CATALYTIC CONVERSION OF SYNTHESIS GAS TO METHANOL AND OTHER OXYGENATED PRODUCTS

This paper reports the results obtained in an extended program on the conversion of synthesis gas to methanol and higher alcohols. Modifications were made in the catalyst composition, method of fabrication, promoters, and moderators. Test conditions were also modified as a temperature, pressure, gas composition, space velocity, and production rate. Methane and other hydrocarbon production was held to less than 5% of the CO reacted. Product could be controlled as to the percent of higher alcohols in the anhydrous product to between 0 and 80%, and the identity of the alcohols could be controlled to predominantly ethanol, propanol, or isobutyl alcohol; these factors plus high production rates gives the process exceptional commercial appeal. An unexpected result of the effort was observing that substantial percentages of acetaldehyde, propioaldehyde, isobutyraldehyde, and methyl ethyl ketone could be produced, which translates to acetic and propionic acids and methyl tert-butyl ether. As a result of the extensive data, a new alcohols synthesis mechanism is proposed.