Low phosphorus chabazites

Patent metadata

Field	Value
Publication number	US-9878316-B2
Application number	US-201614991272-A
Country	US
Kind code	B2
Filing date	Jan 8, 2016
Priority date	Jul 27, 2011
Publication date	Jan 30, 2018
Grant date	Jan 30, 2018

Abstract

A catalyst washcoat is provided having a molecular sieve with a CHA crystal structure; about 0.5 to about 5.0 mol % phosphorus; and SiO 2 and Al 2 O 3 in a mole ratio of about 5 to about 40. The washcoat includes one or more promoters or stabilizers, and may be applied to a monolith substrate to produce a catalytically active article.

First claim

What is claimed is:

1. A catalytically active washcoat comprising:
a. a molecular sieve having CHA framework, the molecular sieve comprising:
i. about 0.5 to about 5.0 mol % phosphorus based on the total moles of framework silicon, aluminum, and phosphorus in said molecular sieve;
ii. SiO 2 and Al 2 O 3 in a mol ratio of at least about 10;
iii. an aluminum to phosphorus mol ratio of at least about 1; and
iv. about 0.025 to about 5 w/w % of copper and/or iron on an anhydrous molecular sieve basis; and

b. at least one component selected from a binder, a promoter, or a stabilizer.

2. A catalytically active article comprising the catalytically active washcoat of claim 1 on a monolith substrate.

3. The catalyst article of claim 2 , wherein the catalytically active washcoat is deposited on a wall flow filter substrate.

4. The catalyst article of claim 2 , wherein the catalytically active washcoat is deposited on a flow-through substrate.

5. The catalyst article of claim 2 , wherein said molecular sieve comprises about 0.05 to about 1.0 mole percent of framework phosphorus based on the total moles of framework silicon, aluminum, and phosphorus in said molecular sieve.

6. The catalyst article of claim 2 , wherein said molecular sieve has a silica-to-alumina ratio of at least about 10 and an Al:P ratio of greater than about 10.

7. The catalyst article of claim 2 , wherein said molecular sieve has a silica-to-alumina ratio of at least about 10 and an Al:P ratio of greater than about 100.

8. The catalyst article of claim 2 , wherein said copper or iron is ion exchanged.

9. The catalyst article of claim 2 , wherein said molecular sieve contains ion exchanged copper.

10. The catalytic washcoat of claim 1 , wherein phosphorus is present as PO 2 and the PO 2 is heterogeneously distributed in individual crystals of the CHA molecular sieve.

Assignees

• Casci John L
• Chen Hai-Ying
• Fedeyko Joseph Michael
• Collier Jillian Elaine
• Rajaram Raj Rao
• Thompsett David
• Hodgkins Robert P
• Johnson Matthey Plc

Inventors

• Casci John L
• Chen Hai-Ying
• Fedeyko Joseph Michael
• Collier Jillian Elaine
• Rajaram Raj Rao
• Thompsett David
• Hodgkins Robert P

Classifications

• B01D2255/20761

  Copper · CPC title

• B01J29/763 Primary

  CHA-type, e.g. Chabazite, LZ-218 · CPC title

• C01B39/54

  Phosphates, e.g. APO or SAPO compounds · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title

• B01J29/85

  Silicoaluminophosphates [SAPO compounds] · CPC title