Method for producing metal exchanged zeolites by solid-state ion exchange at low temperatures

Patent metadata

Field	Value
Publication number	US-10081010-B2
Application number	US-201415126171-A
Country	US
Kind code	B2
Filing date	Oct 15, 2014
Priority date	Apr 7, 2014
Publication date	Sep 25, 2018
Grant date	Sep 25, 2018

Abstract

Method for the preparation of a metal-exchanged zeolites or mixtures of metal-exchanged zeolites, such as Cu-SSZ-13, Cu-ZSM-5, Cu-beta, or Fe-beta, comprising the steps of providing a dry mixture of a) one or more microporous zeotype materials that exhibit ion exchange capacity and b) one or more metal compounds; heating the mixture in a gaseous atmosphere containing ammonia to a temperature lower than 300° C. for a time sufficient to initiate and perform a solid state ion exchange of ions of the metal compound and ions of the zeolite material; and obtaining the metal-exchanged zeolite material.

First claim

The invention claimed is:

1. Method for the preparation of a metal-exchanged zeolite material or mixtures of metal-exchanged zeolites materials comprising the steps of providing a dry mixture containing a) one or more zeolites starting materials that exhibit ion exchange capacity and b) one or more metal compounds; heating the mixture in a gaseous atmosphere containing ammonia at a temperature of between 150° C. and 250° C. to perform a solid state ion exchange of ions of the metal compound and ions of the one or more zeolites; and obtaining the metal-exchanged zeolite material or the mixture of metal-exchanged zeolite materials, wherein the metal compound is Cu (I) oxide.

2. Method according to claim 1 , wherein the one or more zeolite starting materials have the framework code of AEI, AFX, CHA, KFI, LTA, IMF, ITH, MEL, MFI, SZR, TUN, *BEA, BEC, FAU, FER, MOR, LEV.

3. Method according to claim 1 , wherein the one or more zeolite starting materials are selected from the group consisting of ZSM-5, zeolite Y, beta zeolite, SSZ-13, SSZ-39, SSZ-62, and Chabazite.

4. Method according to claim 1 , wherein the one or more zeolite starting materials are in the H + or NH 4 + form.

5. Method according to claim 1 , wherein the one or more zeolite starting materials contain an organic structure directing agent.

6. Method according to claim 1 , wherein the one or more metal compounds are selected from the group of metal oxides, metal nitrates and phosphates, sulfates, oxalates, acetates or combinations thereof.

7. Method according to claim 1 , wherein the content of ammonia in the atmosphere is between 1 and 5000 vol. ppm.

8. Method according to claim 1 , wherein the content of oxygen in the atmosphere is 10% or lower.

9. Method according to claim 1 , wherein the content of water in the atmosphere is 5 vol. % water or less.

10. Method according to claim 1 , wherein the mixture of one or more zeolites starting materials that exhibit ion exchange capacity and one or more metal compounds is heated in the gaseous atmosphere containing ammonia at a temperature of between 150° C. and 250° C.

11. A metal-exchanged zeolite or mixtures of metal-exchanged zeolites obtained by a method according to claim 1 .

12. A method for the removal of nitrogen oxides from exhaust gas by selective catalytic reduction with a reductant, comprising contacting the exhaust gas with a catalyst comprising a metal-exchanged zeolite or mixtures of metal-exchanged zeolites obtained by a method according to claim 1 .

13. A method according to claim 12 , wherein the reductant is ammonia or a precursor thereof.

14. A method according to claim 12 , wherein the reductant comprises hydrocarbons.

Assignees

• Haldor Topsoe As
• Haldor Topsoe As

Inventors

• Janssens Ton V W
• Vennestrøm Peter N R

Classifications

• B01J29/146

  Y-type faujasite · CPC title

• B01D2255/504

  ZSM 5 zeolites · CPC title

• B01J29/68

  Iron group metals or copper · CPC title

• B01J29/83

  Aluminophosphates [APO compounds] · CPC title

• B01J29/763

  CHA-type, e.g. Chabazite, LZ-218 · CPC title