Abstract
With the increasing environmental problems caused by carbon dioxide (CO2) emission and the ultimate carbon resources needed for the development of human society, CO2 hydrogenation to methanol with H2 produced with renewable energy represents a promising path forward. Comprehensive analysis shows that the production of methanol by thermal catalytic CO2 hydrogenation is the most promising technology for large-scale industrialization. This review highlights current developments and future perspectives in the production of methanol from CO2, as well as the main existing problems based on a thorough techno-economic analysis. Moreover, the utilization status and future role of methanol as a platform molecule in the energy system is analyzed. Finally, in this review attention is paid to the development of new catalysts, new routes and new technologies for CO2 conversion aiming to clarify the future direction.
Introduction
While absorbing solar radiation, the earth is also losing energy to the space, so that the energy in and out of the earth system is basically the same (Figure 1A). However, human activities are breaking the balance, and the situation is becoming more and more serious. In May 2019, CO2 concentration in the atmosphere exceeded 415 ppm, about 48% higher than that before the industrial revolution. The magnitude and rate of this increase, at least in the earth’s nearly 800,000 years of history, is unprecedented (Figure 1B). The greenhouse effect caused by carbon emission has led to a series of extreme weather and is threatening the future of our living planet (Iizumi et al., 2018). Researchers speculate that the increase of extremely severe cyclonic storms over the Arabian Sea caused by ocean warming may be the ringleader of this unprecedented locust disaster in 2020 (Murakami et al., 2017). Moreover, global warming will continue to increase the risk of a deadly flood outbreak due to the collapse of an ice lake in the Himalayas (Veh et al., 2020). Related researches also pointed out that global warming is making some originally quiet volcanoes restless due to the increase of extremely heavy rainfall (Zhang et al., 2018; ). Presently, slow GDP growth and rising energy prices have not stopped the rise of energy consumption, and carbon emission exceeded ∼34,000 million tons both in 2018 and 2019, higher than the emission in recent years (Figure 2) ().
FIGURE 1
FIGURE 2
CO2 utilization has been defined as the process of using it as a raw material for products or services with a potential market value. The utilization includes direct approach (International Energy Agency, 2019; Ra et al., 2020), where CO2 is not chemically altered (non-conversion), and the chemical and biological conversion of CO2 to useful products (Figure 3). Most existing commercial applications involve direct utilization, including the production of food and beverages, metals fabrication, dry cleaning, healthcare, fire suppression, and the petroleum industry. Although still under development, the chemical and biological utilization has drawn much attention in recent years, including developing CO2-derived fuels (Satthawong et al., 2013), chemicals and building materials (Jiang et al., 2015; Li et al., 2018; Liu et al., 2018a; Wang et al., 2020a; Zhu et al., 2020). Today, around 230 million tons (Mt) of CO2 are used each year (IEA, 2019a). However, the CO2 utilization is less than 1% of the CO2 released (Figure 4). The largest consumer is agriculture, where around 130 Mt of CO2 per year is used in urea manufacturing, followed by the oil industry, with a consumption of 70 to 80 Mt of CO2 for enhanced oil recovery (IEA, 2019b). More than two-thirds of current global demand for CO2 come from North America (33%), China (21%) and Europe (16%), and the demand for existing uses is expected to grow steadily year-on-year (IEA, 2019a). Until now, the process of CO2 conversion to chemicals is limited by the market scale. Therefore, the development of target product methanol, which can be used as fuels and chemicals (Sakakura et al., 2007; Yu et al., 2010;
FIGURE 3

Simple classification of CO2 utilization pathways.
