The interaction effects of dehydration function on catalytic performance and properties of hybrid catalysts upon LPDME process

Three bi-functional catalysts have been prepared by physical mixing of a commercial methanol synthesis catalyst (CuO–ZnO–Al₂O₃) with three different methanol dehydration catalysts including: H-MFI90, γ-Al₂O₃ and H-Mordenite in order to investigate the role of interaction effects of dehydration component on characteristic properties and performance of these admixed catalysts. The bi-functional catalysts have been characterized by XRD, N₂ adsorption, H₂-TPR, NH₃-TPD and XRF techniques and tested in a mixed slurry bed reactor at the same operating conditions (T = 240 °C, P = 50 bar, H₂/CO = 2, SV = 1100 ml g-cat^− 1 h^− 1) for 60 h time on stream. Among the examined bi-functional catalysts, the physical mixture of KMT + HMFI-90, which had lower reducing peak temperature (T = 200 °C), higher S_Cu (39.1 m² g-cat^− 1) and Cu Dispersion (11.6%), showed higher X_CO (84 mol%), yield of DME (Y_DME = 55.5 mol%), DME selectivity (Select_DME = 66.7 mol%) and also good stability over 60 h time on stream as compared to the other catalysts. This could be assigned, from NH₃-TPD results, to more middle strength acidic sites of H-MFI90 zeolite (SiO₂/Al₂O₃ = 90, total acid site density = 476 µmol/g-cat) which inhibits detrimental interactions with methanol synthesis catalyst and deep dehydration of methanol.