shell side to get converted into DME proved that the presence of water attenuates coke formation on metal
[176]. This coated capsule catalyst is not the perfect catalyst for direct sites. The main origin of the coke is the adsorbed methoxy ions on metal
DME synthesis as multiple defects and cracks are formed on the zeolite sites and water content controls the presence of methoxy ion on the
shell side during acidic hydrothermal synthesis which leads to a de- catalyst surface [60,123].
crease in CO conversion. A second layer of silicate-1 zeolite on the
HZSM-5 shell was given as a protective layer [175,177] for HZSM-5
layer. Pd/SiO2 core encapsulated with dual layer coating has shown 7.2. Effect of different feed compositions
good catalytic activity for DME synthesis. SiO2 has been used as ad-
hesive for the preparation of SAPO encapsulated MSC cores (Cr/ZnO Direct DME synthesis process is reported to be more thermo-
[178], CZA [54]). Urea hydrolysis assisted simple homogeneous pre- dynamically advantageous compared to two-step process and the
cipitation method was also reported to prepare core-shell structure of equilibrium conversion of feed gas (CO and/or CO2) depends upon the
Cu-ZnO@HZSM-5 catalyst for STD reaction [179]. Sánchez-Contador reaction temperature and feed gas composition [190]. Syngas can be
and coworkers [180] have investigated the advantage of the core-shell tailor-made according to the required composition of H2 and CO, for a
structure of CZZ@SAPO11 over simple physically mixed catalyst CZZ- different use. Among the different syngas production methods catalytic
SAPO-11 for DME synthesis from the mixture of CO and CO2 gases in partial oxidation (CPO) produces the required H2/CO ratio for the ap-
fixed bed reactor. The core-shell structure enables separation of the plication in DME synthesis. The increase in H2 proportion in the feed
methanol synthesis and methanol dehydration reactions and therefore gas mixture enhances CO conversion but for WGS reaction the opposite
H2O produced in the dehydration reaction will not affect the methanol trend is observed, because the reaction order for methanol synthesis
formation on metallic function. As a result, methanol while diffusing reaction is 2 and for WGS reaction it is 1. Moradi et al. [191] have
out of the core, will be converted to DME in the shell side of the cat- reported that CO conversion is increased from 48.23% to 78.40% at
alyst. constant space velocity (SV) of 1100 mLN/(g-cat.h) when H2/CO ratio
Nowadays a number of innovative capsule catalysts have been is changed from 1 to 2. In the STD process, CO conversion is not de-
synthesized for STD reaction [182,183]. Zeng et al. [163] proposed a pendent on the methanol dehydration step when the intrinsic methanol
dry sputtering method which is an alternative to a wet chemical method formation rate is much slower than the methanol dehydration rate [46].
and is environmentally benign. They have synthesized a highly dis- With increasing H2/CO ratio, methanol synthesis rate is accelerated and
persed Cu-Zn nano-alloy coated HZSM-5 catalyst via the physical CO conversion enhanced as H2 rich environment favors methanol for-
sputtering method. A wide range of particle size distribution of im- mation and is the highest at 2:1 ratio [184]. At a low content of H2 in
pregnated catalyst was observed from 5 to 15 nm and after calcination syngas (H2/CO = 1:1), H2 becomes the limiting reactant and the me-
followed by reduction, active Cu5Zn8 nanolayer was formed. This nano thanol formation rate becomes very slow with overall low DME yield.
alloyed and well-dispersed catalyst showed good syngas conversion and Higher H2/CO ratio (2:1) suppresses the WGS reaction, which consumes
high DME selectivity. the produced water in a methanol dehydration reaction. Thus by in-
creasing the H2 proportion results into the accumulation of water mo-
7. Effect of operating parameters on DME selectivity lecules which leads to deactivation of catalyst [191]. Along with H2,
CO2 is also produced in the WGS reaction. Some studies reported that
7.1. Water production during DME synthesis CO2 removal before DME synthesis enhances the yield and high purity
CO2 can also be achieved [192]. Otherwise, CO2 is adsorbed on the
Direct DME synthesis processes utilizing CO-rich or CO2-rich feed- catalyst surface faster than CO and H2 [157]. Thus the presence of CO2
stock have different extent of water generated during the course of the in the reactor has to be regulated as both CO conversion and DME se-
reaction. DME synthesis from methanol dehydration process is re- lectivity are decreased in high CO2 concentration [193,194].
sponsible for water generation. The produced water is often consumed Bayat and Dogu [190] have investigated the effect of CO/CO2 ratio
by the water gas shift (WGS) reaction (Eq. (9)) when CO-rich feed gas is on overall DME yield and carbonaceous gas (CO + CO2) conversion by
used and H2 is produced from the WGS reaction, which is again utilized keeping H2/(CO + CO2) ratio constant. They have achieved a very high
in CO hydrogenation reaction [19]. WSG acts as a chemical wheel DME selectivity of 90% at 275 °C with a feed gas composition of 4:1
which gives the syngas based DME synthesis process extra kinetic (CO/CO2). Erene et al. [195] investigated the effect of H2/CO2 ratio on
flexibility to reduce water accumulation and accelerate the methanol CO2 conversion and DME selectivity. The highest DME selectivity is
hydrogenation reaction [184]. But in the case of CO2 rich feed, reverse observed at 8:1 ratio and the lowest at 1:1. At H2/CO2 ratio of 1:1,
water-gas shift (rWGS) reaction is responsible for additional water significant coke deposition was observed on the acid function and the
generation and CO production [185] (Eq. (13)). Therefore it is essential transformation of oxygenates (methanol and DME) depended on the
to remove water from the system, otherwise decrease in DME selectivity acid function of the catalyst. Thus the increased quantity of hydrogen
is inevitable. The higher water content in the system is also unsuitable increases the yield of oxygenates. Ateka et al. [196] investigated the
for methanol generation step by hydrogenation reaction, as CO and CO2 valorization of CO2 for DME synthesis from the feed gas (a mixture of
have to compete with water molecules to get adsorbed on the metallic H2, CO, and CO2) on CZA/S-18 bifunctional catalyst. The CO2 content
sites of MSC [123,186]. In situ removal of water can accelerate rWGS in the feed is varied with the molar ratio of CO2/COx, from 0.0 to 0.5.
reaction to produce more CO from CO2 and DME synthesis will be According to their findings, DME yield is decreased with the co-feeding
improved. In the case of CO-rich feed gas, removal of water can ac- of CO2, which is in a good agreement with other studies. With the
celerate the methanol dehydration reaction and enhance the DME se- syngas feed, the DME yield is reported to reach as high as 14.6%, and
lectivity [187]. Carvill et al. [188] have shown that sorption-enhanced when CO2 is introduced at a CO2/COx molar ratio of 0.25, the DME
reaction process could be useful for water removal by adsorption and yield reduced to 6.6%. The presence of CO2 has a very moderate effect
Iliuta et al. [189] have also adopted sorption-enhanced reaction method on the product distribution, the selectivity of oxygenates remained re-
for in situ water removal for DME synthesis in fixed bed reactor and markably high (< 95%) with paraffin selectivity less than 1%. When
studied the effect of different parameters. DME synthesis with in situ the H2/COx molar ratio is varied from 3 to 4 in the feed gas (CO2/
water removal can improve DME selectivity compared to that without COx > 0.4), the DME yield is slightly enhanced, but for lower value
water removal [189]. But according to Sierra et al. [123] removal of CO2/COx ratio, the opposite trend was observed (Fig. 5). Maximum CO2
water can lead to deactivation of Cu-ZnO-Al2O3 catalyst as coke conversion of 10% is achieved at CO2/COx of 0.4 and H2/COx ratio of 4.

