Synthesis of AFX zeolite

Patent metadata

Field	Value
Publication number	US-10414665-B2
Application number	US-201715718018-A
Country	US
Kind code	B2
Filing date	Sep 28, 2017
Priority date	Sep 30, 2016
Publication date	Sep 17, 2019
Grant date	Sep 17, 2019

Abstract

An alkali-free H-AFX zeolite and synthesis procedure are disclosed, as well the use of such zeolite as a catalyst in an SCR process.

First claim

What is claimed is:

1. A composition comprising a synthetic hydrogen-form zeolite having an AFX framework as the primary crystalline phase, wherein said zeolite is essentially free of alkali metal ions.

2. The composition of claim 1 , wherein the zeolite has a silica-to-alumina ratio of about 22 to about 50.

3. The composition of claim 1 , wherein the zeolite has a silica-to-alumina ratio of about 22 to about 40.

4. The composition of claim 1 , wherein the zeolite has mean crystal size and a D 90 crystal size of about 0.1 to about 10 microns.

5. The composition of claim 1 , wherein the zeolite has a hexagon and/or bipyramid morphology.

6. The composition of claim 1 , wherein the as-made zeolite produces an XRD pattern having a hexagonal space group with a and c parameters that are different compared to a calcined sample and the X-ray characteristics of the as-made zeolite is as shown in Table 1 and the X-ray characteristics of the calcined zeolite is as shown in Table 2:

TABLE 1

Crystal structure of as-made H-AFX (JMZ-10)

d-
Rel.

Pos.
spacing
Int.

No.
[°2θ]
[Å]
[%]
h k l

1
7.62
11.60
8
1 0 0

2
8.81
10.03
49
1 0 1

3
11.67
7.58
52
1 0 2

4
13.15
6.73
11
1 1 0

5
15.18
5.83
20
2 0 0

6
15.30
5.79
13
1 0 3

7
15.82
5.60
60
2 0 1

8
17.58
5.04
54
2 0 2

9
17.71
5.00
31
0 0 4

10
19.28
4.60
2
1 0 4

11
20.11
4.41
20
2 1 0

12
20.59
4.31
100
2 1 1

13
21.99
4.04
83
2 1 2

14
22.09
4.02
11
1 1 4

15
22.82
3.89
18
3 0 0

16
23.45
3.79
27
1 0 5

17
26.40
3.37
36
2 2 0

18
26.88
3.31
4
2 1 4

19
26.95
3.31
3
2 0 5

20
27.75
3.21
61
1 0 6

21
27.85
3.20
4
3 1 1

22
28.92
3.08
15
3 1 2

23
30.07
2.97
15
2 1 5

24
30.56
2.92
9
4 0 0

25
30.79
2.90
8
2 0 6

26
30.89
2.89
35
4 0 1

27
31.86
2.81
35
4 0 2

TABLE 2

Crystal structure of calcined H-AFX

d-
Rel.

Pos.
spacing
Int.

No.
[°2θ]
[Å]
[%]
h k l

1
7.56
11.68
20
1 0 0

2
8.81
10.03
100
1 0 1

3
11.78
7.51
90
1 0 2

4
13.07
6.77
64

Assignees

• Johnson Matthey Plc

Inventors

• Chen Hai-Ying
• Fedeyko Joseph
• Pham Trong

Classifications

• B01J29/70

  of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 · CPC title

• B01D2255/9155

  Wall flow filters · CPC title

• C01B39/026

  After-treatment · CPC title

• C01P2004/62

  Submicrometer sized, i.e. from 0.1-1 micrometer · CPC title

• C01P2004/30

  extending in three dimensions · CPC title