Method for Producing a Catalyst Composition

Abstract

The present invention relates to a method for producing a catalyst composition, in particular a composition for treating NOx-containing exhaust gases. The composition comprises a small pore zeolite having an SAR of 9-30 and one or more rare earth metals. The method achieves higher levels of rare earth (RE) metal incorporation into the zeolite than can be achieved by conventional washcoating techniques.

Description

[Technical field]

[0001] The present invention relates to a method for producing a catalyst composition, in particular a composition for treating NOx-containing exhaust gases, which achieves higher levels of rare earth (RE) metal incorporation into zeolites than can be achieved by conventional washcoating techniques. [Background technology]

[0002] NH3-SCR is the most effective technology for NOx abatement in the aftertreatment of lean-burn engine exhaust. In this regard, Cu-SSZ-13 has been commercialized as an NH3-SCR catalyst due to its significant advantages of excellent catalytic performance and hydrothermal stability. However, as more and more stringent limitations are imposed on emissions from engine exhaust, especially for vehicles under cold start conditions, it is highly desirable to further enhance the low-temperature NH3-SCR activity and hydrothermal stability of SCR catalysts.

[0003] Small pore zeolites such as CHA and AEI, which have a low silica to alumina ratio (SAR), typically have higher fresh activity under comparable SCR operating conditions than high SAR frameworks, but are less durable. To improve the overall performance of low SAR structures, increased durability is necessary.

[0004] WO 2019 / 223761(A1) discloses rare earth-containing materials defined by structure type, SAR range, RE element, and amount (either as wt% or M / Al ratio). The patent discloses RE-stabilized low SAR CHAs with improved performance. The CHAs are synthesized by an organic structure directing agent (OSDA)-free procedure and have a SAR of about 7.5-8.0. The Y incorporation is about 1.0-3.0 wt% based on the silica weight in the zeolite, which was done by conventional ion exchange. In WO 2019 / 223761(A1), rare earth (RE)-containing low SAR CHAs prepared by conventional ion exchange methods showed improved durability.

[0005] Achieving high incorporation of trivalent metal ions (e.g., Fe(III), Ce(III) and La(III) in small pore zeolites (e.g., CHA and AEI) by conventional ion exchange methods is a known challenge. This can be attributed to unfavorable steric effects of the large size of the hydrated cations compared to the size of the zeolite pore openings, and also to the imbalance of charge density between the high SAR zeolite framework and the trivalent cations.

[0006] WO 2019 / 223761 does not achieve a RE-CHA with a SAR substantially higher than 8, and at the same time does not achieve a RE incorporation substantially higher than 1 wt%. Thus, there remains a technical need for small pore zeolites in general, and CHAs in particular, with both high SAR and high RE incorporation. This type of material is expected to show performance advantages in many applications.

[0007] US Patent No. 8,906,329 discloses stabilization of CHA with base metals including cerium and improving performance in Cu SCR applications.

[0008] China Patent Application Publication No. 108786911(A) discloses RE-containing AEI and synthesis method. In Example 1, lanthanum nitrate and water glass were added to 1,1-dimethyl-3,5-dimethyl with a concentration of 25 wt%, and stirred in a solution of piperidine, and then HY molecular sieve, NaOH and deionized water were added to form a synthesis gel, which was then crystallized, filtered and calcined to obtain La-AEI molecular sieve. This patent application did not disclose any information on the SAR, RE content, XRD phase, crystal morphology, phase purity or crystallinity of the claimed RE-AEI, or any XRD data or SEM on the crystal morphology of the claimed RE-AEI.

[0009] Usui et al.,ACS Catal.2018,8,9165-9173, entitled "Improve the Hydrothermal Stability of Cu-SSZ-13 Zeolite Catalyst by Loading a Small Amount of Ce", describes how the high Cu loading capacity on ion exchange sites and abundant acid sites contribute to the high activity of low SAR Cu-CHAs. For a given SAR, there is an optimal Cu loading for the stability of the zeolite structure or retention of crystallinity under aging conditions, which decreases with increasing hydrothermal aging temperature. This is because high Cu loading and Al-rich framework under aging conditions are prone to the formation of inactive CuOx species and dealumination of the framework, respectively. Loading of a small amount of cerium can significantly enhance the stability of CHAs with high Cu loading. High Cu loading is essential for high activity. For CHAs with an SAR of about 13, the best results were found with Ce loadings of 0.2-0.4 wt%. To explain the stabilizing effect, the authors suggested that Ce ions could fill crystal defects or neutralize silanol groups, thus enhancing stability, and that Ce ions on ion-exchange sites could stabilize the framework better than protons. Cerium can be loaded either by conventional solution ion-exchange or by solid-state reactions, with no difference in performance. At high loadings, not all cerium ions occupy ion-exchange sites, as evidenced by the presence of CeO2 by XRD, indicating constraints on Ce loading to ion-exchange sites.