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Fig. 5. Effect of the CO2/COX ratio in the feed on the product yield (a) and selectivity (b) and effect of the H2/COX ratio on the yield of DME (c) and selectivity (d) for
different CO2/COX molar ratios in the feed. Reaction conditions: 275 °C; 30 bar; 10.18 (g-cat) h (molC)−1; feed, H2 + CO + CO2. Reproduced from [196].

7.3. Effect of feed supply rate methanol selectivity (1.5%).


Liu et al. [198] investigated the effect of various space velocities
Feed supply rate is an important parameter for DME synthesis in any (1500 to 3000 mLN g-cat−1 h−1) on CO2 conversion and DME se-
reactor system and it is represented by many units such as space velocity lectivity. It was reported that when SV was increased to 3000 mLN/ (g-
(SV), gas hourly space velocity (GHSV), and space-time (ST). At constant cat h), CO2 conversion is decreased along (27.9 to 22.3%) with DME
H2/CO ratio, CO conversion increases when space velocity (SV) is de- selectivity (64.6 to 58.5%). Similar observations were also made by
creased but when SV is reduced beyond a certain point CO conversion Zhao et al. [199] who reported that when SV was increased to
cannot be enhanced. At higher SV, the fast feeding of reactant gas mix- 3500 mLN. g-cat−1 h−1 from 1500 mLN g-cat−1 h−1, then DME se-
ture promotes high mass transfer rate, but it comes with the cost of the lectivity was decreased to 47.5 from 63.1%.
contact time between the reacting species and the catalyst. Moradi et al.
[191] observed that CO conversion is increased from 71.51% to 89.52%, 7.4. Effect of reaction temperature
when SV was reduced from 1000 mLN/(g-cat.h) to 500 mLN/(g-cat.h) at
constant H2/CO ratio (2:1). However, further increase in CO conversion The reaction temperature plays a big role in reversible exothermic
was not reported for SV less than 500 mLN/(g-cat.h). Hayer et al. [58] reactions such as DME synthesis from syngas or mixture of CO2 and H2.
investigated DME synthesis in a microchannel reactor from syngas. Ex- In the beginning, the reaction is under kinetic control at low temperature
perimentally they confirmed that with increasing the space velocity from and by increasing the reactor temperature, the reaction rate can be en-
4500 to 60000 mLN/(g-cat-h), the CO conversion decreased. Initially, it hanced. As the reaction progresses and tends to achieve reaction equi-
increased to maximum at 9000 mLN/(g-cat-h) as the corresponding feed librium, the reactor temperature starts to increase and as a result, the
rate increased, but after that, it decreased due to short residence time. overall conversion is reduced. Thus any reaction process involving exo-
Increase in SV also decreases the selectivity of DME due to the con- thermic reversible reaction should be operated in such a way that along
secutive product formation from methanol. Kumar and Srivastava [197] the reactor length the reactor temperature should decrease. Kumar and
studied syngas conversion into DME in fluidized bed reactor and reported Srivastava [197] studied the effect of temperature on DME synthesis
that DME productivity initially increased with an increase in GHSV from from syngas in a slurry phase reactor at 230 and 250 °C. A similar con-
80 to 1000 h−1, but it decreased above 1400 h−1. It was reported that at version was achieved at both reaction temperatures, although at the end
turbulent flow the CO conversion, DME selectivity, and yield were of the reaction, a minor difference in productivity was observed. Reac-
higher. CO conversion was very low at bubbling bed flow regime tion at 250 °C showed better selectivity than at 230 °C along most of the
(GHSV = 80 h−1). Beyond GHSV of 1000 h−1 flow regime changed to reactors. Lu et al. [184] have concluded that DME synthesis catalyst
turbulent flow and both CO conversion as well as DME selectivity in- should not be exposed to a temperature higher than 270 °C otherwise the
creased. Ateka et al. [196] investigated the effect of space-time catalyst activity will be reduced due to sintering of Cu metallic sites
(2.5–20 g-cat h (molc)−1) by varying the catalyst mass at different molar which was also confirmed by others [200,201]. Kumar and Srivastava
flow rates on DME yield from syngas in a high pressure fixed bed reactor. [197] explained that with increasing the temperature, the selectivity also
They observed that by increasing the space-time CO conversion and DME increases because at higher temperatures activity of methanol dehydra-
yield were increased with negligible paraffin selectivity and little tion catalyst is higher than that of methanol synthesis catalyst. It was

