Influence of the synthesis method of Cu/Y zeolite catalysts for the gas phase oxidative carbonylation of methanol to dimethyl carbonate

Dimethyl carbonate is an environmentally friendly molecule with increasing applications as reactant, solvent, and fuel additive. Oxidative carbonylation of methanol, with reactants in the gas phase and catalyzed by copper- exchanged Y zeolites, is a promising alternative route for dimethyl carbonate production. This work is focused on the improvement of the catalyst formulation and preparation methods. Catalysts were prepared using two methodologies: solid-state ion exchange and liquid-ethanol ion exchange. Five different copper salts were used as precursors and the NH4+ and Na+ forms of the Y zeolite as supports. The Na+ form of the Y zeolite removed the Bronsted acidity of the support and, therefore, the reaction rate of acid-catalyzed undesired dehydration and decomposition reactions was reduced. The use of copper chloride salts as precursors was crucial to obtain suitable catalysts for dimethyl carbonate formation. Among all the tested catalysts, those prepared using CuCl2 precursor and the Na-Y zeolite by the liquid-ethanol ion exchange method showed the best performance (0.72 molDMC/molCu h). This catalyst exhibited the highest surface chloride content and Lewis acidity.