[0010] Li et al., Ind. Eng. Chem. Res. 2020, 59, 5675-5685, titled "A Density Functional Theory Modeling on the Framework Stability of Al-Rich Cu-SSZ-13 Zeolite Modified by Metal Ions", applied computational modeling methods to theoretically explain the Y stabilization effect in the Al-rich CHA structure via the selective placement of Cu in the framework ring 6 promoted by the selective placement of Y in the framework ring 8 and the formation of multiple coordinate bonds between RE and zeolite framework O.

[0011] Zhao et al., Catal. Sci. Technol., 2019, 9, 241, titled "Rare-earth ion exchanged Cu-SSZ-13 zeolite from organotemplate-free synthesis with enhanced hydrothermal stability in NH3-SCR of NOx", investigated several RE elements (Ce, La, Sm, Y, Yb) and found that yttrium gave the highest stabilizing effect in Al-rich CHA synthesized by OSDA-free procedure. With the increased Y incorporation, Cu-CHA showed improved low-temperature NO conversion activity even after hydrothermal aging. Experimental evidence was provided that Y species were incorporated into the ion-exchange sites of the CHA structure, indicating that Y can stabilize framework Al and also preserve Brønsted acid sites in Al-rich CHA.

[0012] It would therefore be desirable to provide improved catalyst compositions for treating NOx-containing exhaust gases and / or to address at least some of the problems associated with the prior art, or at least to provide a commercially viable alternative thereto. Summary of the Invention

[0013] According to a first aspect, the present invention provides a method for producing a catalytic composition for treating NOx-containing exhaust gas, the composition comprising a small pore zeolite having a silica-to-alumina ratio (SAR) of 9 to 30 and one or more rare earth metals, the method comprising: i) providing a large pore precursor zeolite; ii) introducing one or more rare earth metals into the precursor zeolite by ion exchange and calcination to form a rare earth metal-exchanged precursor zeolite; iii) converting the rare earth metal substituted precursor zeolite into a small pore zeolite in the presence of a structure directing agent.

[0014] The present invention will now be further described. In the following passages, different aspects of the invention are defined in more detail. Each aspect so defined can be combined with any other aspect or aspects, unless otherwise clearly indicated to be contradictory. In particular, any feature indicated as being preferred or advantageous can be combined with any other feature or features indicated as being preferred or advantageous.

[0015] In contrast to the teaching of WO 2019 / 223761, where the zeolite structure was first formed in a synthesis step and the RE incorporation took place in a post-synthesis ion-exchange step, the RE-containing zeolites according to the present invention are prepared by a direct synthesis method in which the RE elements are incorporated as the small pore zeolite structure is formed. The present invention allows for the introduction of higher levels of RE metals into the structure, which leads to improved durability.

[0016] In contrast to the teaching of CN108786911(A) in which the rare earth source and HY molecular sieve are added separately in the preparation of the synthesis gel, in the present invention, before the zeolite is converted into a small pore zeolite, the RE metals are supported on a large pore molecular sieve and calcined to fix the RE metals within the cages of the zeolite, thereby achieving good distribution of the RE metals.

[0017] Preferably, in the present invention, the RE elements are first supported and fixed on a large pore precursor such as zeolite (USY) by ion exchange and calcination, respectively, and then the RE-USY is converted to RE-CHA under synthesis conditions. High quality RE-containing CHA with SAR 9-30 and simultaneously RE in an amount of 0.06-3.5 wt.%, for example 0.6-3.5 wt.%, based on the anhydrous zeolite mass, have been produced according to the method of the present invention.