308
U. Mondal and G.D. Yadav Journal of CO₂ Utilization 32 (2019) 299–320

Fig. 6. Effect of temperature on CO conversion and DME selectivity. Reaction condition: catalyst CZA/HZSM-5 (prepared by impregnation, co-pre-
cipitation–physically mixing and co-precipitation–ultrasound methods), H2/CO molar ratio of 2, GHSV of 600 cm3N/(g-cat.h) [167].

Fig. 7. Effect of pressure on CO conversion and DME selectivity. Reaction condition: catalyst CZA/HZSM-5 (prepared by impregnation, co-precipitation–physically
mixing and co-precipitation–ultrasound methods), H2/CO molar ratio of 2, GHSV of 600 cm3N/(g-cat.h) [167].

suggested that 250 °C was the best reaction temperature for DME 7.5. Effect of operational pressure
synthesis in slurry phase reactor. DME synthesis from syngas in fixed bed
reactor has been studied in the presence of CuO-ZnO-MnO/SAPO-18 According to the thermodynamic analysis of DME synthesis reac-
bifunctional catalyst, and the reaction temperature was varied in the tion, the reaction pressure has a positive effect on overall DME yield.
range of 250–350 °C. It was reported that the highest DME yield was Many researchers have reported that with increasing reaction pressure
obtained at 275 °C and above 300 °C an increase in paraffin yield (me- both the CO conversion and DME selectivity increase. So it is evident
thane is most selective among all C1–C3 molecules) was observed. In the that the equilibrium conversion of CO for the methanol synthesis re-
temperature range of 250–275 °C DME selectivity was found to action is enhanced by the consumption of methanol in the methanol
be > 95% but it was reduced to 65% when the reaction temperature was dehydration reaction. The negative effect of elevated pressure on direct
increased to 350 °C [202]. Khosbin and Haghighi [167] investigated DME synthesis has also been reported as water is produced in both
DME synthesis from CO in the range of 200–300 °C and their results are methanol synthesis and methanol dehydration reactions. Increase in the
shown as CO conversion and DME selectivity in Fig. 6. It shows that CO partial pressure of water suppresses the CO conversion by blocking the
conversion increases up to 275 °C but thereafter it decreases when the active sites for methanol dehydration reaction. Erena et al. [201] in-
temperature is increased to 300 °C. DME selectivity decreases as the re- vestigated the effect of pressure from 10–50 bar on the direct DME
action temperature is increased. Zhau et al. [199] examined the effect of synthesis from a mixture of CO, CO2, and H2 gases. CO conversion was
temperature on CO2 conversion and DME selectivity. It was found that increased when operating pressure was elevated to 50 bar. Hydro-
with the increase in temperature from 240 to 260 °C, CO2 conversion and genation of CO and CO2 leads to a decrease in a number of moles, and
DME selectivity were also increased (20.9% and 63.1%, respectively). consequently, when pressure is elevated, hydrogenation reactions are
But further increase up to 280 °C decreased both CO2 conversion and favored over WGS reaction. The methanol synthesis reaction is the
DME selectivity. The hydrogenation of CO2 is a reversible reaction and limiting step of this process. Thus it can be understood that by in-
therefore an increase in temperature causes enhancement of reverse re- creasing pressure, the rate of methanol dehydration reaction is also
action and a decrease in DME selectivity. Zha et al. [203] had reported elevated. The composition of the hydrocarbons in the product stream is
that when the temperature was increased to 282 °C from 262 °C, DME also affected by the variation of pressure, and the fraction of C1–C4
selectivity was decreased to 30.9% from 45.1%. Liu et al. [198] also had paraffin increased in comparison to C5* paraffin [195]. Therefore it is
reported that when reaction temperature was increased from 240 to very clear that at elevated pressure (up to 50 bar) the hydrogenation of
260 °C DME selectivity was increased to 64.5%, but a sharp decrease in light olefins (intermediate products obtained methanol and DME) pre-
DME selectivity (47.5%) was observed when the temperature was in- dominates over single condensation reactions (aromatization, alkyla-
creased to 280 °C. tion, oligomerization). Jia et al. [204] investigated DME synthesis

309
Table 2
Effect of different catalysts and process parameters on selectivity for DME synthesis in fixed bed reactor.
Synthesis method Catalyst Temperature, °C Pressure, MPa Others essential factor Conversion & yield Authors

Direct method CuO-ZnO-MnO/SAPO-18 275 3 H2:COx = 3; CO2:COx = 0–0.5; Space time = 5.2 gcat. h (molC)−1 CCOx = 47% Ateka et al.
[206]
Direct method Cu-ZnO/γ-Al2O3 220–260 5 H2:CO2:Ar:N2 = 15:15:60:10 YDME = 21. Henrich et al.
U. Mondal and G.D. Yadav