FIGURE 4

Growth in global utilization and emission of CO2. Note: Projections for future global CO2 demand are based on an average year-on-year growth rate of 1.7% (International Energy Agency, 2019). Projections for future global CO2 emission are based on an average year-on-year growth rate of 1.4% (based on the annual average growth rate of 2009–2019) (
Methanol can be integrated into the current energy system and used as 1) a convenient energy-storage material, 2) a fuel, and 3) a feedstock to synthesize hydrocarbons, and an all-around substitute for petroleum (Olah, 2005; He et al., 2013;
Comprehensive reviews were presented about the recent significant advances in CO2 hydrogenation to methanol, focusing on development of catalysts including metals, metal oxides, and bimetallic catalysts, as well as the structure-activity relationship, in situ characterizations on identifying key descriptors and understanding reaction mechanisms (Jiang et al., 2020; Zhong et al., 2020). Researchers also provided an in-depth assessment of core-shell materials for the catalytic conversion of CO2 into chemicals and fuels (
Analysis of the Whole Process of Thermal Catalysis of CO2 to Methanol
CO2 life cycle assessment is helpful to pick out the main problems existing in the process of CO2 conversion. Researchers have introduced a mathematical formulation to select the promising CO2 capture and utilization (CCU) paths. The results indicate that the optimal solution is greatly influenced by the market demand, scale of CO2 emission source, and H2 availability (Roh et al., 2019). Therefore, target products that can be used as fuels and chemicals are of great significance for the large-scale emission reduction. Moreover, small-molecule products have irreplaceable advantages compared with large-molecule products, due to the high selectivity, simple process, low energy consumption, etc. As a fuel and an important chemical feedstock, methanol is used on a large scale, and has been used as a feedstock for the synthesis of chemicals and fuels (Olsbye et al., 2012). The hydrogenation of CO2 to methanol has attracted much attention as a promising way (
The Importance of Methanol in the Field of Energy
In the future we will phase out fossil fuels and switch to sustainable energy, especially hydroelectricity, wind and photovoltaic energy. However, due to the variable nature of the latter sources which depend on time of day, and season of the year, we need to store such energy at peak production times for use in times of low production. Converting such energy into chemical energy and storing it in methanol molecules is regarded as one of the promising methods. Methanol is considered as one of the potential platform molecules because of its available applications in the fields of fuels and chemicals in the future (Figure 5) (Su et al., 2013). At present, methanol-based technologies include methanol synthesis, methanol to olefins, chemicals (formaldehyde, acetic acid, methylamines, glycol, etc.), gasoline, biodiesel, direct combustion and so on (Figure 6). The methanol economy through chemical recycling of CO2 will eventually free human from dependence on fossil fuels (Tountas et al., 2019). In recent years, China has developed a series of clean coal technologies to transform black-dirty coal into clean fuels and chemicals. Clean coal technologies based on methanol platform will play an important role in Chinese energy system in the future (Xu et al., 2017). Shenhua, the largest coal company in China is leading the commercialization of modern clean-coal technologies for value-added chemicals and transportation fuels.
FIGURE 5

The simplified carbon cycle with methanol as platform molecule in the future.
FIGURE 6

Fuels and chemicals based on methanol. Source: Methanol Institute, www.methanol.org.
As a potential clean energy carrier, methanol has been widely used in the transportation fields such as methanol vehicles, ships, heavy trucks, industrial boilers, stoves and other industrial and civil fields. The use of methanol as transport power has begun to take shape. There are more than 6,000 well-running methanol vehicles and 20 methanol filling stations in Xi’an, China (
TABLE 1
Comparison of oil prices.
