US Patent 7645906 Graded catalyst bed for methyl mercaptan synthesis

A process and graded catalyst bed for selectively producing methyl mercaptan from methanol. The methanol is reacted with hydrogen sulfide, in the presence of a graded catalyst bed containing at least three types of nickel or cobalt molybdenum alumina catalysts to convert the methanol to methyl mercaptan in one-pass. At least one of the hydrotreating catalysts can contain aluminium phosphate. Use of the graded catalyst bed prevents the formation of a hot spot within the graded catalyst bed. The methyl mercaptan having less than about 30 wt. % unreacted methanol contained therein.