AEI type zeolite, method for producing same, and uses thereof

Patent metadata

Field	Value
Publication number	US-10357760-B2
Application number	US-201715601382-A
Country	US
Kind code	B2
Filing date	May 22, 2017
Priority date	Nov 21, 2014
Publication date	Jul 23, 2019
Grant date	Jul 23, 2019

Abstract

Provided is a method for producing an inexpensive, high-performance AEI type zeolite and an AEI type zeolite having a Si/Al ratio of 6.5 or less by using neither an expensive Y type zeolite as a raw material nor dangerous hydrofluoric acid. The method for producing an AEI type zeolite having a Si/Al ratio of 50 or less includes: preparing a mixture including a silicon atom material, an aluminum atom material, an alkali metal atom material, an organic structure-directing agent, and water; and performing hydrothermal synthesis of the obtained mixture, in which a compound having a Si content of 20% by weight or less and containing aluminum is used as the aluminum atom material; and the mixture includes a zeolite having a framework density of 14 T/1000 Å3 or more in an amount of 0.1% by weight or more with respect to SiO2 assuming that all Si atoms in the mixture are formed in SiO2.

First claim

The invention claimed is:

1. A method for producing an AEI type zeolite having a Si/Al ratio of 50 or less as measured by X-ray fluorescence analysis (XRF), the method comprising:
preparing a mixture comprising a silicon atom material, an aluminum atom material, an alkali metal atom material, an organic structure-directing agent, and water; and
performing hydrothermal synthesis by using the mixture obtained, wherein
the aluminum atom material is a compound having a Si content of 20% by weight or less and comprising aluminum; and
the mixture comprises a zeolite having a framework density of 14 T/1000 Å 3 or more in an amount of 0.1% by weight or more with respect to SiO 2 assuming that all Si atoms in the mixture are formed in SiO 2 .

2. The method for producing an AEI type zeolite according to claim 1 , wherein 50 mol % or more of alkali metal atoms contained in the alkali metal atom material in the mixture is sodium; and a molar ratio of sodium to the organic structure-directing agent in the mixture is from 0.1 to 2.5.

3. The method for producing an AEI type zeolite according to claim 1 , wherein less than 50 mol % of alkali metal atoms contained in the alkali metal atom material in the mixture is sodium; and a total molar ratio of alkali metal atoms to the organic structure-directing agent in the mixture is from 1.0 to 10.

4. The method for producing an AEI type zeolite according to claim 1 , wherein the aluminum atom material is at least one selected from the group consisting of aluminum hydroxide, aluminum nitrate, aluminum sulfate, aluminum oxide, sodium aluminate, boehmite, pseudoboehmite, and aluminum alkoxide.

5. The method for producing an AEI type zeolite according to claim 1 , wherein d6r defined as a composite building unit by the International Zeolite Association (IZA) is contained in a framework of the zeolite having a framework density of 14 T/1000 Å 3 or more.

6. The method for producing an AEI type zeolite according to claim 1 , wherein the zeolite having a framework density of 14 T/1000 Å 3 or more is an AEI type and/or a CHA type.

7. The method for producing an AEI type zeolite according to claim 1 , wherein the organic structure-directing agent in the mixture is N,N-dimethyl-3,5-dimethylpiperidinium hydroxide.

8. A method for producing a catalyst, the method comprising:
performing the method according to claim 1 to obtain an AEI type zeolite; and
supporting Cu on the AEI type zeolite obtained.

9. The method according to claim 8 , wherein the catalyst is a honeycomb catalyst being applied to a honeycomb.

10. The method according to claim 8 , wherein the catalyst is a catalyst molded article formed by molding the catalyst.

11. A method for purifying a nitrogen oxide, the method comprising:
performing the method according to claim 8 ; and
bringing a nitrogen oxide into contact with a reducing agent in presence of the catalyst.

12. The method for purifying a nitrogen oxide according to claim 11 , wherein the reducing agent is a nitrogen-containing compound.

13. The method for purifying a nitrogen oxide according to claim 12 , wherein the nitrogen-containing compound is ammonia.

Assignees

• Mitsubishi Chem Corp

Inventors

• Tanaka Manabu
• Takewaki Takahiko
• Matsuo Takeshi
• Hara Masahiro

Classifications

• B01J29/76 Primary

  Iron group metals or copper · CPC title

• B01J2229/186

  not in framework positions · CPC title

• B01D2255/2027

  Sodium · CPC title

• B01D53/9418

  for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas · CPC title

• C01B39/04

  using at least one organic template directing agent, e.g. an ionic quaternary ammonium compound or an aminated compound · CPC title