Data from Wanhua Chemical’s Petrochemical Information, 20190911;
Data from: (
Dor Group’s pilot tests in Israel suggest that methanol can at least provide a partial alternative to conventional or reformulated gasoline, particularly in regions with abundant but seemingly stranded supplies of natural gas, such as the United States. Based upon methanol-gasoline price ratios as of early January 2015, a reduction of ∼20% in unit energy costs could be achieved depending on the fluctuating cost of crude oil, as well as other market factors (Netzer et al., 2015). Based on the current methanol-gasoline price ratio, at least in China, it is economically feasible to replace conventional gasoline with methanol. Methanol is also used as internal combustion engine fuel for large ships. Diesel methanol dual-fuel ships have entered the marine transportation trade. The first methanol smart industrial park is located at Jiangxi, China. The intelligent industrial park of new energy will be the first specialized industrial cluster in China with “methanol smart industrial chain” as the main body, and the annual output value is expected to reach 10 billion after it is put into operation. ZHONGSHANG GUOXIN is planning to build six distribution centers in China, striving to gradually cover more than 10,000 retail terminals in 3–5 years. As the world’s largest methanol producer and consumer, Chinese methanol production capacity accounts for more than 50% of the world’s total. As of 2016, the annual production capacity has reached 80 million tons, and the production capacity of methanol is still increasing (
Technical Feasibility
Thermocatalytic methanol synthesis from CO2 has a solid theoretical basis. Catalysts with different metals like Cu, Zn, Ag, Cr, and Pd have been employed for CO2 hydrogenation to methanol (Kattel et al., 2017a;
Thermal catalytic methanol production from CO2 has a mature industrial application background (Luu et al., 2015). As early as 1923, methanol was produced at the industrial scale from syngas derived from coal, thanks to the work of Alwin Mittasch and Mathias Pier at BASF (
Techno-Economic Analysis for Methanol Synthesis From CO2
Techno-economic assessment for CO2 hydrogenation to methanol is helpful to guide decision-making regarding R&D investment and construction of large-scale CCU plants in the future. Therefore, researchers have investigated a solar-based system for methanol synthesis from CO2 and H2O. The entire system (thermochemical reactor, water gas shift reaction system, methanol synthesis reaction system, amine-based CO2 separation system and methanol purification system) is based on mature industrial processes, except for the thermochemical reactor currently under development. Thermochemical reactor is a solar chemical heat engine that allows for the thermochemical splitting of CO2, which is an ultra-high temperature two-step FeO/Fe3O4 cycle process. Detailed sensitivity analysis shows that a breakeven price of methanol produced using this process would be 1.22 $/kg; which is higher than current market price of 0.24 $/kg. Importantly, the analysis here identifies that more than 90% of the capital investment comes from the solar concentrator/reactor system (Kim et al., 2011). Life cycle analysis shows that methanol synthesis from CO2 emitted by coal plant exhaust is predicted to be 1.3–2.6 times higher than that of its fossil-based analogue, which can be estimated to decrease significantly with a drop in electricity cost for H2 production (González-Garay et al., 2019). China will levy carbon tax after 2020 for enterprises whose comprehensive energy consumption is less than 5,000 tons of standard coal (
Based on a comprehensive economic analysis, the best-case scenario, where electricity price is 0.06 $/kWh with 30 years plant lifetime, 0.02 $/kg CO2 cost and solar-to-hydrogen (STH) efficiency of 10%, has a break-even value of 0.96 $/kg for methanol (
TABLE 2
| Electricity price | Cost of H2 produced | Cost of CO2 captured | STH efficiency | Methanol yield | Methanol price | |
|---|---|---|---|---|---|---|
| Data analysis parameters | 0.06 $/kWh | 0.65 $/kg | 0.02 $/kg | 10% | 92% | 0.96 $/kg |
| Current data | 0.14 $/kWha | 1.6 $/kg Pinaud et al. (2013) | 0.035 $/kg Rubin et al. (2015) | 1% | 14.5% Wang et al. (2019b) | 0.24 $/kgb |
Optimization parameters of techno-economic analysis and current data.
Electricity price of china.
Data from Wanhua Chemistry (20200702).
Research Direction of Catalysis
A wide variety of heterogeneous catalysts have been evaluated in CO2 hydrogenation to methanol (Figure 7) (Jiang et al., 2015;
FIGURE 7

Heterogeneous catalysts for methanol synthesis from CO2 hydrogenation.