[0018] The method of the present invention relates to the preparation of a catalytic composition for treating NOx-containing exhaust gases. Such exhaust gases are produced in combustion reactions, particularly in the combustion of fuels in engines, such as gasoline and diesel automobile engines. The catalytic composition of the present invention is capable of treating NOx-containing exhaust gases by SCR to produce harmless gases, such as N2 and HO. x The process is well known in the art.

[0019] The composition may be provided on a substrate for inclusion in an exhaust gas treatment system. For example, the composition may be washcoated onto a honeycomb monolith body or provided as an inherent component of an extrusion composition used to form the honeycomb monolith body. Techniques for forming such catalytic articles containing the catalyst composition are well known in the art.

[0020] The composition includes a small pore zeolite having a silica to alumina ratio (SAR) of 9 to 30. Zeolites are structures formed from alumina and silica, and the SAR determines the reactive sites within the zeolite structure. Small pore zeolites are structures formed from eight tetrahedral atoms (Si 4+ and Al 3+These pores, each connected by a shared oxygen, provide access for small molecules to the intracrystalline void space while restricting the ingress and egress of larger molecules, which is important for overall catalytic performance. Small pore zeolites are materials containing pore openings with eight tetrahedral atoms in the ring, while medium pore zeolites are those in which the smallest pores have ten tetrahedral atoms in the ring, and large pore zeolites are those in which the smallest pores have twelve tetrahedral atoms in the ring.

[0021] Preferably, the small pore zeolite has a framework structure selected from the group consisting of AEI, AFT, AFX, CHA, EMT, GME, KFI, LEV, LTN, ERI, SWY, SAV, LTA and SFW (including mixtures of two or more of these). In some embodiments, the small pore zeolite has a framework structure selected from the group consisting of AEI, CHA, AFX, LTA, ERI and SWY. It is particularly preferred that the zeolite has a CHA or AEI type framework structure.

[0022] Preferably, the small pore zeolite has a silica-to-alumina ratio (SAR) of 10 to 25, more preferably 12 to 20. In some embodiments, the SAR is 10 to 24, e.g., 11 to 23, 13 to 22, 14 to 21, 15 to 20, or 16 to 18. These SAR values ​​are higher than those achieved in WO 2019 / 223761. A higher SAR ratio indicates a lower acidity (Al 3+ Note that the α-amino acid sequence is more stable (fewer sites).

[0023] Preferably, the one or more rare earth metals are selected from the group consisting of Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, La, Ce, Pr, Nd, Pm, Y, and Sc, and mixtures of two or more thereof. In some embodiments, the one or more rare earth metals are selected from the group consisting of La, Er, Pr, Ce, and Y. Preferably, the rare earth metals are selected from Y, Ce, and mixtures thereof.

[0024] Preferably, the small pore zeolite comprises one or more rare earth metals in a total amount of 0.05-3.5 wt%, preferably 0.05-3.5 wt%, more preferably 0.05-2 wt%, based on the anhydrous zeolite mass. In some embodiments, the small pore zeolite comprises one or more rare earth metals in a total amount of 0.1-3 wt%, e.g., 0.15-2.8 wt%, 0.2-2.5 wt%, 0.3-2.2 wt%, 0.5-2 wt%, 1-1.8 wt%, 1.2-1.5 wt%, based on the anhydrous zeolite mass. This amount provides the required durability necessary to maintain high activity both fresh and aged.

[0025] The method includes providing a large pore precursor zeolite. Preferably, the large pore precursor zeolite has a USY, Beta, or ZSM-20 framework structure type, preferably a USY framework structure type.

[0026] In the first step, one or more rare earth metals are introduced into the precursor zeolite by ion exchange and calcination to form a rare earth metal-exchanged precursor zeolite. Ion exchange techniques and the necessary calcination are well known in the art for introducing RE metals into zeolites. For example, ion exchange and calcination can be accomplished by dissolving the necessary rare earth metal salts (e.g., rare earth metal nitrates) in a solution. The solution can be added to a zeolite slurry (e.g., a USY slurry) under stirring. The resulting mixture can then be heated (e.g., to 100°C) for a period of time (e.g., 1 hour). It can then be filtered, washed, and dried to form a solid product. The resulting dried product can then be calcined (e.g., at 550°C for 1 hour, preferably at a heating rate of 3°C / min).

