Zeolite, method for manufacturing zeolite, honeycomb catalyst, and exhaust gas purifying apparatus

Patent metadata

Field	Value
Publication number	US-9656253-B2
Application number	US-201414578493-A
Country	US
Kind code	B2
Filing date	Dec 22, 2014
Priority date	Jul 7, 2014
Publication date	May 23, 2017
Grant date	May 23, 2017

Abstract

A zeolite has a CHA structure, a SiO 2 /Al 2 O 3 composition ratio less than about 15, and an average particle size from about 0.1 μm to about 0.5 μm.

First claim

The invention claimed is:

1. A zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to 0.46 μm; and
Cu supported on the zeolite.

2. The zeolite according to claim 1 ,
wherein the zeolite has a ratio of a total integrated intensity of a (211) plane, a (104) plane, and a (220) plane in an X-ray diffraction spectrum obtained by a powder X-ray diffraction method of about 3.1 or more relative to a total integrated intensity of a (111) plane and a (200) plane in an X-ray diffraction spectrum of lithium fluoride.

3. The zeolite according to claim 2 ,
wherein the Cu in an amount of about 3.5% by mass to about 6.0% by mass of the zeolite is supported on the zeolite.

4. The zeolite according to claim 1 ,
wherein the Cu in an amount of about 3.5% by mass to about 6.0% by mass of the zeolite is supported on the zeolite.

5. A honeycomb catalyst comprising:
a honeycomb unit having partition walls extending along a longitudinal direction of the honeycomb unit to define through holes, the honeycomb unit comprising:
an inorganic binder; and
a zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to 0.46 μm; and
Cu supported on the zeolite.

6. The honeycomb catalyst according to claim 5 ,
wherein the honeycomb unit further contains inorganic particles, and
the inorganic particles comprise at least one of alumina, titania, and zirconia.

7. An exhaust gas purifying apparatus comprising:
a honeycomb catalyst comprising:
a honeycomb unit having partition walls extending along a longitudinal direction of the honeycomb unit to define through holes, the honeycomb unit comprising:
an inorganic binder; and
a zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to 0.46 μm; and
Cu supported on the zeolite.

8. A method for manufacturing a zeolite, the method comprising:
reacting a raw material composition containing a Si source, an Al source, an alkali source, water, and a structure directing agent to synthesize the zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to about 0.46 μm, a compound of the Al source having a solubility of about 1.0 g or less in 100 g of a 1 mol/L aqueous potassium hydroxide solution; and
Cu supported on the zeolite.

9. A method for manufacturing a zeolite; the method comprising:
reacting a raw material composition containing a Si source, an Al source, an alkali source, water, and a structure directing agent to synthesize the zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to 0.46 μm, a ratio of a mole number of water to a total mole number of Si in the Si source and Al in the Al source more than or equal to about 15; and
Cu supported on the zeolite.

10. A method for manufacturing a zeolite, the method comprising:
reacting a raw material composition containing a Si source, an Al source, an alkali source, water, and a structure directing agent to synthesize the zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to 0.46 μm, the alkali source comprising a Li compound; and
Cu supported on the zeolite.

11. A method for manufacturing a zeolite, the method comprising:
reacting a raw material composition containing a Si source, an Al source, an alkali source, water, and a structure directing agent to synthesize the zeolite comprising:
a CHA structure;
a SiO 2 /Al 2 O 3 composition ratio less than about 15;
an average particle size from about 0.1 μm to 0.46 μm, a seed crystal of the zeolite being not used; and
Cu supported on the zeolite.

Assignees

• Ibiden Co Ltd

Inventors

• Usui Toyohiro
• Murakami Takunari

Classifications

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/57

  Honeycombs · CPC title

• B01J35/34

  Mechanical properties · CPC title

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title