Understanding the Active Sites
One of the main obstacles in developing rational strategies for heterogeneous catalysis is that the complexity of catalysts hinders efforts to characterize their active sites. Deeper insights aid in the design of next-generation catalysts in an optimal manner, which will provide the opportunity to tune the catalytic performance by optimizing the functions of the components. In recent years, surface composition and structure of commercial Cu-ZnO-Al2O3 for methanol synthesis have attracted wide attention from both industry and academia. Active sites such as Zn-Cu bimetallic sites (Li et al., 2016), ZnO-Cu interfacial sites (Kattel et al., 2017b) and Cu steps decorated with Zn atoms have been reported (Figures 8A,B) (
FIGURE 8

(A) Aberration-corrected HRTEM images of Cu particles in the conventionally prepared, most-active Cu/ZnO/Al2O3 catalyst (
Supported Cu-based catalysts for methanol synthesis display strong support effects. Researchers attribute the difference between oxides to variation in the initial activation of CO2 (Reichenbach et al., 2018). Through DFT (density functional theory) calculations and spectroscopic characterizations, researchers found that the ZrO2-Cu interface is crucial for the conversion of formate to methanol (Larmier et al., 2017). It was also pointed that the beneficial role of the Zn ensemble in the Cu-vacant site of the stepped Cu (211) surface can enhance the reactivity and durability of catalysts for methanol production. The increased activity in the Zn-associated stepped sites is related to the enhancement of the surface affinity toward the adsorbate with the oxygen moiety (especially, HCOO) (Jo et al., 2019). The pre-assembled Zr6(μ3-O)4(μ3-OH)4 and bpy sites in UiO-bpy metal-organic frameworks were used to anchor ultrasmall Cu/ZnOx nanoparticles, thus preventing the agglomeration of Cu nanoparticles and phase separation of Cu/ZnOx nanoparticles (Figure 9A). The Cu/ZnOx@MOF shows high activity with a space-time yield of up to 2.59 gMeOH kgCu−1h−1, 100% methanol selectivity and high stability over 100 hours (
FIGURE 9

(A) CuZn@UiO-bpy for selective methanol synthesis from CO2 hydrogenation (
The study on metal-oxide interface provides a better understanding of the complex reaction network to identify the key descriptors of the activity and tune reaction performance (Kattel et al., 2017a). Surface organometallic chemistry has been used to tailor active components and oxide supports to understand the structure-activity relationship of catalysts. Cu/Al2O3 catalysts prepared by surface organometallic chemistry display higher activity toward CO2 hydrogenation compared to Cu/SiO2. Researchers found that methanol formation involves formate intermediates and that the increase of rate originates from the metal-oxide interface (Lam et al., 2019). Moreover, Cu nanoparticles supported on isolated Zr(IV) sites modified SiO2 exhibit high methanol selectivity and activity compared to those loaded on SiO2 (Lam et al., 2018). SiO2 decorated with isolated Ti(IV) sites also show significantly improved methanol selectivity and CO2 hydrogenation activity. These isolated Ti(IV) sites stabilize intermediates at the interface between the support and Cu nanoparticles (Noh et al., 2019). However, researchers found that the surface organometallic chemistry approach does not affect the rate of CO formation. Here, further exploration is needed to understand the differences of active sites and reaction paths for methanol and CO formation.
In the study on the support effect of Cu-based catalysts, we need to understand the difference between oxide supports with and without oxygen vacancies. Moreover, the exact structure and composition of the active sites need to be further identified under the reaction conditions, especially for the Cu-ZnO-Al2O3 catalysts. This also requires us to rethink the role of supports in industrial Cu-based catalysts, which is an active component and participating in the construction of interfacial active sites for CO2 and H2 activation or is mainly used to disperse active metals.
New Catalyst Development
Metal oxide (indium-, zinc-based oxide, etc.) catalysts have drawn increasing attention, due to their excellent catalytic performance in the CO2 hydrogenation reaction (Wang et al., 2020a). High activity and stability for 1,000 h on stream of In2O3/ZrO2 has been achieved. Characterization points that the oxygen vacancies are active sites for methanol synthesis (Martin et al., 2016). Pd is applied to enhance the performance of indium-based catalysts. Pd atoms replacing indium atoms in the active In3O5 attract additional Pd atoms to form low-nuclearity clusters, which promotes H2 activation (Frei et al., 2019). Methanol synthesis on the defective In2O3(110) surface was investigated by DFT calculations. The calculation results indicate that the hydrogenation of H2CO* to H3CO* is the rate-limiting step for methanol formation (Ye et al., 2013). A binary metal oxide, ZnO-ZrO2 solid solution catalyst, can achieve high methanol selectivity, high CO2 single-pass conversion and high stability for at least 500 hours. Moreover, no deactivation was observed in the presence of SO2 or H2S in the reactants (Wang et al., 2017). ZrO2 support always plays important roles such as dispersants of active components, promoter and even active component. The interaction between ZrO2 and metals (or oxides) affects the adsorption and activation of CO2 and H2, and changes the reaction pathways and/or the binding of key intermediates (Figure 9B) (Li and Chen, 2019).