[207]
Direct method Pd-Ga NP/γ-Al2O3 250–300 2 Ar:N2:H2:CO = 5:2:1.5:1.5 CCO2 = 60% Gentzen et al.
Total flow = 50 mLNTP/min [208]
Direct method Cu-Zn NP/HZSM-5 250–300 5 Ar:N2:H2:CO = 5:2:1.5:1.5 Gentzen et al.
Total flow = 50 mLNTP/min [209]
Direct method Cu-ZnO-ZrO2/SAPO-11 275 3 H2:COx = 3; CO2:COx = 0.5; Space time = 2.5 gcat. h (molC)−1 CCO = 30% Sánchez-
Contador et al.
[181]
Indirect method SAPO-11 nanocrystals (20–30 nm) 260 0.1 N2: MeOH = 240 (vol ratio) YDME = 19.6 Chen et al. [210]
Direct method CuO-ZnO-Al2O3/SAPO-18 275 3 H2:CO2 = 3; CO2:COx = 0–0.5 CCO = 40% Ateka et al.
St = 10.18 gcat. h (molC)−1; [196]
Direct method Cu-infiltrated Zr doped SBA-15 250 3.3 H2:CO2 = 3:1 YDME = 25 Atakan et al.
[211]
−1
Direct method Cu–Zn/Al2O3; sol-gel method 220 0.9 H2/CO/Ar = 5.0/5.0/1.0 mL min CCOx = 9% Takeishi et al.
[212]
Direct method CuO/ZnO/Al2O3 & HZSM-5 250 1–5 Syngas YDME = 6.5 Dadgar et al.
AV = 800 N cm3/min/g [213]
Direct method CuO/ZrO2 + montmorillonite K10 220–300 4 H2 + CO2 = 6 m ml/min CMeOH = 80% Kornas et al.
(modified by 3 wt% of Ga, Cr, Mn and Ag) [214]
Direct synthesis Cu–Fe–Ce/HZSM-5 with 3.0 wt% CeO2 240–280 2–4 Plasma catalytic reactor = 11.0–15.0 kV, H2: C02 = 4:1 CCOx = 9.5% Su et al. [215]
GHSV = 1500–3500 mL.gcat−1h−1
Direct method Cu.ZnO/Al2O3 or Nb2O5 250/270 3 H2/CO2 = 3 YDME = 14.5% Silva et al. [216]

310
SV = 10 h−1
Direct method Cu based MSC (C18W019) + Silicotungstic acid 275 5 H2/CO/CO2 = 50/40/10, CCO2 = 15% Bayat et al.
impregnated mesoporous alumina (STA@MA) Space time = 0.48 s gcat/mL. [190]
Total flow rate of feed gas = 25 ml/min
Indirect method Diatomite catalysts modified using nitric acid 250–350 0.1 MeOH:N2 = 1:4; total flow rate = 60 ml/min Pranee et al.
[217]
Direct synthesis CuO-ZnO-MnO/SAPO-18 270–350 3 H2/CO = 3; YDME = 8% Ateka et al.
space time (2.5–20 gcat h (molC)−1) [202]
Direct synthesis CuO-Fe2O3-CeO2/HZSM-5 240–280 2–4 H2/CO2 = 4; Zhau et al. [199]
GHSV = 1500–3500 mL gcat−1 h−1
Direct synthesis Cu/mesoAL(HT) 250 5 H2:CO:N2 = 63:31.5:5.5; S DME = 35% Ham et al. [218]
SV = 2000 L/(kgcat.h)
Direct synthesis CuO–ZnO–Al2O3/HZSM-5 260 2 H2/CO = 2 (mole ratio) CCO2 = 69.5% Cai et al. [172]
GHSV = 3600 cm/gcat/h
Indirect synthesis MgO/HZSM-5 200–300 MeOH:EtOH = 3:1 YDME = 16.9% Liu et al. [219]
WHSV = 4 h−1
Direct synthesis Cu-Zn-Zr/MFI Zeolite 180–240 5 SV = 2500 NL/Kgcat/h; CO2:H2:N2 = 3:9:1 CCO2 = 9% Frusteri et al.
[154]
Direct synthesis Cu–Fe–Zr/HZSM-5 240–280 2–4 H2: CO2 = 5:1; S DME = 31% Qin et al. [220]
GHSV = 1500– 3000 mL.gcat−1h−1
Direct synthesis Cu/ZnO/Al2O3 & HZSM-5 (modified with MgO, CaO & 260 4 H2/CO/CO2/N2 = 59.93:27.33:4.12:8.62 (vol%); GHSV = 1500 mL CCOx = 90% Mao et al. [221]
BaO) h−1 g−1 cat
Direct synthesis Cu/Zn/Al citric/TPA- K10 280–360 4 Syngas (CO:CO2:H2 = 5:30:65) YDME = 26.0% Samson et al.
GHSV = 3600 h−1 [222]
Direct synthesis CuO–ZnO–Al2O3 and SiO2-ZSM-5 260 2 H2: CO = 2 SDME = 90% Ordomsky et al.
GHSV = 3600 cm3 gas/g−1 cat h−1 [169]
Direct synthesis Cu–ZnO–Al2O3–ZrO2 (with different Zr ratio) and γ-Al2O3 270 5 Biomass derives syngas(H2/CO/CO2/CH4 = 52/24/23/1), CCOx = 36% Song et al. [223]
GHSV = 1500 h−1
(continued on next page)
Journal of CO₂ Utilization 32 (2019) 299–320
Table 2 (continued)

Synthesis method Catalyst Temperature, °C Pressure, MPa Others essential factor Conversion & yield Authors

Direct synthesis Core- shell structure catalyst (CuO–ZnO–Al2O3@ 220–320 2–6 Syngas (H2/CO = 2) YDME = 13% Wang et al.
SiO2–Al2O3) GHSV = 1000–4000 mL/(h gcat) [224]
Direct synthesis Cu/ZnO/H-ZSM5 by by sputtering and impregnation 250 5 Syngas (CO: 33.8 v%, CO2: 5.10 v%, Ar: 3.09 v%, balanced with H2; CCOx = 20.9% Sun et al. [225]
methods Wcatalyst/Fsyngas = 10 g h mol−1
U. Mondal and G.D. Yadav

