Methanol synthesis over Cu/ZnO catalysts prepared by ball milling

Cu/ZnO catalysts (with a Cu/Zn atomic ratio of 30/70) have been prepared by high intensity mechanical mixing of copper and zinc oxide powder in air and under vacuum. During milling in vacuum gradual amorphisation of the constituents occurs, as evidenced by broadening of the Cu⁰ and ZnO diffraction peaks in XRD, but the two original phases remain. The result of such treatment is a catalyst with low BET area and low Cu metal surface area. Consequently, the activity of the vacuum milled samples in batch methanol production from synthesis gas (CO/CO₂/H₂=20/5/75) at 50 bar and 250°C is low. Milling in air leads to oxidation of the copper metal phase and much higher BET surface area and, after reduction, Cu metal surface area. Prolonged milling times in air result in more than 90% Cu²⁺ formation as evidenced by TPR. Activity in methanol synthesis for the air milled samples is comparable to a conventional Cu/ZnO catalyst prepared by coprecipitation. It is concluded that high intensity ball milling at ambient conditions is a promising method to prepare mixed oxide catalysts or catalyst precursors. This revised version was published online in July 2006 with corrections to the Cover Date.