A Novel Synthesis Route for Cu/ZnO/Al₂O₃ Catalysts used in Methanol Synthesis: Combining Continuous Consecutive Precipitation with Continuous Aging of the Precipitate

Abstract

A novel continuous method for the preparation of a ternary Cu/ZnO/Al 2 O 3 catalyst based on a cascade of micromixers and a tubular aging reactor is presented as a promising alternative route to the conventional batch process. Its application, in combination with immediate spray drying, enables monitoring of the formation of the final precursor by exchange reactions between initially separated phases during the aging step.These exchange reactions were successfully simulated by consecutive precipitation by using micromixers in series as analytical tool. After 60 min of continuous aging, calcination, and reduction, a catalyst is produced that exhibits an almost equal mass-related activity in methanol synthesis compared to a commercial catalyst and an area-related activity that is about 50 % higher.[a] Dr.

Structure–activity relationships of Co-modified Cu/ZnO/Al2O3 catalysts applied in the synthesis of higher alcohols from synthesis gas

“…However, due to the chosen calcination temperature of 350 °C the thermal decomposition of thehydrotalcite-type precursor phases was incomplete resulting in theformation ofhigh temperature carbonate species, which were stable up to450 °C.Thus,an increasing amount of amorphous carbonate phase remained in the calcined precursorwith increasing Cu content. Similar results were reported in literature for Cu/ZnO/Al 2 O 3 methanol synthesis catalystsobtained from precursors containinghydrotalcitetype phases [26]. All TPR profilesshown inFig.…”

Facile Structure Tuning of a Methanol‐Synthesis Catalyst towards the Direct Synthesis of Dimethyl Ether from Syngas

“…The y value in this work was 13, 20, 30, and 40, because catalysts with y <10 produced no DME. The SP method was recently tried, but the relationship between the structural properties and catalytic performance was not fully discussed. For comparison, Cu,Zn,Al precursors were prepared by using the conventional coprecipitation (CP) method (precipitation of all metal components together).…”

A model‐based precipitation study of copper‐based catalysts

“…Precipitation systems under investigation were barium sulfate, zinc oxide, lead (II) sulfide, or cadmium sulfide . Micromixers were used before to prepare methanol catalysts . However, the focus of these publications were on the continuous production of catalysts.…”