A kinetic model for the synthesis of high-molecular weight alcohols over a sulfided Co-K-Mo/C catalyst

A statistically designed set of experiments was run in a recycle reactor to evaluate the kinetics of the formation of higher-molecular-weight alcohols (higher alcohols) and total hydrocarbon byproducts from synthesis gas (hydrogen and carbon monoxide) in a range of experimental conditions that mirrors the limits of commercial production. The alkali-promoted, C-supported Co-Mo sulfide catalyst that was employed in this study is well known for its sulfur resistance. The reaction was carried out in a gradientless Berty-type recycle reactor. A two-level fractional-factorial set consisting of 16 experiments was performed. Five independent variables were selected for this study, namely, temperature, partial pressure of carbon monoxide, partial pressure of hydrogen, partial pressure of inerts, and methanol concentration in the feed. The major oxygenated products were linear alcohols up to n-butanol, but alcohols of higher carbon number were also detected, and analysis of the liquid product revealed the presence of trace amounts of ethers also. Yields of hydrocarbons were non-negligible. The alcohol product followed an Anderson-Schultz-Flory distribution. From the results of the factorial experiments, a preliminary power-law model was developed, and the statistically significant variables in the rate expression for the production of each alcohol were found. Based on the results of the power-law models, rate expressions of the Langmuir-Hinshelwood type were fitted. The observed kinetics are consistent with the rate-limiting step for the production of each higher alcohol being a surface reaction of the alcohol of next-lower carbon number. All other steps, including CO-insertion, H-2-cleavage, and hydrogenation steps, do not appear to affect the rate correlations.