Formaldehyde Synthesis From Methanol Over Silver Catalysts: Min Qian, M.A. Liauw, G. Emig
Formaldehyde Synthesis From Methanol Over Silver Catalysts: Min Qian, M.A. Liauw, G. Emig
Formaldehyde Synthesis From Methanol Over Silver Catalysts: Min Qian, M.A. Liauw, G. Emig
Abstract
The formaldehyde synthesis from methanol was investigated over a polycrystalline silver catalyst at temperatures up to
993 K. Water was added to the feed (water ballast process) like in the commercial BASF process. The conversion of methanol
and the selectivity to formaldehyde appeared to increase with respect to the methanol ballast process with no added water. A
long-time experiment was carried out lasting over more than 300 days time-on-stream. While the methanol conversion does
not change significantly, there is a pronounced change in hydrogen and CO2 selectivity. A most noteworthy observation is
that over months of operation, the width of the temperature region where formic acid is formed increases in a linear manner.
Finally, interrupting the oxygen supply for a few hours led to a temporary deterioration of the product selectivity after oxygen
re-admittance. All observations may well be interpreted in the framework of the commonly discussed silver–oxygen chemistry
with its three different oxygen species (O␣ , O and O␥ ).
© 2002 Elsevier Science B.V. All rights reserved.
Keywords: Methanol oxidation; Oxidative dehydrogenation; Formaldehyde; Silver catalyst; Catalyst deactivation; Oxygen species
0926-860X/02/$ – see front matter © 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 9 2 6 - 8 6 0 X ( 0 2 ) 0 0 3 4 0 - X
212 M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222
Fig. 1. Variation of the operating temperature in the water ballast process with 225 days time-on-stream.
M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222 215
was converted (open triangles). However, the longer 3.1.3. Influence of molar ratio of H2 O/CH3 OH in
residence time was not beneficial for the formalde- the feed
hyde formation: its selectivity decreased apparently The influence of water vapor in the reaction gas on
under the longer residence time, which may be partly the formaldehyde selectivity was estimated. Water va-
due to the fast decomposition of formaldehyde in the por content was varied in the region of H2 O/CH3 OH
gas phase to H2 and CO at high operation tempera- molar ratio of 0–2.0. The space velocity was kept
tures. The H2 selectivity did increase with residence constant by varying the N2 flow accordingly. This
time, albeit not to the extent that the formaldehyde led to a constant CH3 OH/O2 molar ratio. Each re-
selectivity decreased. sult was an average over a 15 h lasting stationary
Fig. 3. Selectivity to HCHO and CO2 vs. the molar ratio of H2 O/CH3 OH (823 K; CH3 OH, 8.5%; O2 , 3.5%).
216 M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222
Fig. 5. Comparison of HCOOH selectivity between the water and methanol ballast process (lines indicate a moving average over a 10 K
temperature interval).
M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222 217
Fig. 6. The life time of silver catalyst in the water ballast process (823 K).
adding water vapor to the reaction gas. The selectivity 3.3. Aging behavior
to CO2 , the product of total oxidation, was obviously
suppressed in the water ballast process as compared In order to gauge the long-time behavior, conver-
to the methanol ballast process. sions and selectivities were measured for over 300
In addition, the selectivity to formic acid was also days time-on-stream. After a short initialization, both
clearly smaller in the water ballast process. Fig. 5 methanol conversion and formaldehyde selectivity
shows the result of two experiments carried out one were basically constant (steady state performance).
immediately after the other. The selectivity to formic The latter may have displayed a slight decrease
acid in the water ballast process was almost 30% lower (Fig. 6). A much more pronounced change was ob-
at 620 K than that in the methanol ballast process. served for the selectivities to CO2 and H2 (Fig. 7).
Fig. 7. Selectivity to CO2 and H2 vs. time-on-stream in the water ballast process (823 K).
218 M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222
S(CO2 ) increased gradually over the entire experi- two trends made the region of HCOOH formation
ment. S(H2 ) decreased from 14 to 8% during the first broader with time.
100 days. It then dropped to about 5–6%, where it To study the nature of this deactivation, the opera-
remained basically constant for the remainder of the tion was interrupted once during the time while the up-
experiments. per limit still changed (180 days time-on-stream) and
Fig. 8 shows the selectivity to formic acid as a once when it was constant (280 days time-on-stream).
function of temperature for various times-on-stream. The interruption consisted of 4 weeks during which
No formic acid was detected during the first 100 the catalyst bed was kept under flowing N2 at 523 K.
days. After this period, formic acid appeared, but only In both cases, after the experimental conditions had
in a limited temperature region of 600–690 K with
S(HCOOH) < 0.05. However, this region grew with
time, such that after 8 months (240 days), formic acid
could be observed over a wide range of temperatures
(580–870 K). In order to visualize the slow extension
of formic acid formation into the high temperature
region, we define an upper (Tupper ) and a lower
(Tlower ) temperature limit such that these two bound
the region where formic acid could be detected in the
outlet with S(HCOOH) > 0.01. The two tempera-
tures are plotted in Fig. 9 versus time-on-stream. The
upper temperature increased linearly to 870 K during
the first 8 months with a correlation coefficient of
R 2 > 0.97. After this time, the shift into the higher
temperature region stopped and the upper tempera-
ture stayed constant with time. The lower temperature
limit decreased with time-on-stream, but in a less Fig. 9. Upper and lower detection temperature of HCOOH vs.
pronounced manner and without a discontinuity. The time-on-stream.
M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222 219
been restored, no marked discontinuities were ob- oxygen (and hence the normal feed composition) was
served (Fig. 9). switched back on. The exit gas composition was av-
eraged over 5 h following the oxygen-free treatment.
3.4. Oxygen-free treatment Fig. 10a shows that, at three different temperatures
(623, 773 and 823 K, respectively), the conversion of
For more insight into the interaction between oxy- methanol and the yield of CH2 O decreased strongly af-
gen and silver during the partial oxidation of methanol, ter oxygen-free treatment as compared to steady state.
the catalyst was temporarily exposed to an oxygen-free In addition, the yields of carbon dioxide and formic
atmosphere. Starting from steady state, the oxygen acid had increased while the hydrogen yield was lower.
feed was interrupted for 5 h. Methanol, water vapor The decrease of the ratio of S(CH2 O)/S(CO2 ) after
and nitrogen kept flowing over the catalyst. After this, oxygen-free treatment is depicted in Fig. 10b.
Fig. 10. Influence of oxygen-free treatment on: (a) the conversion and the yield; (b) the ratio of S(CH2 O)/S(CO2 ) as compared to steady
state in the water ballast process.
220 M. Qian et al. / Applied Catalysis A: General 238 (2003) 211–222
re-development of O␥ formation over the Ag catalyst support by the Bayerische Forschungsstiftung in the
when it was exposed again to O2 after a 30 min treat- framework of FORKAT and by the DFG (Li 669/2-1)
ment with pure N2 [51]. As a result, treatment un- is gratefully acknowledged. The authors thank their
der oxygen-free conditions followed by re-admission industry partners H.-G. Pirkl (Bayer), A. Nagy (for-
of oxygen should temporarily lead to an increase of merly Bayer), and G. Stochniol and J. Sauer (Degussa
O␣ -catalyzed formation of carbon dioxide and formic AG) for their support.
acid as well as a decrease of O␥ -catalyzed hydrogen
formation as compared to the steady state. This is in-
deed found (Fig. 10a). Consequently, the oxygen-free References
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