Process for the preparation of a catalyst and a catalyst comprising the use of more than one silica source is provided herein. Thus, in one embodiment, the invention provides a particulate FCC catalyst comprising about 5 to about 60 wt % one or more zeolites, about 15 to about 35 wt % quasicrystalline boehmite (QCB), about 0 to about 35 wt % microcrystalline boehmite (MCB), greater than about 0 to about 15 wt % silica from sodium stabilized basic colloidal silica, greater than about 0 to about 30 wt % silica from acidic colloidal silica or polysilicic acid, and the balance clay and the process for making the same. This process results in attrition resistant catalysts with a good accessibility.

Process for the preparation of a catalyst and a catalyst comprising the use of more than one silica source is provided herein. Thus, in one embodiment, the invention provides a particulate FCC catalyst comprising about 5 to about 60 wt % one or more zeolites, about 15 to about 35 wt % quasicrystalline boehmite (QCB), about 0 to about 35 wt % microcrystalline boehmite (MCB), greater than about 0 to about 15 wt % silica from sodium stabilized basic colloidal silica, greater than about 0 to about 30 wt % silica from acidic colloidal silica or polysilicic acid, and the balance clay and the process for making the same. This process results in attrition resistant catalysts with a good accessibility.

Provided is a system for treating a flowing exhaust gas comprising a lean NOx trap, a catalyzed soot filter, an ammonia or an ammonia precursor metering system for metering ammonia or an ammonia precursor into the flowing exhaust gas; and an SCR catalyst, wherein the SCR catalyst is disposed downstream of the lean NOx trap and comprises copper and/or iron supported on a small pore molecular sieve.

STA-18, a molecular sieve having a SFW structure and containing phosphorus in the framework, is described. STA-18AP (as prepared) can have a lower alkyl amine, such as trimethylamine, and one of 1,6-(1,4-diazabicyclo[2.2.2]octane)hexyl cations (from diDABCO-C6) or 1,7-(1,4-diazabicyclo[2.2.2]octane)heptyl cations (from diDABCO-C7) or 1,8-(1,4-diazabicyclo[2.2.2]octane)octyl cations (from diDABCO-C8) as SDAs. A lower alkyl ammonium hydroxide, such as tetrabutylammonium hydroxide, can be used as a pH modifier for making SAPO STA-18. A calcined product, STA-18C, formed from STA-18AP is also described. Methods of preparing STA-18AP, STA-18C and metal containing calcined counterparts of STA-18C are described along with methods of using STA-18C and metal containing calcined counterparts of STA-18C in a variety of processes, such as treating exhaust gases and converting methanol to olefins are described.

STA-19, a molecular sieve having a GME structure and phosphorus in the framework, is described. STA-19AP (as prepared) can have a lower alkyl amine, such as trimethylamine, and olig-(1,4-diazabicyclo[2.2.2]octane)-pentyl dibromide ([DABCO-C5].sub.x where x represents the number of repeating units) or olig-(1,4-diazabicyclo[2.2.2] octane)-hexyl dibromide ([DABCO-C6].sub.x) as SDAs. A lower alkyl ammonium hydroxide, such as tetrabutylammonium hydroxide (TBAOH), can be used as a pH modifier for the preparation of SAPO-STA-19. A calcined product, STA-19C, formed from STA-19AP is also described. Methods of preparing STA-19AP, STA-19C and metal containing calcined counterparts of STA-19C are described along with methods of using STA-19C and metal containing calcined counterparts of STA-19C in a variety of processes, such as treating exhaust gases and converting methanol to olefins are described.

In a process for producing a phosphorus-modified zeolite catalyst, an aqueous reaction mixture comprising a source of silica and a source of an organic directing agent effective to direct the synthesis of a desired zeolite is heated at a temperature and for a time sufficient to produce crystals of the desired zeolite. Wet zeolite crystals can then be separated from the reaction mixture and, without removing all the water from the wet zeolite crystals, the zeolite can be converted into the ammonium form by ion exchange, and the crystals can be treated with a phosphorus compound. The phosphorus-treated, ammonium-exchanged zeolite can then be formed into a catalyst to be heated in one or more stages to remove the water and organic directing agent from the zeolite crystals and to convert the zeolite to the hydrogen form.

In a process for producing a phosphorus-modified zeolite catalyst, an aqueous reaction mixture comprising a source of silica and a source of an organic directing agent effective to direct the synthesis of a desired zeolite is heated at a temperature and for a time sufficient to produce crystals of the desired zeolite. Wet zeolite crystals can then be separated from the reaction mixture and, without removing all the water from the wet zeolite crystals, the zeolite can be converted into the ammonium form by ion exchange, and the crystals can be treated with a phosphorus compound. The phosphorus-treated, ammonium-exchanged zeolite can then be formed into a catalyst to be heated in one or more stages to remove the water and organic directing agent from the zeolite crystals and to convert the zeolite to the hydrogen form.

A catalyst article having an extruded support having a plurality of channels through which exhaust gas flows during operation of an engine, and a single layer coating or a bi-layer coating on the support, where the extruded support contains a third SCR catalyst, the single layer coating and the bilayer-coating contain platinum on a support with low ammonia storage and a first SCR catalyst. The catalytic articles are useful for selective catalytic reduction (SCR) of NOx in exhaust gases and in reducing the amount of ammonia slip. Methods for producing such articles are described. Methods of using the catalytic articles in an SCR process, where the amount of ammonia slip is reduced, are also described.

A catalyst article having an extruded support having a plurality of channels through which exhaust gas flows during operation of an engine, and a single layer coating or a bi-layer coating on the support, where the extruded support contains a third SCR catalyst, the single layer coating and the bilayer-coating contain platinum on a support with low ammonia storage and a first SCR catalyst. The catalytic articles are useful for selective catalytic reduction (SCR) of NOx in exhaust gases and in reducing the amount of ammonia slip. Methods for producing such articles are described. Methods of using the catalytic articles in an SCR process, where the amount of ammonia slip is reduced, are also described.

An AFI-CHA hybrid crystal molecular sieve and an NH.sub.3-SCR catalyst using the AFI-CHA hybrid crystal molecular sieve as a carrier, and preparation methods thereof are disclosed. The AFI-CHA hybrid crystal molecular sieve includes an AFI-type SAPO-5 molecular sieve and a CHA-type SAPO-34 molecular sieve, with hybrid crystal grains of AFI and CHA. The hybrid crystal molecular sieve is synthesized by a hydrothermal synthesis method and can be obtained by changing the structure directing agent, the heating rate and the calcinating temperature in the preparation process. Further, copper is loaded on the basis of the hybrid crystal molecular sieve to prepare copper-based NH.sub.3-SCR catalyst and corresponding monolithic catalyst. The catalytic activity and hydrothermal stability of the catalyst are significantly improved by the hybrid crystal molecular sieve.