Preparation of Cu/ZnO/Al2O3 catalysts in a solvent-free routine for CO hydrogenation

The synthesis of methanol and dimethyl ether (DME) from CO hydrogenation has been investigated on Cu-based catalysts. A series of Cu/ZnO/Al₂O₃ catalysts were prepared using a solvent-free routine which involved a direct blend of copper/zinc/aluminum salts and citric acid, followed by calcination at 450 °C. The calcination processes were monitored using thermogravimetry differential scanning calorimetry (TG-DSC). Catalysts were further characterized using N₂ adsorption, scanning electronic microscopy (SEM), X-ray diffraction (XRD), N₂O oxidation followed by H₂ titration, and temperature-programmed reduction with H₂ (H₂-TPR). The reduction processes were also monitored with in-situ XRD. The physicochemical properties of catalysts depended strongly on the types of precursor salts, and catalysts prepared using Al acetate and Cu nitrate as starting materials had a larger surface area, larger exposed metallic copper surface area, and lower reduction temperature. The CO hydrogenation performances of these catalysts were compared and discussed in terms of their structures. Catalysts prepared with copper nitrate, zinc and aluminum acetates exhibited the highest catalytic activity.