Exploring how surface properties regulate catalytic activity is also very important to deepen the mechanistic understanding. A molybdenum phosphide catalyst for methanol synthesis can improve the activity and stability of the catalyst in a wide range of CO/CO2/H2 feeds through weakening the interaction with formate (
Researchers reported that supported Pt nanoparticles on MoOx/TiO2 promote selective hydrogenation of CO2 to methanol under mild conditions (Toyao et al., 2019). Another kind of catalyst (NiaInbAl/SiO2) for methanol synthesis at ambient pressure was prepared by a phyllosilicate precursor, which can form well-dispersed metallic particles. The performances of NiaInbAl/SiO2 is better than that of conventional Cu/ZnO/Al2O3 catalyst at ambient pressure (Richard and Fan, 2017). A Ni-Ga catalyst can reduce CO2 to methanol at ambient pressure. Ni5Ga3 is particularly active and selective among a series of tested catalysts (Studt et al., 2014). Moreover, SiO2, acting as a ligand and support, can also modify cobalt species via Co-O-Si linkages, which favors the reactivity of *CH3O intermediates and hydrogenation to methanol rather than the C-O dissociation to produce methane (Wang et al., 2020b).
At present, the harsh operation conditions of industrial process restrict the development of the methanol industry, and also bring large energy consumption. In the future, the research and development of new catalysts should proceed toward mild operating conditions, with the purpose of reducing energy consumption. Simultaneously, if H2 production is decentralized, small-scale CO2 reduction devices that can be operated at low pressures and low temperature are required. Moreover, the development of catalysts with high activity at low temperature is also conducive to coupling the active components of CO2 capture, and realizing the integrated operation of CO2 capture and conversion. Transition metals (Ni, Co, etc.) often have high hydrogenation activity. How to realize the synthesis of methanol with high selectivity by transition metal catalysts is a fascinating research direction in the future.
New Route Exploration
Integrative CO2 Capture and Conversion
The integration of CO2 capture and conversion can simplify the CO2 cycle process and reduce energy consumption. An air-stable and well-defined Mn-PNP pincer complex catalyzed one-pot homogeneous CO2 hydrogenation to methanol is demonstrated. The hydrogenation consists of two steps, N-formylation of an amine utilizing CO2 and H2, and subsequent formamide reduction to methanol, regenerating the amine. Methanol yields up to 71% and 84% (w.r.t amine) were obtained, when morpholine and benzylamine were used, respectively; and a TON (turn over number) of 36 was observed (Kar et al., 2017). CO2 can also be captured in amine aqueous solution and then hydrogenated to methanol (>90% yield) in a biphasic 2-Methyltetrahydrofuran/water system, which allows for easy separation and recycling of the amine. CO2 from air can also be converted to methanol using this route (Kar et al., 2018). Amines were also immobilized onto silica support and employed for tandem CO2 capture and methanol synthesis. Covalently attached amine functionalities on solid supports displayed high recycling potential with almost no leaching under the reaction conditions (Kar et al., 2019). CZA-HT catalyst was prepared by physically mixing copper-based catalyst for methanol synthesis with hydrotalcite for high temperature CO2 adsorption. The catalytic performance of the CZA-HT catalyst was clearly promoted by CO2 adsorption on hydrotalcite. The sample containing 40 wt% hydrotalcite and 60 wt% CZA shows the highest methanol selectivity of 73.4% (
In the current demonstration project, CO2 capture and conversion are two independent operation units, which may also involve CO2 transportation, storage and different downstream conversion processes. We postulate that tandem CO2 capture and hydrogenation to methanol system presented here could be an important step toward the implementation of the carbon neutral and methanol economy concept, which can reduce the energy consumption and simplify the production process. However, matching the working conditions of CO2 conversion and capture is a key issue that must be solved, and the adsorbent also faces the problems of decomposition and poisoning of nitrogen oxides and sulfur oxides. Although this process is still in the embryonic stage of research and facing many problems, it has an attractive prospect.
