A Modified Two-Step Coprecipitation Method Provides Better CuZnO/Al2O3 Methanol Synthesis Catalyst with More Uniform Distribution of Alumina

A modified two-step coprecipitation method has been formulated to prepare a series of model CuZnO/Al2O3 catalysts for methanol synthesis from syngas. Evaluation at industrially relevant condition showed slightly higher activity and much higher stability for model catalysts than for a commercial catalyst. Due to the same CuZn-binary precursor, the model catalysts had similar structural properties with large specific surface area and pore volume, small CuO crystallites and good reducibility, resembling that of the commercial catalyst. However, the model catalysts showed much better uniformity of alumina distribution, which accounted for their better performance. Strong positive correlation between the deactivation rate and the coefficient of variation of Al/Zn indicates the uniformity of alumina distribution plays an important role in determining stability. Specifically, CuZnO/Al2O3 catalysts with alumina distributed more uniformly had higher stability. This work demonstrated that the formulated modified two-step coprecipitation could provide excellent CuZnO/Al2O3 catalysts for industrial applications. Additionally, it also affords new clues for the development of even better industrial catalysts.