Afx zeolite

Patent metadata

Field	Value
Publication number	US-2016137518-A1
Application number	US-201514940198-A
Country	US
Kind code	A1
Filing date	Nov 13, 2015
Priority date	Nov 14, 2014
Publication date	May 19, 2016
Grant date	—

Abstract

Provided is a novel form of AFX zeolite, a novel synthesis technique for producing pure phase AFX zeolite, a catalyst comprising the AFX zeolite in combination with a metal, and methods of using the same.

First claim

1 . An aluminosilicate zeolite comprising at least about 90% phase pure AFX framework and a silica-to-alumina ratio of about 12-50.

2 . The aluminosilicate zeolite of claim 1 , wherein the zeolite has a mean crystal size of about 0.5-7 μm.

3 . The aluminosilicate zeolite of claim 1 , wherein the zeolite has a D 90 crystal size of about 0.5-7 μm.

4 . The aluminosilicate zeolite of claim 3 , wherein the zeolite has a D 90 crystal size of about 0.5-2.5 μm.

5 . The aluminosilicate zeolite of claim 3 , wherein the zeolite has a D 90 crystal size of about 2.5-5 μm.

6 . The aluminosilicate zeolite of claim 1 , wherein the zeolite comprises 95% phase pure AFX framework.

7 . The aluminosilicate zeolite of claim 1 , wherein the zeolite comprises 97% phase pure AFX framework.

8 . The aluminosilicate zeolite of claim 1 , wherein the zeolite is substantially free of medium and large pore frameworks.

9 . The aluminosilicate zeolite of claim 1 , wherein the zeolite is substantially free of zeolite Y framework.

10 . The aluminosilicate zeolite of claim 1 , wherein the zeolite has a silica-to-alumina ratio of about 15-20.

11 . The aluminosilicate zeolite of claim 1 , wherein the zeolite has a silica-to-alumina ratio of about 20-25.

12 . The aluminosilicate zeolite of claim 1 , wherein the zeolite has a silica-to-alumina ratio of about 25-30.

13 . A method for making an aluminosilicate zeolite having an AFX framework comprising the step of reacting a synthesis gel comprising a silica source, an alumina source selected from ammonium-form zeolites and/or hydrogen-form zeolites, and a structured directing agent at a temperature of at least 100° C. until crystals of AFX zeolite form.

14 . The method of claim 13 , wherein the AFX zeolite crystals are at least about 90% phase pure.

15 . The method of claim 13 , wherein the AFX zeolite crystals have a SAR of about 12-32.

16 . The method of claim 13 , wherein the AFX zeolite crystals have a mean crystal size of about 0.5-7 μm.

17 . The method of claim 13 , wherein the alumina source is ammonium-form zeolite Y and/or hydrogen-form zeolite Y.

18 . The method of claim 13 , wherein the synthesis gel has a ratio of Na 2 O/Al 2 O 3 of about 7-23.

19 . The method of claim 13 , wherein the synthesis gel has a ratio of OH − /SiO 2 of about 0.4-0.9.

20 . The method of claim 17 , wherein the synthesis gel has the following compositional ratios:
SiO 2 /Al 2 O 3 of about 18-105 Na 2 O/Al 2 O 3 of about 1.5-18 SDA 2 O/Al 2 O 3 =about 1.5-18 H 2 O/Al 2 O 3 of about 775-2845 OH − /SiO 2 of about 0.3-0.65

21 . The method of claim 13 , wherein the structure directing agent is 1,3-Bis(1-adamantyl)imidazolium hydroxide.

22 . The method of claim 13 , wherein the reacting step is performed at a temperature of about 120-160° C. for about 2-15 days.

23 . An catalyst for treating an exhaust gas comprising a pure phase AFX zeolite loaded with a metal selected from V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Mo, Ru, Rh, Pd, Ag, W, Re, Os, Ir, Pt, and Au.

24 . The catalyst according to claim 23 , wherein the metal selected from Fe and Cu.

25 . The catalyst according to claim 23 , wherein the metal is selected from Pt, Ru, and Pd.

26 . A method for storing NO x comprising contacting an exhaust gas stream containing NO x with a catalyst of claim 23 .

27 . A method for selectively reducing NO x comprising contacting an exhaust gas stream containing NOx with a catalyst of claim 23 .

28 . A method for oxidizing a component of an exhaust gas comprising contacting an exhaust gas stream containing the component with a catalyst of claim 23 , wherein the component is selected from CO, hydrocarbon, and NH 3 .

29 . A catalyst article comprising a catalyst according to claim 23 supported on or embodied in a substrate selected from a wall-flow honeycomb filter and a flow-through honeycomb substrate.

30 . A zeolite having an AFX framework and an XRD pattern according to FIG. 1 .

Assignees

• Johnson Matthey Plc

Inventors

• Rivas-Cardona Alejandra
• Chen Hai-Ying
• Fedeyko Joseph Michael

Classifications

• B01J29/70

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

• B01D53/864 Primary

  Removing carbon monoxide or hydrocarbons · CPC title

• B01J2229/186

  not in framework positions · CPC title

• C01B39/48 Primary

  using at least one organic template directing agent · CPC title

• B01D53/8628

  Processes characterised by a specific catalyst · CPC title