Methods and systems for production of consistently-sized BEA zeolite nano-crystals, the method including mixing an emulsion, the emulsion comprising a surfactant and an organic solvent; heating the emulsion; mixing a zeolite solution, the zeolite solution comprising a silicon-containing compound and an aluminum-containing compound; heating the zeolite solution; adding the emulsion to the zeolite solution drop-wise over time to create an zeolite emulsion solution mixture; heating the zeolite emulsion solution mixture; and precipitating the consistently-sized BEA zeolite nano-crystals.

SCR-active molecular-sieve based catalysts with improved low-temperature performance are made by heating a molecular-sieve in a non-oxidizing atmosphere with steam (hydrothermal treatment), or in a reducing atmosphere without steam (thermal treatment), at a temperature in the range of 600-900° C. for a time period from 5 minutes to two hours. The resulting SCR-active iron-containing molecular sieves exhibit a selective catalytic reduction of nitrogen oxides with NH.sub.3 or urea at 250° C. that is at least 50% greater than if the iron-containing molecular-sieve were calcined at 500° C. for two hours without performing the hydrothermal or thermal treatment.

Process for preparing a catalyst composition containing a modified crystalline aluminosilicate and a binder, wherein the catalyst composition comprises from 5 to 95% by weight of crystalline aluminosilicate as based on the total weight of the catalyst composition, the process being remarkable in that it comprises a step of steaming said crystalline aluminosilicate: at a temperature ranging from 100° C. to 380° C.; under a gas phase atmosphere containing from 5 wt % to 100 wt % of steam; at a pressure ranging from 2 to 200 bars; at a partial pressure of H.sub.2O ranging from 2 to 200 bars; and said steaming being performed during at least 30 min and up to 144 h;
and in that the process also comprises a step of shaping, or of extruding, the crystalline aluminosilicate with a binder, wherein the binder is selected to comprise at least 85 wt % of silica as based on the total weight of the binder, and less than 1000 ppm by weight as based on the total weight of the binder of aluminium, gallium, boron, iron and/or chromium.

A method of making a xylene isomerization catalyst comprises the steps of (i) contacting a ZSM-5 zeolite starting material having a silica to alumina molar ratio of 20 to 50 and having a mesopore surface area in the range of 50 m.sup.2/gram to 200 m.sup.2/gram in a reactor with a base to provide an intermediate zeolite material; (ii) recovering the intermediate ZSM-5 zeolite material of step (i); (iii) contacting the intermediate zeolite material with an acid to provide an acid treated ZSM-5 zeolite product; (iv) recovering the acid treated ZSM-5 zeolite material; and (v) calcining the acid treated ZSM-5 zeolite material to provide a desilicated ZSM-5 zeolite product having a silica to alumina molar ratio of 20 to 150 and having a mesopore surface area in the range of 100 m.sup.2/gram to 400 m.sup.2/gram.

A catalyst includes LTA zeolite including copper ions, wherein a Si/Al ratio of the LTA zeolite is 2 to 50. The catalyst is coated on a honeycomb carrier or a filter. The catalyst removes NOx from a reaction gas at 100° C. or above. The catalyst has an NOx conversion rate of 80% at 450° C. or above.

Disclosed are processes for conversion of a feedstock comprising C.sub.8+ aromatic hydrocarbons to lighter aromatic products in which the feedstock and optionally hydrogen are contacted in the presence of the catalyst composition under conversion conditions effective to dealkylate and transalkylate said C.sub.8+ aromatic hydrocarbons to produce said lighter aromatic products comprising benzene, toluene and xylene. The catalyst composition comprises a zeolite, a first metal, and a second metal, and is treated with a source of sulfur and/or a source of steam.

The presently disclosed and claimed inventive concept(s) generally relates to a method of making a solid catalyst component comprising a zeolite with a modifier and at least one Group VIII metal alloyed with at least one transition metal and a process of converting mixed waste plastics into low molecular weight organic compounds using the solid catalyst component. The process of converting mixed waste plastics into low molecular weight organic compounds may employ the use of a non-thermal catalytic plasma reactor, which may be configured as a fluid bed reactor or fixed bed reactor.

A method of producing a hierarchical zeolite composite catalyst is provided. The method includes dissolving, in an alkaline solution and in the presence of a surfactant, a catalyst precursor comprising mesoporous zeolite to yield a dissolved zeolite solution, where the mesoporous zeolite comprises large pore ZSM-12 and medium pore ZSM-5. The method also includes condensing the dissolved zeolite solution to yield a solid zeolite composite from the dissolved zeolite solution and heating the solid zeolite composite to remove the surfactant. The method further includes impregnating the solid zeolite composite with one or more active metals selected from the group consisting of platinum, rhenium, rhodium, molybdenum, nickel, tungsten, chromium, ruthenium, gold, and combinations thereof to yield impregnated solid zeolite composite and calcining the impregnated solid zeolite composite to produce the hierarchical zeolite composite catalyst. The hierarchical zeolite composite catalyst has a mesostructure comprising at least one disordered mesophase and at least one ordered mesophase.

A NaY molecular sieve with an aluminum-rich surface is prepared using a process that includes the steps of: a. mixing a directing agent and a first silicon source to obtain a first mixture, wherein the directing agent has a molar composition of Na.sub.2O: Al.sub.2O.sub.3: SiO.sub.2: H.sub.2O=(6-25): 1: (6-25): (200-400); b. mixing the first mixture obtained in the step a with a second silicon source, an aluminum source and water to obtain a second mixture; c. carrying out hydrothermal crystallization on the second mixture obtained in the step b, and collecting a solid product. Calculated as SiO.sub.2, the weight ratio of the first silicon source to the second silicon source is 1: (0.01-12). The NaY molecular sieve has larger aluminum distribution gradient from the surface to the center of the particle than the conventional molecular sieve.

The present disclosures relate to a catalyst for removing a nitrogen oxide and a manufacturing method thereof, and the catalyst for removing the nitrogen oxide includes: a first catalyst that includes a zeolite support containing copper and having a first framework; and a second catalyst that is physically mixed with the first catalyst and includes a zeolite support containing copper and having a second framework different from the first framework.