High-performance Cu/ZnO/(Al 2 O 3 ) methanol synthesis catalysts are conventionally prepared by co-precipitation from nitrate solutions and subsequent thermal treatment. A new synthesis route is presented, which is based on similar preparation steps and leads to active catalysts, but avoids nitrate contaminated waste water.High concentrations of nitrate in aqueous solutions are environmentally harmful, require extensive waste water treatment, and-according to the principles of green chemistryshould be avoided during chemical synthesis processes. Industrial preparation of Cu/ZnO/(Al 2 O 3 ) catalyst 1 precursors by co-precipitation creates large amounts of concentrated nitrate waste water due to the application of nitrate salts as soluble metal sources. It is therefore highly desirable to find new synthesis routes for high-performance methanol synthesis catalysts. A variety of alternative methods, like citrate 2 or cyanide 3 precursor decomposition, sol-gel 4 or colloidal methods, 5 or mechano-chemical synthesis 6 have been reported in the literature. The big success, however, of the industrially applied conventional catalyst synthesis, which was introduced already in 1966 by ICI company, has so far prevented its substitution by usually less feasible or less successful alternative approaches.This success is based on a sequential meso-and nanostructuring of the catalyst precursor, 7 allowing a high dispersion of the active Cu phase as well as an intimate contact between Cu and ZnO, which is beneficial for the methanol synthesis activity of the resulting catalyst, 8-11 and on the highly optimized synthesis conditions. 12 In more detail, a mixed basic carbonate precursor, zincian malachite (Cu 1Àx Zn x ) 2 (OH) 2 CO 3 , is prepared by co-precipitation and ageing in form of needles. These needles decompose into nano-particulate CuO/ZnO mixtures upon calcination, in which the CuO component can be reduced to Cu(0) during the activation step. The precursor plays a key role for preparation of a good catalyst and one critical property is a low thickness of the crystallite needles on the order of the final Cu particle size (few nanometres), allowing high porosity of the resulting catalyst aggregates (mesostructure). In addition, a high Zn content x is desired, which, depending on the exact synthesis conditions, is around 0.3 in zincian malachite, allowing an effective nano-structuring and homogeneous Fig. 1 Cartoon of the industrially applied preparation of Cu/ZnO catalysts via needle-like zincian malachite precursors (a), SEM of the (Cu 0.78 Zn 0.22 ) 2 (OH) 3 HCO 2 precursor before and after calcination (b) and TEM of an ex-formate Cu/ZnO catalyst (Cu : Zn = 81 : 19); inset shows a power spectrum of the Cu particle (c).