A study on the precipitating and aging processes of CuO/ZnO/Al2O3 catalysts synthesized in micro-impinging stream reactors

CuO/ZnO/Al2O3 catalyst precursors were precipitated in a novel micro-impinging stream reactor (MISR) and a traditional stirred tank reactor (STR), respectively, followed by a period time of aging in the mother liquid. Being different from the simultaneous precipitating and aging of catalyst precursors within the same STR reactor, these two processes occurred in two separate containers in the MISR route, hence providing a more uniform and steady environment for both the precipitating and aging processes on top of the higher micromixing efficiency and better process control of the MISR. Therefore, substantial changes in the phase compositions and microstructures of the catalyst precursors were obtained with MISR, which resulted in smaller and more homogeneous catalyst particles with a larger BET surface area and specific copper surface area, better Cu/Zn dispersion as well as higher catalytic activity when compared to those prepared in the STR. The aging process also played an important role in catalyst preparation and it could be controlled more easily and precisely in the MISR route to form a more desirable phase structure, morphology and eventually more superior catalytic performance in methanol synthesis for the final catalysts.