Direct synthesis CuZnAl/zeolite 260 4 Gas mixture = 90% syngas(66% H2/30% CO/4% CO2) + 10% Ar SDME = 63.1% García-Trenco
SV = 2550 cm3/(gcat.h) et al. [226]
Direct synthesis Multi-walled carbon nanotubes promoted CuO–ZnO–Al2O3/ 262 3 H2/CO2 = 3/1 CCOx = 11.5% Zha et al. [203]
HZSM-5. GHSV = 1800 mL gcat−1 h−1
Direct synthesis CuO–Fe2O3–ZrO2/HZSM-5 240–280 2–3.5 H2/CO2 = 5/1 SDME = 76.1% Liu et al. [227]
GHSV=
1500–3000 mL gcat−1 ·h−1
Direct synthesis Cu/ZnO/H-ZSM5 sputtering catalyst 250 5 Syngas (CO: 32.5%, CO2: 5.2%, Ar: 3.1%, balanced with H2) CCOx = 75.0% Zeng et al. [163]
Direct synthesis Cu–ZnO/γ-Al2O3 270 3.5 Syngas= SDME = 69.8% Ahn et al. [228]
H2/CO = 2 along with 5.6 mol% N2
GHSV = 2000 ml/gcat.h
Direct synthesis Core shell CuOZnO Al2O3@Al2O3 260 5 Syngas = H2/CO Wang et al.
GHSV = 1500 mLh−1 gcat−1 [183]
Indirect synthesis Undoped and doped γ-alumina spherical particles (CuO, Up to 350 0.1 2 mol% CH3OH mixed with N2 was fed into the reactor at a flow rate of CCOx = 23.6% Pillai et al. [229]
CuO + ZnO) by sol-gel method 60 mL min−1
Direct synthesis core–shell like silicoaluminophosphate (SAPO-46) 350 5 Syngas = 58.10% H2: 33.80% CO: 5.10% CO2: 3.09% Ar SDME = 49.3% Pinkaew et al.
encapsulated Cr/ZnO capsule catalyst [178]
3 −1
Indirect synthesis Ba2+ impregnated on γ-Al2O3 260 –290 0.1 MeOH flow rate = 0.3–0.9 cm min CCO = 30% Hoda et al.
[230]
Direct synthesis Cu/ZnO/Al2O3 and phosphate on γ-Al2O3 250 5 Syngas (H2/CO) = 2 CCOx = 93.8% Montesano et al.
GHSV = 8400 h−1 [231]
Direct synthesis Mesoporous Cu/γ-Al2O3 280–325 5 Syngas = CO(6 ml/min) + H2 (12 ml/min) + N2 (2 ml/min) SDME = 64.4% Jiang et al.

311
[139]
Direct synthesis Core-shell design CuO-ZnO/HZSM-5 257 3 H2/CO2 = 2 (mol/mol) Li et al. [232]
SV = 1600 h−1
Direct synthesis CuO–ZnO–Al2O3 with acid catalyst NH4ZSM-5, HZSM-5 or 200–260 2 syngas mixture (BOC gases) which contained (62% H2, 31% CO, 4% CCOx = 65% Abu-Dahrieh
γ-Al2O3 CO2 and 3% Ar) et al. [141]
SV = 2400 ml h−1 g−1
cat
Direct synthesis XNC-98/HZSM-5 = 4:1, 220–280 3 H2/CO = 1 SDME = 45% Zhang et al.
GHSV = 3000 ml/gcat.h [233]
Indirect Synthesis aluminum fluoride (AlF3) modified HZSM-5 180 MeOH SV = 40 ml h−h CCO = 74% Yang et al. [234]
N2 SV = 6000 h−1
Direct synthesis CuO-ZnO-Al2O3 to pseudo-boehmite was 2/1 220–260 4 H2:CO: CO2 = 1.0/1.0/0.08 SDME = 69% Liu et al. [235]
Indirect synthesis Al-SBA-15 120–450 0.1 MeOH vapour + He = 44.4 cm3 min−1. CCO = 79.3% Tokey et al.
[118]
Direct synthesis hybrid CuZnAl/ZSM-5 260 4 A mixture of 90 vol% syngas (molar composition: 66%H2/30%CO/ SDME = 85.8% Trenco et al.
4%CO2) and 10 vol% Ar. [171]
SV = 1700 mLsyngas/(gcat. h)
Direct synthesis CuO–ZnO–Al2O3/γ-Al2O3 with excess γ-Al2O3 225–325 2–4 H2/CO2 = 2/1 to 4/1 Space time Erena et al. [60]
ST = 42.0 (g of catalyst) h (mol of carbon)−1 yield = 5.08 mol/L/h
Direct synthesis Cu-Zn/γ-Al2O3 260 5 H2/CO = 1 CCO = 71.1% Park et al. [236]
GHSV = 3000 ml/g-cat.·h
Direct synthesis Double shell capsule catalyst Cr/ZnO–S–Z (S = neutral 300–350 5 Ar 3.02%, CO 32.6%, CO2 5.16%, H2 59.22% in molar base SDME = 61.9% Yang et al. [237]
Silicalite-1 zeolite layer; Z = HZSM-5 layer)
Direct synthesis CuO/ZnO/Al2O3 and γ-alumina 220–260 3–7 H2: 60–75%, N2: 9–12%, CO: 12–20%, CO2: 1–5%. Cheng et al.
GHSV = 1000–2500 mL/g h [238]
Direct synthesis Cu–ZnO/γ-Al2O3 250 5 H2:CO = 2:1; CCO = 13.7% Beak et al. [239]
space velocity (SV) = 4000 mL gcat−1 h−1
(continued on next page)
Journal of CO₂ Utilization 32 (2019) 299–320
Table 2 (continued)

Synthesis method Catalyst Temperature, °C Pressure, MPa Others essential factor Conversion & yield Authors

