Methanol Synthesis from CO₂ Using Skeletal Copper Catalysts Containing Co-precipitated Cr₂O₃ and ZnO

Abstract

Skeletal Cu-Cr₂O₃-ZnO catalysts have been prepared by leaching CuAl₂ alloy particles at 273 K using 6.1 M aqueous NaOH solutions containing sodium chromate (Na₂CrO₄) and sodium zincate (Na₂Zn(OH)₄). The presence of sodium chromate and sodium zincate in the caustic solution was found to affect the pore structure and surface areas of the resulting catalysts. Both BET and Cu surface areas were increased by increasing the concentration of Na₂CrO₄ and of Na₂Zn(OH)₄.

Increasing the Na₂CrO₄ level from 0 to 0.06 M in a 6.1M NaOH solution containing 0.2M Na₂Zn(OH)₄ caused the content of ZnO in the catalyst to decrease from 8.8 to 3.0 wt% whilst increasing the Cr₂ O₃ content from 0 to 1.7 wt%, indicating that the presence of Na₂CrO₄ in the leach liquor not only resulted in deposition of a Cr compound but also inhibited precipitation of zinc hydroxide onto skeletal Cu catalysts. On the other hand, increasing the concentration of Na₂Zn(OH)₄ from 0 to 0.6 M in a 6.1 M NaOH solution containing 0.008 M Na₂ CrO₄ resulted in increasing the ZnO loading from 0 to 8.9wt% with an almost constant content of Cr₂ O₃ (1.3 ± 0.2%) in the catalysts, revealing that sodium zincate only led to precipitation of zinc hydroxide and did not suppress Cr₂O₃ formation.

Hydrogenation of CO₂ was studied using a gas mixture of 24% CO₂ in H₂ at a total pressure of 4MPa, space velocities up to 210000L kg^-1h^-1 and temperatures in the range 493-533K. The catalysts were found to be both highly active and selective for methanol synthesis. This study confirms the role of ZnO in promoting the activity of copper for methanol synthesis from CO₂ and improving the selectivity by inhibiting the reverse water-gas shift reaction. The role of Cr₂O₃ is to improve the structural development of high surface area skeletal copper.