[0027] In the second step, the rare earth metal substituted precursor zeolite is converted to a small pore zeolite in the presence of a structure directing agent. Examples of structure directing groups include hydroxides or salts of N,N,N-trimethyladamantylammonium, N,N,N-dimethylethylcyclohexylammonium, trimethyl(cyclohexylmethyl)ammonium, tetraethylammonium, N,N-dimethyl-3,5-dimethylpiperidinium and 1,1-diethyl-2,6-dimethylpiperidinium. Preferably, the structure directing agent is N,N,N-trimethyladamantylammonium hydroxide or a salt thereof. This step involves forming a synthesis gel comprising the rare earth metal substituted precursor zeolite and the structure directing agent, and then heating the gel under conditions necessary to form the desired final zeolite. The synthesis gel may comprise the rare earth metal substituted precursor zeolite, the structure directing agent, water and an alkali metal (e.g., Na and / or K). The rare earth metal substituted precursor zeolite is preferably used as a source of silica and alumina. Alternative sources of Si and Al can also be used. For example, the Al source can be selected from the group including aluminum salts such as sodium aluminate, aluminum sulfate, aluminum nitrate, aluminum chloride, aluminum hydroxide, aluminum alkoxides, and alumina. The Si source can be selected from the group including sodium silicate, potassium silicate, silica gel, silica sol, fumed silica, silicon alkoxides, and precipitated silica. The synthesis gel is preferably heated at a temperature of 100-200° C. for 5 hours to 10 days.

[0028] The synthesis gel may contain the rare earth metal substituted precursor zeolite in an amount of 1% to 30%, preferably 2% to 15%, for example, 3% to 6%, 6% to 9%, 9% to 11%, or 11% to 15%, where % is by weight based on the total weight of the synthesis gel.

[0029] The synthesis gel may contain the structure directing agent in an amount of Q / SiO2 molar ratio of 0.01 to 0.2, preferably 0.02 to 0.15, for example 0.03 to 0.05, 0.04 to 0.07, 0.07 to 0.1 or 0.1 to 0.15, where Q is a structure directing agent.

[0030] The second step can include forming a synthesis gel (e.g., a synthesis gel including a rare earth metal substituted precursor zeolite and a structure directing agent) and heating the gel at a temperature and for a period of time suitable for the growth of a small pore zeolite. The synthesis gel can be heated at a temperature of 100°C to 200°C, more preferably at a temperature of 110°C to 190°C, 120°C to 180°C, 120°C to 170°C, or even at 125°C to 165°C. The period during which the gel is heated to the appropriate temperature is preferably at least 10 hours, more preferably 20 to 60 hours, such as 5 hours to 10 days, for example 10 hours to 8 days, 20 hours to 7 days, 1 to 6 days, 2 to 5 days. It is particularly preferred to heat the gel to these temperatures and hold it at these temperatures for these periods of time, for example at least 10 hours at a temperature of 100°C to 200°C.

[0031] Preferably, the zeolite product obtained by heating the synthesis gel at such a temperature and for such a period is recovered by typical vacuum filtration. Preferably, the filtered product is washed with demineralized water (also known as deionized water) used to remove residual mother liquor. Preferably, the zeolite product is washed until the conductivity of the filtrate is less than 0.1 mS. Preferably, the filtered and washed product is then dried at a temperature above 100°C, preferably about 120°C. The dried product can then be calcined (e.g., to burn out the OSDA content). Ammonium ion exchange can then be used (e.g., to remove alkali cations). A final calcination can then be used (e.g., to convert the product from the ammonium form to an activated form). These steps can be carried out by typical procedures commonly known to those skilled in the art and are illustrated in the examples.

[0032] To prepare the synthesis gel, USY is used as the preferred source for both silica and alumina, but other sources commonly used in zeolite synthesis can also be used. For example, the Al source can be selected from the group including sodium aluminate, aluminum sulfate, aluminum nitrate, and other aluminum salts, aluminum chloride, aluminum hydroxide, aluminum alkoxides, and alumina. The Si source can be selected from the group including sodium silicate, potassium silicate, silica gel, silica sol, fumed silica, silicon alkoxides, and precipitated silica.

[0033] RE nitrates may be used as the RE metal source, and aqueous solutions of other RE salts can also be used, for example acetate, yttrium or halogens (such as F, Cl, Br and I) can be used as the RE salt.