Indirect synthesis Macro porous sulphonic acid ion exchange resign 118–150 2.0 MeOH = 0.20 ml/min SDME = 92.1% Lei et al. [240]
Direct synthesis bifunctional catalyst (JC207/HZSM5 [Si/Al = 25, 38, 50, 250–290 3 gas product from biomass gasification containing H2 42.1%, N2 13.4%, Xu et al. [241]
150]) CO 33.9%, CH4 5.0%, CO2 5.6%
SV = 1300 L/(kg. hr)
U. Mondal and G.D. Yadav

Direct synthesis CuO–ZnO–Al2O3 (Cu:Zn:Al ≈ 5:4:1 mass ratio)/γ-Al2O3 210–300 1-6 H2/CO = 2–4; CCO = 87–90% Hayer et al. [58]
SV = 15.000 Nml/gcat/h
Direct synthesis 6CuO–3ZnO–Al2O3/γ-Al2O3 and 6CuO–3ZnO–1Al2O3/ 260 5 reactant gas (CO2/3H2) SDME = 64% Naik et al. [124]
HZSM-5 GHSV = 3000 ml/gcat. h
Direct synthesis bifunctional catalyst (JC207/HZSM5 [Si/Al = 38, MgO, 240–280 3 Biomass pyrolysis gas (H2 42.1%, N2 13.4%, CO 33.9%, CH4 5.0%, CO2 Xu et al. [242]
Cao and ZnO]) 5.6%)
SV = 1300 L/(kg hr)
Indirect synthesis γ-Al2O3 260–380 0.1–1.6 MeOH, CCO2 = 46.2% Moradi et al.
SV = (W/F = 1.724 g/ml·min) [243]
Indirect synthesis novel silicotungstic acid (STA) incorporated nano- 180–350 MeOH = 2.1 mL/hr SDME = 45.2% Ciftci et al.
composite catalysts (silicate structured mesoporous MeOH/He = 0.48 (vol/vol) [244]
catalysts TRC-62(L), TRC-82(L) and TRC-92(L)),
Indirect synthesis mesoporous nanocrystalline γ-Al2O3 300 0.1 MeOH YDME = 20.9% Keshavarz et al.
WHSV, (1.75–9.62 h−1) [245]
Indirect synthesis Nafion-Incorporated Silicate Structured Nanocomposite 120–300 0.1 MeOH = 2.1 ml/min CCO2 = 28.4% Ciftci et al. [89]
Mesoporous Catalysts He = 23 ml/min
Space Time = 0.27 s g cm-3
MeOH: Feed Gas = 0.48
Indirect synthesis γ-Al2O3 derived from Nordstrandite 300 0.1 MeOH, GHSV = 6000 SDME = 64.5% Seo et al. [246]
Direct synthesis Cu–ZnO–Al2O3 promoted with Zr or Ga on γ-Al2O3 250 5 H2:CO = 2:1 Kang et al. [247]
(SV) = 4000 mL gcat−1 h−1
Direct synthesis CuO-ZnO- Al2O3/γ- Al2O3 225–350 1–4 H2/CO = 2–4 CCO = 13% Sierra et al.

312
ST = 0.1–68.0 (g of catalyst) h (mol of reactants)−1 [123]
Reactant flow rate = 1 mmol/min (H2 + CO)
Indirect synthesis 1. Rh-SiO2 catalyst (0.406 wt% Rh in SiO2) 1.660 0.1 1. liquid 48 wt%HBr/H2O was 6.5 ml/h SDME = 93.5% You et al. [248]
2. ZnCl2/SiO2 2.180 (CH4, O2, N2, CO, and CO2 were 20.0 ml/min, 5.0 ml/min, 5.0 ml/min,
3.0 ml/min, and 4.0 ml/min)
2. CH3Br, N2, and H2O (L) are 10.0 ml/min, 10.0 ml/min, and 0.5 ml/h)
Direct synthesis Cu/Zn/Al/HZSM-5 260 4.3 H2/CO = 2 CCO = 47.6% Li et al. [249]
GHSV = 3000 h−1
Tail gas recycled GHSV = 650-3000 h−1
Direct synthesis Cu–ZnO–Al2O3/Zr-ferrierite (CZA–ZrFER) 250 4 CO/CO2/H2 = 41/21/38 (molar feed composition) SDME = 61.1% Bae et al. [250]
SV = 5500 L/(kgcat h)
Direct synthesis CuO–TiO2–ZrO2 (with various Ti and Zr molar 200 3 Feed gas = CO2 (23.3%), H2 (64.5%) and N2 (the rest) CCO = 35.2% Wang et al.
ratios) + HZSM5 [251]
Direct synthesis Cu-Zn-Al-M (M = Ga, La, Y, Zr)/γ- Al2O3 250–280 4.13 H2/CO = 1.5 SDME = 61.1% Venugopal et al.
GHSV = 6000–12000 h−1 [134]
Indirect synthesis γ-Al2O3 and η-Al2O3 260 GHSV = 6000 CMeOH = 100% Seo et al. [252]
from boehmite and bayerite
Direct synthesis CuO–ZnO–Al2O3–ZrO2 + HZSM-5 250 5 H2/CO2 = 3 CCOx = 6.9% An et al. [253]
SV = 6000 mL/(g cat · h)
Direct synthesis CuO/ZnO/Al2O3 for methanol forming, γ-alumina for 260 6 Coal gasification H2/CO = 0.5 YDME = 37% Yoo et al. [254]
methanol dehydration GHSV = 3000 l/kg-cat h
Direct synthesis Cu–ZnO–Al2O3/Zr-modified zeolites (Ferrierite, ZSM-5 and 250 4 CO/H2/CO2 (41/38/21) CMeOH = 27.7–46.33% Kang et al. [255]
Y) SV = 5550 ml/h gcat
Indirect synthesis Cu0.5(1+y)FeyZr2−y(PO4)3 197–397 0.1 MeOH + Ar/Air = 2.4l/h Pet'kov et al.
y = (0, 0.5, 1.0, 1.5 and 2.0) [256]
Indirect synthesis commercially available γ- Al2O3 300 1.6 MeOH = 0.55 ml/min CCO = 72% Mollavali et al.
GHSV = 26.07 h−1 [257]
Direct synthesis CuO-ZnO-Al2O3-ZrO2/HZSM-5 (SiO2:Al2O3 = 25) 250 3 H2/CO2 = 3 SDME = 69% Zhao et al. [258]
GHSV = 1600 h−1
Journal of CO₂ Utilization 32 (2019) 299–320

