Achieving
the desired catalytic activity and selectivity
in CO2 hydrogenation to methanol remains a grand challenge
using
nonprecious metals. Herein, the well-known ternary Cu-ZnO-ZrO2 (CZZ) was spatially sequestered as fine, uniformly dispersed
active interfaces onto an engineered mesoporous silica sphere (MSS),
giving rise to Cu-ZnO-ZrO2/MSS (CZZ-MSS) with confined
binary Cu-ZnO/Cu-ZrO2 and ternary interfaces that fostered
methanol production under moderate conditions (30 bar and 200–280
°C). By systematically investigating the CZZ-MSS performance,
we show that spatial confinement and optimization of the interfacial
environment of the catalytically active interfaces inside well-fabricated
mesoporous silica deliver a markedly enhanced specific methanol yield
(2211 gMEOH·kgCu
–1·h–1) compared to conventional supported catalysts including
an industrial catalyst (368 gMEOH·kgCu
–1·h–1) and a vast majority of
reported catalysts. Besides, the strong metal–support interaction
arising from interacting metallic Cu and metal oxides (ZnO and ZrO2) within the confined, ultrasmall nanoparticles (<3.0 nm)
demotes the sintering of Cu NPs while retaining their H2 dissociation strength, resulting in superior and prolonged catalytic
stability over 100 h. In situ DRIFTS of confined catalysts with monophasic,
biphasic, and triphasic interfaces expectedly suggests the occurrence
of different CO2 hydrogenation reaction paths over triphasic
Cu-ZnO-ZrO2/MSS (formate pathway) compared to monophasic
Cu/MSS (reverse water–gas shift (RWGS) pathway) and biphasic
ZnO-ZrO2/MSS. From the appreciable insights gained herein,
the rational support synthesis bringing the confinement effect to
the robust ZnO-Cu-ZrO2 interface is the rationale behind
the higher rate of methanol synthesis observed in the CO2 hydrogenation.