To be able to produce an SCR catalyst (2), in particular one having a zeolite fraction (Z) as catalytically active fraction, in a reliable process and at the same time achieve good catalytic activity of the catalyst (2), an inorganic binder fraction (B) which is catalytically inactive in the starting state and has been treated to develop catalytic activity is mixed into a catalyst composition (4). The inorganic binder component for the binder fraction (B) is, in the starting state, preferably porous particles (10), in particular diatomaceous earth, which display mesoporosity. To effect catalytic activation, the individual particles (10) are either coated with a catalytically active layer (12) or transformed into a catalytically active zeolite (14) with maintenance of the mesoporosity.

Disclosed in certain embodiments are ZSM-5 zeolite microspheres. Disclosed in certain embodiments is a method of forming ZSM-5 zeolite microspheres including: 1) shaping a mixture into microspheres where the mixture includes a silica material and of particulates selected from at least one high-density material with an absolute bulk density of at least 0.3 g/cc, ZSM-5 zeolite crystals, and combinations thereof; 2) calcining the microspheres; and 3) reacting and subsequently heating the microspheres with at least one alkali solution to form ZSM-5 zeolite in-situ on the microspheres, where the ZSM-5 zeolite microspheres contain substantially no clay or calcined clay material.

Catalyst compositions comprising an inorganic porous material with pore diameters of at least 2 nm and of crystals of molecular sieve, characterized in that the crystals of molecular sieve have an average diameter, measured by scanning electron microscopy, not bigger than 50 nm, and in that the catalyst composition presents a concentration of acid sites ranges from 50 to 1200 mol/g measured by TPD NH3 adsorption; and the XRD pattern of said catalyst composition is the same as the X ray diffraction pattern of said inorganic porous material.

The present invention relates to a process for modifying the physical and chemical properties of Faujasite Y-type zeolites (FAU), mainly used as a base material of catalyst used in the Fluid Catalytic Cracking (FCC) process, for the interest of the oil refining industry, in which the conversion of oil heavy fractions into lighter fractions, with a higher commercial value, is carried out. The process produces a modified Faujasite Y-type zeolite, with lower sodium content, as low as 75%, than that of the starting Faujasite Y-type zeolite. A mesoporous material associated with the modified Faujasite Y-type zeolite has an average pore size ranging from 2 to 100 nm, having a bimodal or multimodal pore size distribution. The proportion of modified Faujasite Y-type zeolite with respect to the meso-porous material associated to the Faujasite Y type Zeolite can be regulated through the process operation conditions.

Disclosed in certain embodiments are ZSM-5 zeolite microspheres. Disclosed in certain embodiments is a method of forming ZSM-5 zeolite microspheres including: 1) shaping a mixture into microspheres where the mixture includes a silica material and of particulates selected from at least one high-density material with an absolute bulk density of at least 0.3 g/cc, ZSM-5 zeolite crystals, and combinations thereof; 2) calcining the microspheres; and 3) reacting and subsequently heating the microspheres with at least one alkali solution to form ZSM-5 zeolite in-situ on the microspheres, where the ZSM-5 zeolite microspheres contain substantially no clay or calcined clay material.

Embodiments of the invention generally provide compositions of crystalline zeolite materials with tailored crystal habits and the methods for forming such crystalline zeolite materials. The methods for forming the crystalline zeolite materials include binding one or more zeolite growth modifiers (ZGMs) to the surface of a zeolite crystal, which results in the modification of crystal growth rates along different crystallographic directions, leading to the formation of zeolites having a tailored crystal habit. The improved properties enabled by the tailored crystal habit include a minimized crystal thickness, a shortened internal diffusion pathlength, and a greater step density as compared to a zeolite having the native crystal habit prepared by traditional processes. The tailored crystal habit provides the crystalline zeolite materials with an aspect ratio of about 4 or greater and crystal surfaces having a step density of about 25 steps/m.sup.2 or greater.

A carrier for selectively synthesizing kerosene fraction from syngas, the carrier including the following components in parts by weight: 5-50 parts of mesoporous zirconia (ZrO.sub.2), 10-55 parts of a silicoaluminophosphate (SAPO) molecular sieve, 5-50 parts of modified mesoporous molecular sieve Al-SBA-16, 1-3 parts of sesbania gum powder, and 10-70 parts of alumina A catalyst includes a soluble cobalt salt and the aforesaid carrier. The soluble cobalt salt is loaded on the surface of the carrier.

A catalyst for the selective catalytic reduction of NOx comprises a zeolitic material which comprises (A) one or more zeolites having a GME framework structure containing YO.sub.2 and X.sub.2O.sub.3, and optionally further comprises one or more zeolites having a CHA framework structure containing YO.sub.2 and X.sub.2O.sub.3, and/or comprises, (B) one or more zeolite intergrowth phases of one or more zeolites having a GME framework structure containing YO.sub.2 and X.sub.2O.sub.3 and one or more zeolites having a CHA framework structure containing YO.sub.2 and X.sub.2O.sub.3, wherein Y is a tetravalent element, and X is a trivalent element, and the zeolitic material contains Cu and/or Fe as non-framework elements in an amount ranging from 0.1 to 15 wt. % calculated as the element and based on 100 wt. % of YO contained in the zeolitic material. Also provided are a process for its preparation, and a use in a method for the selective catalytic reduction of NOx.

A catalyst composition contains an inorganic porous material with pore diameters of at least 2 nm and of crystals of molecular sieve. The crystals of molecular sieve have an average diameter, measured by scanning electron microscopy, not bigger than 50 nm. The catalyst composition has a concentration of acid sites ranges from 50 to 1200 mol/g measured by TPD NH3 adsorption. An XRD pattern of the catalyst composition is the same as an XRD pattern of the inorganic porous material.

To be able to produce an SCR catalyst (2), in particular one having a zeolite fraction (Z) as catalytically active fraction, in a reliable process and at the same time achieve good catalytic activity of the catalyst (2), an inorganic binder fraction (B) which is catalytically inactive in the starting state and has been treated to develop catalytic activity is mixed into a catalyst composition (4). The inorganic binder component for the binder fraction (B) is, in the starting state, preferably porous particles (10), in particular diatomaceous earth, which display mesoporosity. To effect catalytic activation, the individual particles (10) are either coated with a catalytically active layer (12) or transformed into a catalytically active zeolite (14) with maintenance of the mesoporosity.