(continued on next page)


Table 2 (continued)

Synthesis method Catalyst Temperature, °C Pressure, MPa Others essential factor Conversion & yield Authors

Direct synthesis Cu–Mn–Zn/zeolite Y modified with La, Ce, Pr, Nd, Sm and 245 2 H2/CO = 3/2 and CCO = 81% Jin et al. [259]
Eu SV = 1500 h−1
Direct synthesis Cu/ZnO/Al2O3 and SAPO-34 and -18 260 4.2 H2/CO = 1.5 SDME = 67% Yoo et al. [260]
GHSV = 3000 mL/gcat h
U. Mondal and G.D. Yadav

Indirect synthesis aluminum phosphate catalysts with Al/P = 1 175–275 0.1 MeOH = 2 ml/h Kumar et al.
[261]
Direct synthesis Al2O3 on the Cu-ZnO-Al2O3-SiO2 catalysts prepd. by a 250 3 20%CO2 and 80%H2 CCO = 63.4% Wang et al.
pseudo sol-gel method SV of 3200 h−1 [262]
Indirect two step 1. 0.1 wt% Ru/SiO2 1. 530– 560 0.1 1. HBr/H2O (40 wt% in water) = 4.0 mL/h. SDME = 10.8% Xu et al. [263]
process 2. RuCl3 2. 150– 180 CH4 = 5 ml/min
O2 = 15–20 ml/min
2. CH3Br = 0.5 g
H2O = 0.4-0.7 g
Indirect synthesis aluminum was 850–425 mm (about 18–35 mesh)and 200–325 MeOH = 0.39 kg/dm3 CCO = 70% Usui et al. [264]
magnesium was 20–70 mesh (about 740–210 mm) power
Direct synthesis Copper catalyst (Süd-Chemie Catalysts Japan Inc., MDC-3) 220–290 1–3 Syngas = (H2/CO/CO2/Ar) 60/30/5/5) Omata et al.
and γ-alumina Flow rate = 44 mmol/h [265]
Direct synthesis Cu-Zn-Al/HZSM-5 240 5 H2/CO = 2 CMeOH = 86% Jia et al. [266]
Space velocity = 1000−1
Direct synthesis Cu-ZnO-ZrO2/Al2O3-HZSM-5 260–280 8 Syngas derived from CH4 catalytic partial oxidation CCO = 81% Hengyong [267]
(CPO) = H2:CO:N2:CO2:CH4 = 39.8″14.7:37.2:5.9:2.4
SV = 1500−1
Direct synthesis C301/HZSM-5 230–270 4 H2 to (CO + CO2) equal to 2.6 SDME = 67% Wang et al. [56]
C301/γ-Al2O3 GHSV = 927 ml/gcat.h
Direct synthesis Cu-ZnO-X (X = Al2O3, Cr2O3, ZrO2 or Ga2O3 250 1 Blast furnace gas CMeOH = 52% Akiyama [268]
CO/CO2/H2 = 4/4/1

313
Feed gas flowrate = 1.O x 10−6m3/sec
Direct synthesis CuO/ZnO/γ-Al2O3 270 3 H2/CO/CO2 = 64/31/5 (mol) SDME = 100% Li et al. [269]
GHSV = 2000 h−1
Based on carbon molecule
Direct synthesis Pd/SiO2, Pd/Al2O3, modified Pd/Al2O3 and hybrid (phys. 230–350 1.1–5.1 H2/CO = 2/1 CCO = 93% Han et al. [270]
mixed) catalysts containing. Pd/SiO2 or Cu-Zn-Al (O) and γ- (5% CO2 was added in the case of methanol synthesis on Cu-Zn-Al
Al2O3 catalyst)
Contact time = 0.3–4.2 g-cat.-hr/mol.
Journal of CO₂ Utilization 32 (2019) 299–320
U. Mondal and G.D. Yadav Journal of CO₂ Utilization 32 (2019) 299–320

