The present disclosure provides catalyst compositions for NO.sub.x conversion and wall-flow filter substrates comprising such catalyst compositions. Certain catalyst compositions include a zeolite with sufficient Cu exchanged into cation sites thereof to give a Cu/Al ratio of 0.1 to 0.5 and a CuO loading of 1 to 15 wt. %; and a copper trapping component (e.g., alumina) including a plurality of particles having a D.sub.90 particle size of about 0.5 to 20 microns in a concentration of about 1 to 20 wt. %. The zeolite and copper trapping component can be in the same washcoat layer or can be in different washcoat layers (such that the copper trapping component serves as a “pre-coating” on the wall-flow filter substrate).

The disclosure provides methods of preparing small pore zeolites, the method including using a first organic structure-directing agent and a second organic structure-directing agent to crystallize the zeolites, wherein the first organic structure-directing agent is bis-quaternary ammonium cations, and the second organic structure-directing agent is mono-quaternary ammonium cations. Further disclosed are small pore zeolites having a controlled framework aluminum distribution, and selective catalytic reduction catalyst compositions, articles, and systems including such zeolites promoted with a metal.

The present disclosure relates to processes for formation of a molecular sieve, particularly a metal-promoted molecular sieve, and more particularly an Iron(III) exchanged zeolite. Preferably, the zeolite is of the chabazite form or similar structure. The processes can include combining a zeolite with Iron(III) cations in an aqueous medium. The process can be carried out at a pH of less than about 7, and a buffering material can be used with the aqueous medium. The processes beneficially result in Iron exchange that can approach 100% along with removal of cations (such as sodium, NH.sub.4, and H) from the zeolite. An Iron(III)-exchanged zeolite prepared according to the disclosed processes can include about 2,000 ppm or less of cation and about 1% by weight or greater of Iron(III). The disclosure also provides catalysts (e.g., SCR catalysts) and exhaust treatment systems including the Iron(III)-exchanged zeolite.

Certain selective catalytic reduction (SCR) articles, systems and methods provide for high NOx conversion while at the same time low N.sub.2O formation. The articles, systems and methods are suitable for instance for the treatment of exhaust gas of diesel engines. Certain articles have zoned coatings containing copper-containing molecular sieves disposed thereon, where for example a concentration of catalytic copper in an upstream zone is lower than the concentration of catalytic copper in a downstream zone.

The present invention further provides a method of making an metal-loaded aluminosilicate zeolite having a maximum pore opening defined by eight tetrahedral atoms from pre-existing aluminosilicate zeolite crystallites, wherein the metal is present in a range of from 0.5 to 5.0 wt. % based on the total weight of the metal-loaded aluminosilicate zeolite.

The present invention relates to a method for producing automobile exhaust gas catalytic converters, to the catalytic converters as such and to the use thereof. In particular, the method comprises a step which results in a smaller particle size of the catalytically active material used.

The present invention is directed to a method of preparing a synthetic crystalline material, designated as JMZ-12, with a framework built up by the disorder AEI and CHA structures, substantially free of framework phosphorous and prepared preferably in the absence of halides such as fluoride ions. Such method comprises the step of heating a reaction mixture under crystallization conditions for a sufficient period to form a disordered zeolite having both CHA and AEI topologies, wherein the reaction mixture comprises at least one source of aluminum, at least one source of silicon, a source of alkaline or alkaline-earth cations, and a structure directing agent containing at least one source of quaternary ammonium cations and at least one source of alkyl-substituted piperidinium cations in a molar ratio of 0.20 to about 1.4. The resulting zeolites are useful as catalysts, particularly when used in combination with exchanged transition metal(s) and, optionally, rare earth metal(s).

The present invention relates to a method for the preparation of a molecular sieve of the CHA-type as well as catalytic applications thereof.

JMZ-1, a zeolite having a CHA structure and containing trimethyl(cyclohexylmethyl)ammonium cations as a structure directing agent is described. A calcined zeolite, JMZ-1C, that does not contain a structure directing agent, is also described. Metal containing JMZ-1C has improved SCR activity compared to CHA-containing zeolites having the same metal loading and comparable silica:alumina ratios (SAR). Methods of preparing JMZ-1, JMZ-1C and metal containing calcined counterparts of JMZ-1C are described along with methods of using JMZ-1C and metal containing calcined counterparts of JMZ-1C in treating exhaust gases.

A method includes: providing a SCR system comprising a SCR catalyst; heating the SCR system to a temperature greater than 500 degrees Celsius for a predetermined time so as to increase sulfur resistance of the SCR catalyst; and installing the SCR system in an aftertreatment system.