[0034] N,N,N-trimethyladamantylammonium hydroxide solution is the preferred OSDA, although other applicable OSDAs commonly known for the synthesis of CHA structures may also be used. Examples of structure-directing groups include hydroxides or salts of N,N,N-trimethyladamantylammonium, N,N,N-dimethylethylcyclohexylammonium, trimethyl(cyclohexylmethyl)ammonium, tetraethylammonium, N,N-dimethyl-3,5-dimethylpiperidinium, and 1,1-diethyl-2,6-dimethylpiperidinium.

[0035] Control of the gel composition within certain ranges is important for forming RE-containing CHA, where the SAR ranges from 10 to 100, preferably from 20 to 50, the RE / Al2O3 molar ratio ranges from 0.01 to 1.00, preferably from 0.05 to 0.30, the NaOH / SiO2 molar ratio ranges from 0.05 to 2.00, preferably from 0.15 to 0.95, the Q / SiO2 molar ratio ranges from 0.001 to 0.20, preferably from 0.02 to 0.10, and the H2O / SiO2 molar ratio ranges from 5 to 100, preferably from 20 to 50. Q is a structure directing agent.

[0036] The gel composition can have a SAR range of 10-100, for example, 20-90, 30-80, 40-70, or 50-60.

[0037] The synthesis gel can have one or more, two or more, three or more, or all four of the following compositional molar ratios: RE / Al2O3 is 0.01 to 1.00, for example, 0.01 to 1, 0.05 to 0.5, or 0.1 to 0.3; NaOH / SiO2 is about 0.05 to about 2.00, for example, 0.05 to 2, 0.1 to 0.95, 0.15 to 0.95, 0.2 to 0.9, 0.3 to 0.8, or 0.5 to 0.7; Q / SiO2 is about 0.001 to about 0.20, for example, 0.001 to 0.2, 0.01 to 0.15, 0.02 to 0.1, 0.05 to 0.9, 0.1 to 0.8, or 0.2 to 0.5; H2O / SiO2 is about 5 to about 100, for example, 10 to 80, 20 to 75, 30 to 60, or 40 to 50.

[0038] The crystallization temperature ranges from 100°C to 200°C, preferably 110 to 180°C. The time for complete crystallization is from 5 hours to 10 days, preferably 10 to 60 hours. After crystallization, the as-synthesized zeolite is recovered from the synthesis mixture by conventional solid-liquid separation methods and washed with demineralized water until the conductivity of the filtrate is less than 0.1 mS. The filter cake is then oven-dried to reduce the surface water and obtain a dry powder product. Calcination of the dried product to burn off the OSDA content, followed by ammonium ion exchange to remove the alkali cations, and final calcination to convert the product from the ammonium form to the activated form are carried out by typical procedures commonly known to those skilled in the art and are illustrated in the examples.

[0039] Powder X-ray diffraction (PXRD) is used to determine the degree of crystallinity of the desired zeolite structure and to identify the presence or absence of impurity phases. Scanning electron microscopy (SEM) is used to examine the crystalline morphology of the formed zeolite product. X-ray fluorescence spectroscopy (XRF) is used to determine the elemental composition of the formed zeolite.

[0040] Preferably, the small pore zeolite has a crystallinity of greater than 90%, preferably greater than 95%, even more preferably greater than 98%.

[0041] Preferably, the small pore zeolite has granular particles, i.e., the zeolite has a particle morphology in which the zeolite crystals have a three-dimensional shape, as opposed to rod-like particles having a substantially one-dimensional shape, or disk or plate-like particles having a two-dimensional shape. The zeolite has granular particles that include or consist of cubic crystals. In one embodiment, the small pore zeolite has a cubic morphology.

[0042] Preferably, the small pore zeolite further comprises one or more transition metals selected from the group consisting of Cr, Mn, Fe, Co, Ce, Ni, Cu, Zn, Ga, Mo, Ru, Rh, Pd, Ag, In, Sn, Re, Ir, Pt, and mixtures thereof. These are preferably present in a total amount of 0.1-6 wt%, preferably 2-5 wt%, more preferably 2-4 wt%. The transition metals may be present in a total amount of 0.1-6 wt%, for example, 0.5-5.5 wt%, 1-5 wt%, 1.5-4.5 wt%, 2-4 wt%, or 2.5-3 wt%. The transition metals may be selected from Cu, Fe, Mn, Pt, Pd, and Rh. The most preferred transition metals are Cu and / or Fe.