reaction up to 100 bar and concluded that there is no significant en- Some strategies have been taken up for direct DME synthesis process
hancement of CO conversion beyond 50 bar and this result is very much from syngas and CO2, but it is a two-step process. The main obstacles of
similar to that of Erena et al. [205]. In slurry reactor, the effect of the process are the catalyst deactivation due to water generation and
pressure has shown an additional effect, with increasing the pressure coke deposition on the surface of the acid catalyst. Copper-based multi-
the bubble size decreases and as a result mass transfer coefficient in- component catalysts have been studied extensively. The vastly used
creases, which influences the overall conversion. Kumar and Srivastava CO2 or syngas hydrogenation catalyst is Cu/ZnO/Al2O3 (CZA) and for
[197] also confirmed a similar phenomenon for DME synthesis reaction the methanol dehydration reaction, acidic catalysts are needed.
in fluidized bed reactor from syngas. Khosbin et al. [167] investigated Compared to the syngas to DME (STD) process, DME synthesis from CO2
the influence of reaction pressure from 10–40 bar on CO conversion and produces more amount of water leading to catalyst poisoning. A vast
DME selectivity. A positive effect of reaction pressure has been reported array of catalysts have been tested for acid function for methanol de-
on CO conversion and DME selectivity, as shown in Fig. 7. Table 2 hydration reaction. HZSM-5 shows the highest water tolerability and
summarizes different catalysts and operating parameters influencing activity. Catalyst preparation methods also have a profound effect on
the conversion, yield and selectivity of DME studied over recent years. catalyst properties, and it is found that co-precipitation- sedimentation
Zhou et al. [199] varied the reaction pressure from 20–40 bar in one and co-precipitation coupled with ultrasound irradiation were the most
pot DME synthesis process to investigate the effect on CO2 conversion suitable catalyst preparation methods for achieving high catalyst ac-
and DME selectivity. CO2 conversion was increased when reaction tivity. Many studies have employed core-shell structure of bifunctional
pressure was elevated to 30 bar, but when it was increased beyond 30 to catalyst wherein CZA catalyst is covered by a thin layer of acidic cat-
40 bar, CO2 conversion was decreased. DME selectivity was also shown alyst (HZSM-5). This type of catalyst configuration shows high DME
to have a similar relationship with reaction pressure. The one-step CO2 selectivity and less amount of by-product formation.
to DME synthesis process is a series of volume decreasing reactions, and The performance of any DME synthesis process is hugely affected by
therefore by increasing pressure, the CO2 conversion can be enhanced. several operating parameters. A majority of the DME synthesis study
Zhou et al. [199] concluded that the decrease in CO2 conversion (17.2% has been carried out in the temperature range of 200–300 °C and
from 20.9%) and DME selectivity (55.5% from 60.3%) might be due to pressure range up to 70 bar. For the conversion of CO2 to DME, the
water formation in the reactor when the pressure was elevated from optimum operational pressure is 30 bar and temperature 270–275 °C.
30 to 40 bar. Based on several studies, it was also concluded that 30 bar Direct conversion of CO2 is very difficult as more amount of water is
was the optimum pressure for one pot DME synthesis from CO2 produced via rWGS reaction. Therefore co-feeding of CO with the feed
[198,199,203]. gas can convert water into H2 via WGS reaction and CO2 conversion
will increase. Comparatively syngas conversion is much easier, and the
8. Conclusions highest conversion and DME selectivity are achieved in the range of
250–260 °C and at pressure of 40 bar. The molar ratio of H2 and CO2
Dimethyl ether (DME) has great potential as fuel and precursor for also has a pronounced effect on DME selectivity and CO2 conversion. At
chemical manufacture. DME is the cleanest high-efficiency compression a higher molar ratio of H2/CO2 (8:1) the highest DME selectivity is
ignition fuel as a substitute for diesel. In order to establish DME pro- observed but as the molar ratio is decreased to 1:1, then CO2 conversion
duction and utilization system, it is very important to establish the is increased, but DME selectivity is decreased as huge coke is deposited
required infrastructure for raw material supply chain, DME synthesis on the catalyst surface. Although a few pilot plant studies on DME
process, and development of necessary machinery. The purpose of this synthesis are reported in recent times, most of the DME synthesis from
review was to take stock of DME as fuel and find out the technological various raw materials are only based on laboratory scale studies. To
challenges in converting CO2 to DME. Fossil fuels are the largest source project DME as a future fuel for our society, new studies encompassing
of energy, and the combustion of fossil fuels tends to generate a huge process optimization and scale-up of one-pot DME synthesis and eco-
amount of greenhouse gases in the atmosphere. A large amount of nomic aspects of an efficient and practical DME synthesis plant must be
greenhouse gases (CO and CO2) are generated in coal or petroleum explored. More and more research on the noble catalyst development
operated thermal power plants and there is a dire need to provide a CO2 has to be taken up for getting the most active, reusable, economical and
capture and sequestering (CCS) facility to deal with this huge pollution. highly water tolerant catalyst. Feed type, its cost and supply rate is a
However, the economy of the CCS plant only can be sustainable when it very important factor for DME synthesis process, and its effect on DME
is supported by dimethyl ether synthesis plant with a production ca- selectivity and syngas gas and/CO2 conversion is dependent on the type
pacity in the range of 3000–7500 metric ton per day. Tremendous work and capacity of the reactor. Therefore optimization of the space velocity
has been done to explore the most suitable reaction conditions for DME of the feed gas is of great importance for establishing a practical DME
synthesis. Bio-DME is a very attractive alternative to diesel, which plant. The type of reactors and separators and their configurations have
yields very low tailpipe emissions, near-zero amount of CO2 emission a great bearing on both fixed and operating costs of DME production.
and thus there is no need to CO2 capture and sequestration in the bio- The production of syngas, irrespective of nature of feed, is critical in
DME plant. However, the production cost of DME is higher with pre- DME synthesis. Part II covers all these aspects. Overall, DME has a great
sently available technologies when it is produced from natural gas, coal, future.
and biomass because the conversion of raw materials to syngas is an
expensive process. Methanol based indirect DME synthesis is com- Conflict of interest statement
paratively safer as methanol production from syngas is a mature and
well-established process. Companies like Linde/Lurgi, Haldor Hospice, The authors declare no conflict of interest.
Uhde, Toyo Engineering, and Mitsubishi Gas Chemical Company are
holding the licenses for the single-step DME synthesis technology. MGC, Acknowledgement
Toyo, Udhe, and Lurgi are developing DME production technology
based on indirect synthesis. A tabular summary of different studies of UM got financial support as D.S. Kothari Post-Doctoral Fellowship of
the DME synthesis processes, catalysts, and operating conditions was UGC. GDY received support from R.T. Mody Distinguished Professor
presented. Endowment, Tata Chemicals Darbari Seth Distinguished Professor of
Other routes of DME synthesis process which are already practised Leadership and Innovation, and J.C. Bose National Fellowship, DST,
and being developed were discussed in detail. Govt. of India.

314
U. Mondal and G.D. Yadav Journal of CO₂ Utilization 32 (2019) 299–320

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