Metal Oxide-zeolite Catalysts
To improve the efficiency of CO2 conversion, researchers are trying to transform the methanol and other intermediates into fuels and chemicals in situ (Wang et al., 2018a; Ye et al., 2019). Therefore, metal oxide-zeolite bifunctional catalysts have been developed, which can catalyze CO2 to gasoline. Metal oxide is responsible for CO2 hydrogenation to oxygenates, and zeolite accounts for the subsequent C-C coupling reaction (Figure 10A). A bifunctional catalyst composed of reducible In2O3 and ZSM-5 has shown high selectivity to gasoline (78.6%) with a very low methane selectivity (1%) (Gao et al., 2017). Moreover, the catalysts exhibit a better performance during an industry-relevant test, which indicates promising prospects of its industrial application.
FIGURE 10

(A) Schematic for CO2 conversion on metal oxide-zeolite bifunctional catalysts. (B) ZnO/ZrO2-ZSM-5 bifunctional catalyst was designed for the direct conversion of CO2 to aromatics. (C) Highly selective conversion of CO2 to aromatics over ZnZrO/ZSM-5 (Li et al., 2019).
Metal oxide-zeolite bifunctional catalysts can also catalyze CO2 to lower olefins with high selectivity. For example, a series of bifunctional catalysts containing In2O3-based or ZnO-based oxides and various SAPO (Silicoaluminophosphate) zeolites with different crystal sizes, pore structures and amount of acid sites were developed for the production of lower olefins by CO2 hydrogenation (
Researchers have also developed metal oxide-zeolite bifunctional catalysts to convert CO2 to aromatics in a single path with methanol and other oxygenates as the intermediates. A composite catalyst of ZnAlOx and H-ZSM-5 has high aromatics selectivity (73.9%) with low CH4 selectivity (0.4%) among hydrocarbons. Furthermore, The selectivity of p-xylene in xylenes is 58.1% on the composite catalyst containing Si-H-ZSM-5 (Ni et al., 2018). Cr2O3/H-ZSM-5 bifunctional catalyst can also realize the one-step conversion of CO2 to aromatics. Due to the synergistic effect between the two components, aromatics selectivity of ∼76% was achieved, and there was no deactivation after 100 h on stream (Wang et al., 2019). ZnO/ZrO2-ZSM-5 tandem catalyst was prepared for direct CO2 conversion to aromatics with a selectivity of 70%, and the selectivity of CH4 is greatly suppressed to lower than 1% (Figure 10B) (Zhang et al., 2019). Similarly, CO2 is converted into aromatics with selectivity up to 73% over ZnZrO/ZSM-5 tandem catalyst (Figure 10C). The presence of H2O and CO2 suppresses the formation of polycyclic aromatics and enhances the stability of the catalyst (Li et al., 2019). Moreover, the conversion of CO2 into para-xylene was also reported, in one-pass by combining Zn-ZSM-5@SiO2 and Cr2O3. Through regulation of the acidity of Zn-ZSM-5@SiO2, high p-xylene selectivity (38.7% in the total products) at a CO2 conversion of 22.1% was achieved (Wang et al., 2019a).
In brief, the direct transformation of CO2 into high value-added hydrocarbons (i.e., olefins and aromatics) has obtained important fruits (Ye et al., 2019). The development of multifunctional catalysts can often achieve high-value and complex chemicals synthesis. Moreover, the multifunctional catalyst has become a research direction favored by the industry due to its simple operation and low energy consumption. However, there is a lack of in-depth understanding of its reaction paths, intermediate species, and the synergistic effect among multiple components. The bifunctional catalyst has shown obvious advantages in terms of anti-carbon deposition deactivation compared with the single methanol conversion process. The permanent deactivation of the acid sites of the zeolite, due to the migration of metal oxides during the reaction, restricts the regeneration and utilization of the catalyst. At present, we still lack powerful tools to control the distance between two components to prevent the acidic sites from being covered by metal oxides. The development of multi-functional catalysts also requires more efficient technology for precise control of the distance between different components. Although the current understanding is limited, its excellent performance attracts the unremitting efforts of researchers.
