Carbon dioxide hydrogenation to methanol by flame-deposited CuO/ZrO2-polymer membrane reactors

Carbon dioxide hydrogenation for methanol synthesis, within the framework of carbon dioxide utilization represents a promising strategy. Nevertheless, high conversion of carbon dioxide into methanol presents significant challenges, primarily arising from thermodynamic constraints and catalyst deactivation due to the formation of water as a by-product. In response to these challenges, this investigation focused on the development of an innovative hybrid catalytic membrane reactor utilizing flexible polymeric membranes with flame-made catalysts. The nanostructured CuO/ZrO2 thin layers were synthesized by flame spray pyrolysis and directly deposited on two polyimide polymers and polybenzimidazole membranes. The CuO/ZrO2-polymer membranes are reduced by H2 at 300 °C resulting in Cu/ZrO2-polymer nanocomposites. This novel hybrid membrane design facilitated the efficient separation of by-product water from the reaction environment, effectively promoting carbon dioxide conversion and ultimately leading to enhanced methanol production rate. At 200 °C and 20 bar, these catalytic membrane reactors demonstrate exceptional performance, achieving 113 % improvement in carbon dioxide conversion and a remarkable 106 % increase in methanol production rate compared to conventional catalytic fixed bed reactors. Overall, the catalytic membrane, synthesized using flame spray pyrolysis, has shown long-term stability and ability to suppress catalyst deactivation caused by water, ensuring sustained catalyst stability throughout the reaction.