High-performance zeolite for reducing nitrogen oxide emissions, method of preparing same and catalyst using same

Patent metadata

Field	Value
Publication number	US-11465133-B2
Application number	US-202017009235-A
Country	US
Kind code	B2
Filing date	Sep 1, 2020
Priority date	Sep 9, 2019
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

Disclosed is a method of preparing a high-performance zeolite catalyst for reducing nitrogen oxide emissions, and more particularly a technique for preparing a zeolite catalyst, suitable for use in effectively removing nitrogen oxide (NOx), among exhaust gases emitted from vehicle internal combustion engines through selective catalytic reduction (SCR), thereby exhibiting high efficiency, high chemical stability and high thermal durability upon SCR using the prepared catalyst.

First claim

What is claimed is:

1. A copper-impregnated LTA zeolite catalyst for selective catalytic reduction of nitrogen oxide, the catalyst comprising
a high-silica-content LTA zeolite in which copper is ion-exchanged,
wherein a silicon/aluminum (Si/Al) molar ratio is 8 to 30 and a particle size is 0.5 to 5.0 μm,
wherein the copper-impregnated LTA zeolite has a crystallinity of 50% or more after a hydrothermal treatment at 900° C. for 1 to 25 hours and a crystallinity of 30% or more after a base treatment, and
wherein in the base treatment, the catalyst is placed in an aqueous ammonia solution adjusted to a pH of 9.0 to 9.5, left to be heated at 50 to 70° C. for 100 to 200 hours, and then filtered and dried.

2. The catalyst of claim 1 , wherein the particle size is 0.5 to 2.0 μm, a specific surface area is 700 m2/g or more, the Si/Al molar ratio is 8 to 16, a Cu/Al molar ratio is 0.45 to 0.5, and a residual fluorine (F) content in a skeleton of the catalyst is 0.02% or less.

3. The catalyst of claim 1 , wherein a nitrogen oxide (NOx) conversion efficiency of the catalyst is 70% or more upon reaction with an ammonia reducing agent at 150° C. to 600° C. after the hydrothermal treatment at 900° C.

4. The catalyst of claim 1 , which is applied to a selective catalytic reduction (SCR) or an SCR-catalyzed diesel particulate filter (SDPF) for an internal combustion engine exhaust system.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Coporation
• Heesung Catalysts Corp
• Kia Motors Corp
• Heesuna Catalysts Corp

Inventors

• Kim Pyung Soon
• Kim Young Jin
• Kim Chang Hwan
• Na Seung Chui
• Oh Seung Ho
• Yoo Young San
• Kim Ho Dong

Classifications

• B01J37/04

  Mixing {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• B01D2255/9207

  Specific surface · CPC title

• B01J37/10

  in the presence of water, e.g. steam · CPC title

• B01J37/0018

  Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat) · CPC title

• B01D2257/404

  Nitrogen oxides other than dinitrogen oxide · CPC title