New Technology Exploration
3D-Printing Technology
3D-printing technology has been considered for numerous research fields, ranging from medicine, mechanical engineering, and materials science to chemistry. For example, 3D-printing technologies pave the way for the design and manufacture of higher performing and cheaper electrochemical devices (
FIGURE 11

3D printing of artificial leaf with tunable hierarchical porosity for CO2 photoreduction (
Plasma Technology
Plasma technology is increasingly attracting interest in the preparation of catalysts. Nucleation and crystal growth of materials under the influence of plasma is different from those in the conventional thermal method. Plasma is also an effective tool for oxidation, reduction, etching, doping, coating and surface treatment. It can operate at room temperature and allows the catalyst preparation on temperature-sensitive supporting materials. A method using plasma to remove template has been established for zeolites synthesis (Liu et al., 2015). In addition, transition-metal catalysts prepared by plasma technology show enhanced activity at low-temperature (Yan et al., 2015; Wang et al., 2018b). Moreover, plasma-assisted CO2 conversion is attracting more and more attention (Zhang et al., 2010; Shirazi et al., 2017). However, the process is highly complex due to the interaction between plasma and catalysts, and little is known about the factors leading to the observed synergy. Catalytic mechanisms relevant to the specific application should be extensively studied (Neyts et al., 2015). Plasma has been introduced as a promising technology for modification of carbon materials, and modification of surface can often provide sites that can anchor active components. Hydrophobic/hydrophilic properties can also be tuned via plasma technology (Zhang et al., 2017). The water produced in the process of CO2 hydrogenation can accelerate the sintering of metal catalysts and occupy the active sites through competitive adsorption. The stability of catalysts used for the hydrogenation of CO2 to methanol can be enhanced by replacing oxide supports (i.e., Al2O3, SiO2, TiO2, etc.) with hydrophobic carbon supports (Furimsky, 2020). Therefore, plasma technology can further optimize the performance of catalysts by adjusting the hydrophobic/hydrophilic properties. Cold plasma is also used to improve the dispersion of active components and enhance metal-support interaction. Plasma reduction under room temperature was developed for the reduction of metal oxides, where no hazardous reducing agent or H2 were needed. This provides many opportunities for the preparation of supported catalysts with heat sensitive supports (high surface area carbon, metal organic frameworks (MOFs), covalent organic framework (COFs), peptide, proteins and others) (Liu et al., 2016). As an example, β-Mo2C nanorods were coupled with non-thermal plasma to catalyze CO2 reduction to CO by H2. In the absence of additional thermal input, the turnover frequency was an order of magnitude higher than that obtained during thermal catalysis (Zhang et al., 2020). The combination of the plasma with Pt/γ-Al2O3 or Cu/γ-Al2O3 enhanced the methanol yield compared to the plasma hydrogenation of CO2 without catalyst. The methanol selectivity of 53.7% and methanol yield of 11.3% were achieved over Cu/γ-Al2O3 with a CO2 conversion of 21.2% in the plasma process (Wang et al., 2018). Chemicals (e.g., acetic acid, methanol, ethanol, and formaldehyde) were synthesized in a one-step process from CO2 and CH4 at 30 °C and atmospheric pressure by using a plasma reactor with a water electrode. The total selectivity to oxygenates was approximately 50–60%, with acetic acid being the major component at 40.2% selectivity (Wang et al., 2017). The use of plasma with the catalytic bed enhanced the CO2 conversion (∼20 times) relative with thermal catalysis, whereas CH4 selectivity increased around 5 times by introducing nickel catalyst into plasma discharge compared to plasma only at 150 °C (
Atomic Layer Deposition Technology
Atomic layer deposition (ALD) technology is expanding into new areas and discovering other applications that benefit from its precise control capability (George, 2010). The design of catalysts for CO2 conversion requires high selectivity, activity and stability. ALD is a promising technology to address the main problems of CO2 reduction, since it can construct catalysts with atomic precision in a highly controllable manner. Researchers have been focusing on the designs of nanomaterials via ALD technology and its applications in CO2 capture and conversion (
Summary and Future Perspective