[0043] According to a second aspect, the present invention provides a catalytic composition for treating NOx-containing exhaust gas, the catalytic composition being obtainable according to the method of the first aspect above, the small pore zeolite of the catalytic composition having a SAR of 9-30 and one or more rare earth metals.

[0044] According to a third aspect, the present invention provides the use of a catalyst composition for the selective catalytic reduction of NOx in a NOx-containing exhaust gas.

[0045] The invention will now be further described with reference to the following non-limiting examples.

[0046] Example 1 (P04D2QA) First, USY was ion-exchanged with yttrium(III) and calcined. The resulting Y-USY, sodium hydroxide solution, 17.61 g of 25.5% N,N,N-trimethyladamantylammonium hydroxide solution, and demineralized water were mixed to produce an initial synthesis gel. The resulting synthesis mixture was a homogeneous slurry with the molar composition listed in Table 1.

[0047] The synthesis mixture was then transferred to a reactor for crystallization.

[0048] The prepared synthesis mixture was sealed in a 600 mL stainless steel stirred autoclave and heated to 130 °C for crystallization for 22 h. The solid product was collected by conventional solid-liquid separation method, and the obtained solid phase was washed with sufficient amount of demineralized water and then dried in an oven at 120 °C. XRD confirmed that the obtained product was highly crystallized pure CHA. The as-synthesized solid product was calcined in a muffle furnace heated to 550 °C at a heating rate of 1 °C / min and held at 550 °C for 6 h.

[0049] The calcined product was cooled and then ammonium exchanged twice. Ion exchange was carried out using ammonium sulfate at 80°C for 2 hours. The solid product was collected by filtration, washed and the filter cake was dried at 120°C. The resulting dried product in NH4 form was calcined in a muffle furnace heated at a rate of 1°C / min and held at 550°C for 2 hours. The final product is an activated H- and Y-containing zeolite product.

[0050] The final product exhibited an X-ray diffraction pattern of highly crystallized pure CHA structure (Figure 2), indicating that the material remains stable after calcination to remove the organic template, ion exchange to remove the alkali cations, and final activation to convert the NH4 form to the H form. The results of elemental analysis of the final activated product are listed in Table 2. The morphology of the crystalline grain images was observed by SEM.

[0051] Examples 2 to 16 The procedure of Example 1 was repeated, but adjusting the amounts of starting materials and / or using cerium nitrate instead of yttrium nitrate to produce reaction mixtures having specific molar ratios and / or incorporation of various RE elements as shown in Table 1. Crystallization and other post-synthesis processing steps leading to the activated form of the product were carried out in the same manner as described in Example 1, although in some cases, crystallization conditions (temperature and time) were changed somewhat as required for completion of crystallization in the particular example, as shown in Table 1. Product results from each example are listed in Table 2.

[0052] Comparative Examples 1 to 4 The syntheses of Examples 1, 8, 10 and 16 were repeated, except that the synthesis gel was prepared by using USY without loading of RE by ion exchange and calcination treatment. These syntheses correspond to Comparative Examples 1, 2, 3 and 4, respectively. The RE-free CHA obtained from these Comparative Examples is used to compare with the corresponding RE-containing CHA. The crystallization and other post-synthetic processing steps leading to the activated form of the RE-free CHA were carried out in the same manner as described in the corresponding Examples. The results from these Comparative Examples are listed in Table 2.

[0053] [Table 1] [1] RE represents the rare earth metals, yttrium and cerium. [2] Q represents N,N,N-trimethyladamantylammonium hydroxide. [3] 165°C / 48 hours, followed by 180°C / 21 hours.

[0054] [Table 2] [1] Measured by X-ray fluorescence spectroscopy.

[0055] Selective Catalytic Reduction (SCR) performance Activated zeolites prepared according to the procedures described for Examples 5, 6 and 17 and Comparative Example C1 were impregnated with metals using the required amount of copper (II) acetate dissolved in demineralized water. The metal-impregnated zeolites were dried overnight at 80° C. and then calcined in air at 550° C. for 4 hours. Copper was added to the zeolites to achieve 2.75 wt. % copper based on the total weight of the zeolite.

