Flame-made Cu/ZnO/Al2O3 catalyst for dimethyl ether production

•Preparation of a Cu/ZnO/Al2O3 methanol/DME catalyst by flame-spray pyrolysis.•Cu/ZnO/Al2O3 shows high metal dispersion and homogeneous distribution.•Cu/ZnO/Al2O3 shows large Cu surface area and small Cu crystallites.•High catalytic activity for the single step synthesis of DME from synthesis gas.•Good CO-conversion and excellent product selectivity are achieved.

For the single step synthesis of dimethyl ether (DME) from synthesis gas a Cu/ZnO/Al2O3-catalyst has been prepared using flame-spray pyrolysis. The resulting powder was co-mixed with γ-alumina to give an admixed system for DME production. The flame-made catalyst was analyzed using the BET method, in situ XRD, N2O decomposition, TPR and XPS. These studies unraveled that the catalyst exhibited a high Cu surface area including good contact with zinc oxide and alumina as well as small Cu particles resulting in high catalytic activity and product selectivity, also in comparison to a commercially available catalyst.