Capturing CO2 from flue gas and the atmosphere and its catalytic conversion to fuel and chemicals using H2 from renewable energy can lead to a sustainable future for humankind. Methanol can be used as fuel-substitute and raw material for hydrocarbon and chemicals with many industrial applications. The hydrogenation of CO2 to methanol not only effectively alleviates the greenhouse effect, but also produces fuel and value-added chemicals. Carbon capture and storage efforts are expected to reduce CO2 emissions by about 8 Gt in the IEA 2010 Energy technology perspectives by year 2050 (Styring et al., 2015). At present, the production capacity of methanol in the world is about 0.20 Gt (
Various strategies have been explored for thermocatalytic CO2 hydrogenation into methanol via heterogeneous catalysis, spanning from new catalyst development (transition metals/metal oxides to main group metal/metal oxides) to new route exploration (metal oxide-zeolite catalysts and integrative CO2 capture and hydrogenation). The development of new catalysts is toward the direction of lower energy consumption (e.g., low-pressure hydrogenation process) and higher methanol yield (e.g., low temperature methanol synthesis). Here, we need to take into account the problem that highly active catalysts are more likely to be poisoned by impurities. On the other hand, the design of membrane reactor is of great practical significance for delaying water-induced catalyst deactivation and for the shift of thermodynamic equilibrium after the in situ removal of the water byproduct. Highly efficient in situ by-product H2O removal through water-conduction membrane has led to a drastic increase in ethanol yield in CO2 hydrogenation to `methanol (Li et al., 2020). Moreover, nano-reactor with hydrophilic/hydrophobic surfaces will act as powerful supports for metal nanoparticles, and the molecular-fence concept should open a promising route to more-efficient catalysts for methanol synthesis (Jin et al., 2020). The construction of multifunctional catalysts to realize the further conversion of product methanol to high value-added chemicals can also drive the shift of thermodynamic equilibrium. What we must explore is how to achieve controllable coupling between different components while avoiding cross-contamination issues. Moreover, more sensitive spectroscopy techniques should be used to characterize key intermediate species, and combined with kinetic simulation to explore the influence of reaction atmosphere and intermediates concentration on the yield of the target products. It is expected to guide the development of high-performance composite catalysts based on a deep understanding of the reaction paths.
The research and development of catalysts will also go hand in hand in high-throughput screening mode and precision construction mode. Because the function of heterogeneous catalysts is defined by a mixture of molecular and mesoscopic components, atomistic simulations cannot fully capture this multi-length-scale complexity in present, and the design of such catalyst from first principles is still rare (Woodley and Catlow, 2008). At present, the integration of machine learning and high-throughput technology have been emerging to improve the development of new materials and performance of catalysts (
FIGURE 12

Schematic diagram of CO2 capture and conversion process and industrialization process of catalysts assisted by new technologies.
Statements
Author contributions
XZ summarized the literature and wrote the paper. GZ made the manuscript design, writing-reviewing and funding acquisition. CS made the writing-reviewing, editing and supervision. XG made the writing-reviewing, editing, supervision and funding acquisition. All authors contributed to the article and approved the submitted version.
Funding
The authors acknowledge funding from the National Key Research and Development Program of China (2016YFB0600902-4), National Natural Science Foundation of China (21902019), and the Fundamental Research Funds for the Central Universities (DUT20RC(5)002).
Conflict of interest
The authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.
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Summary
Keywords
CO2 conversion, methanol synthesis, new catalysts, new routes, new technologies
Citation
Zhang X, Zhang G, Song C and Guo X (2021) Catalytic Conversion of Carbon Dioxide to Methanol: Current Status and Future Perspective. Front. Energy Res. 8:621119. doi: 10.3389/fenrg.2020.621119
Received
25 October 2020
Accepted
29 December 2020
Published
09 February 2021
Volume
8 - 2020
Edited by
Michele Aresta, IC2R srl, Italy
Reviewed by
Eugenio Quaranta, University of Bari Aldo Moro, Italy
Stefano Stendardo, Energy and Sustainable Economic Development (ENEA), Italy
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© 2021 Zhang, Zhang, Song and Guo.
This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) and the copyright owner(s) are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
*Correspondence: Guanghui Zhang, gzhang@dlut.edu.cn; Chunshan Song, chunshansong@cuhk.edu.hk; Xinwen Guo, guoxw@dlut.edu.cn
This article was submitted to Carbon Capture, Storage, and Utilization, a section of the journal Frontiers in Energy Research
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