Layered catalyst loading for synthesis gas conversion

Abstract

Systems and methods are provided for conversion of gas phase reactants including CO and Hto Cproducts using multiple catalysts in a single reactor while reducing or minimizing deactivation of the catalysts. Separate catalysts can be used that correspond to a first catalyst, such as a catalyst for synthesis of methanol from synthesis gas, and a second catalyst, such as a catalyst for conversion of methanol to a desired Cproduct. The separate catalysts can be loaded into the reactor in distinct layers that are separated by spacer layers. The spacer layers can correspond to relatively inert particles, such as silica particles. Optionally, the spacer layer can include an adsorbent, such as boron supported on alumina or boron carbide particles. The adsorbent can be suitable for selective adsorption of the one or more reaction products (such as one or more reaction by-products), to allow for further reduction or minimization of the deactivation of the conversion catalysts.