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

A novel continuous method for the preparation of a ternary Cu/ZnO/Al2O3 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 novel continuous method for the preparation of a ternary Cu/ZnO/Al2O3 catalyst for use in methanol synthesis has been developed, and is based on a cascade of micromixers and a tubular aging reactor (see figure). Advantages over the conventional batch process led to an area‐related activity about 50 % higher than that of a commercial catalyst.