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In the present contribution, the utilization of steel-mill gases for an industrial methanol synthesis process is described. The focus of this work is on the influence of syngas compositions derived from steel-mill gases on an industrial Cu/ZnO/Al2O3 catalyst. Elevated CO2 and H2O concentrations seem to have an irreversible impact on the activity of the catalyst. In order to obtain realistic gas composition for the catalyst tests, a process simulation of the methanol synthesis was conducted. The calculated gas compositions at the reactor inlet were applied in a practical test in order to evaluate the catalyst stability under steel mill gas conditions. No noticeable deactivation was observed.
Cu–Co-based model catalysts were prepared by a sophisticated alkali-free synthesis method and tested in the conversion of synthesis gas to higher alcohols. MoO3-coated alumina was used as the support, providing both high specific surface area and strongly interacting sites for the deposition of the active metals. A bulk Cu/Co ratio of ~2 was found to be most suitable in terms of activity and product distribution. Surface enrichment of Mo for all samples was observed by XPS, which significantly influenced the performance of the catalysts. Mo was found to be both a structural and a chemical promoter. Strong metal–support interactions were further achieved by modification of alumina with magnesia. With 12 wt% Mg incorporated, the catalysts showed 40% total oxygenate selectivity including 11% selectivity to ethanol.