[0056] Each sample was pelletized and tested using a gas stream containing 500 ppm NO, 550 ppm NH3, 350 ppm 10% H2O and 10% O2. The amount of each catalyst used in the test was 0.3 g. The flow rate of the gas stream used in the test was 2.6 L / min, which is equivalent to 520 L / hr per gram of catalyst. The samples were heated from room temperature to 150° C. under the gas mixture described above except for NH3. At 150° C., NH3 was added to the gas mixture and the samples were held under these conditions for 30 minutes. The temperature was then increased from 150° C. to 500° C. at a rate of 5° C. / min. The downstream gas treated by the zeolite was monitored to measure NO x The conversion and N2O selectivity were determined.

[0057] Some of the Cu-impregnated samples were hydrothermally aged for 16 hours at 850° C. in air containing 5 vol.% H2O. These samples were tested on the rig under conditions similar to those described above for the fresh samples. [Brief description of the drawings]

[0058] The invention will now be further described with reference to the following non-limiting figures. [Figure 1] 1 shows the XRD patterns of the as-synthesized Y-containing CHA structures prepared in Example 1, Example 2, Example 3, Example 4, Example 5, Example 6, Example 7, Example 8 and Example 9. [Diagram 2] 1 shows the XRD patterns of the as-synthesized Ce-containing CHA structures prepared in Example 10, Example 11, Example 12, Example 13, Example 14, Example 15, and Example 16. [Diagram 3] 1 shows XRD patterns of activated Y-containing CHA structures prepared in Examples 1, 2, 3, 4, 5, 6, 7, 8 and 9. [Figure 4] 1 shows XRD patterns of activated Ce-containing CHA structures prepared in Examples 10, 11, 12, 13, 14, 15, and 16. [Diagram 5] 1 shows XRD patterns of activated Y-containing CHA structures prepared in Examples 5, 6, 8, 9, and Comparative Examples C1 and C2. [Figure 6] 1 shows XRD patterns of activated Ce-containing CHA structures prepared in Examples 12, 14, 16, and Comparative Examples C1, C3, and C4. [Figure 7] 1 shows a microscope image of the as-synthesized Y-CHA prepared in Example 2. [Figure 8] 1 shows a microscope image of the as-synthesized Ce-CHA prepared in Example 10. [Figure 9(a)]1 is a graph showing NOx conversion activity and N2O selectivity, respectively, of fresh and aged catalysts of Example 15 and Comparative Example C1 tested at temperatures from 150 to 500° C. at a heating rate of 5° C. per minute. [Figure 9(b)] 1 is a graph showing NOx conversion activity and N2O selectivity, respectively, of fresh and aged catalysts of Example 15 and Comparative Example C1 tested at temperatures from 150 to 500° C. at a heating rate of 5° C. per minute. [Figure 10(a)] 1 is a graph showing NOx conversion activity and N2O selectivity, respectively, of fresh and aged catalysts of Example 5 and Comparative Example C1 tested at temperatures from 150 to 500° C. at a heating rate of 5° C. per minute. [Figure 10(b)] 1 is a graph showing NOx conversion activity and N2O selectivity, respectively, of fresh and aged catalysts of Example 5 and Comparative Example C1 tested at temperatures from 150 to 500° C. at a heating rate of 5° C. per minute. [Figure 11(a)] 1 is a graph showing the NOx conversion activity and N2O selectivity, respectively, of aged catalysts of Examples 5, 6 and Comparative Example C1 tested at temperatures from 150 to 500° C. at a heating rate of 5° C. per minute. [Figure 11(b)] 1 is a graph showing the NOx conversion activity and N2O selectivity, respectively, of aged catalysts of Examples 5, 6 and Comparative Example C1 tested at temperatures from 150 to 500° C. at a heating rate of 5° C. per minute. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0059] It was noted that while some of the as-synthesized forms of the Y-CHA samples from Examples 1-9 have a non-CHA shoulder peak at about 2-theta 12.65 (Figure 1), all of the activated forms of the same Y-CHA are absent of such a shoulder peak (Figure 3). This shoulder peak appears and grows with increasing yttrium content in Y-CHA.

[0060] Unlike Y-CHA, the as-synthesized Ce-CHA shows XRD peaks of CHA only (Figure 2). Overlaid XRD patterns of activated Y-CHA (Examples 5, 6, 8, 9) and Ce-CHA (Examples 12, 14, 16) and non-RE-containing CHAs with similar SAR (Comparative Examples C1, C2, C3, C4) show very consistent diffractograms in terms of peak broadening and peak position (Figures 5 and 6).

[0061] The location of the RE atom in the CHA structure may be either in the framework as an isomorphous replacement of the T atom, or off the framework as an extra framework species in a cage. Framework REs may also be expelled from framework locations to off-framework locations during post-synthesis processing steps such as calcination.

[0062] The well-formed cube-like crystals with uniform size of about 0.5-1.0 μm of the RE-CHA from Examples 2 and 10 are similar to the RE-free CHA produced from the equivalent synthesis (FIGS. 7 and 8).

[0063] As shown in Figures 9(a) and 9(b), a catalyst made according to the method of the present invention and containing 0.41 wt. % ceria with an SAR of 13.7 (Example 15) showed similar fresh NOx conversion and NO selectivity as Comparative Example C1, which uses CuCHA zeolite with approximately the same SAR of 13.

[0064] However, as shown in the same Figures 9(a) and 9(b), a catalyst formed according to the method of the present invention and containing 0.41 wt. % ceria having an SAR of between 13.7 (Example 15) shows significantly improved aged NOx conversion and NO selectivity over temperatures from 150 to 500 °C.

[0065] As shown in Figures 10(a) and 10(b), a catalyst (Example 5) formed according to the method of the present invention and having a SAR of 13.9 and containing 0.24 wt% Y showed the same fresh activity as Comparative Example C1. However, after aging, Example 5 shows significantly improved NOx conversion and NO selectivity over temperatures from 150 to 500 °C compared to Comparative Example C1 using CuCHA zeolite. Note that the amount of copper for both of these catalysts is the same at 2.75 wt%, therefore the improvement in activity is due to the 0.24 wt% Y loading achieved by forming the zeolite according to the method of the present invention.

[0066] A similar effect is achieved when the Y loading of the catalyst is 0.11 wt %, as shown in Figures 11(a) and 11(b), which show the aged NOx conversion and N2O selectivity of Examples 5, 6 and Comparative Example C1.

[0067] Thus, Figures 9-11 show that by forming the zeolite according to the method of the present invention, the inclusion of rare earth metals such as ceria and yttria in the zeolite achieves improved aged NOx conversion and NO selectivity.

[0068] Although preferred embodiments of the invention have been described in detail herein, those skilled in the art will recognize that modifications can be made without departing from the scope of the invention or the appended claims.

Claims

1. A method for manufacturing a catalyst composition for treating NOx-containing exhaust gas, wherein the composition comprises a small-pore zeolite having a SAR of 9 to 30 and one or more rare earth metals, and the method comprises i) providing a large-pore precursor zeolite; ii) introducing one or more rare earth metals into the precursor zeolite by ion exchange and calcination to form a rare earth metal-substituted precursor zeolite; iii) converting the rare earth metal-substituted precursor zeolite into a small-pore zeolite in the presence of a structure-directing agent.

2. The method according to claim 1, wherein step (iii) comprises forming a synthesis gel comprising the rare earth metal-substituted precursor zeolite and the structure-directing agent, and then heating the synthesis gel to form the small-pore zeolite.

3. The method according to claim 1 or 2, wherein the small-pore zeolite contains the one or more rare earth metals in a total amount of 0.05 to 3.5% by weight, preferably 0.05 to 2% by weight.

4. The method according to claim 1, wherein the small-pore zeolite further contains Cu and / or Fe, preferably in a total amount of 0.1 to 6% by weight, more preferably in a total amount of 1 to 3% by weight.

5. The method according to claim 1, wherein the large-pore precursor zeolite has a USY framework structure type.

6. The method according to claim 1, wherein the small-pore zeolite has a CHA or AEI framework structure type.

7. The method according to claim 1, wherein the structure-directing agent is N,N,N-trimethyladamantylammonium hydroxide or a salt thereof.

8. The method according to claim 1, wherein the rare earth metal is selected from Y and Ce and mixtures thereof.

9. A catalyst composition for treating NOx-containing exhaust gas, wherein the catalyst composition can be obtained according to the method described in claim 1, and the microporous zeolite of the catalyst composition has an SAR of 9 to 30 and one or more rare earth metals.

10. Use of the catalyst composition according to claim 9 for the selective catalytic reduction of NOx in NOx-containing exhaust gas.

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