Design, fabrication, and usage of a reactor are presented for synthesis of structured materials from a liquid-phase precursor by heating. The structured materials are particles, membranes or films of micro-porous molecular sieve crystals such as zeolite and meso-porous materials. The precursor solution and structured materials in the reactor are uniformly heated by a planar heater with characteristic heat transfer dimension in the range of 3 mm to 10 cm. A planar heater having width and length at least three times of the characteristic heat transfer dimension provides at least one surface of uniform temperature distribution for heating purposes. Heating is conducted over a temperature range of 20 to 300 C. The planar heater can be heated by electrical power of by thermal fluid.

Molecular sieves comprising intergrowths of cha and aft having an sfw-GME tail, at least one structure directing agent (SDA) within the framework of the molecular sieve, an intergrowth of CHA and GME framework structures, cha cavities, and aft cavities are described. A first SDA comprising either an N,N-dimethyl-3,5-dimethylpiperidinium cation or a N,N-diethyl-2,6-dimethylpiperidinium cation is required. A second SDA, which can further be present, is a CHA or an SFW generating cation. The amount of the second SDA-2 used can change the proportion of the components in the cha-aft-sfw-GME tail. Activated molecular sieves formed from SDA containing molecular sieves are also described. Compositions for preparing these molecular sieves are described. Methods of preparing a SDA containing JMZ-11, an activated JMZ-11, and metal containing activated JMZ-11 are described. Methods of using activated JMZ-11 and metal containing activated JMZ-11 in a variety of processes, such as treating exhaust gases and converting methanol to olefins are described.

The present disclosure describes, inter alia, binary catalyst compositions including a (metal) zeolite having a crystal lattice that incorporates a metal oxide, wherein the metal oxide is covalently bound to elements within the crystal lattice. The metal oxide forms an integral part of the (metal) zeolite crystal lattice, forming covalent bonds with at least the Si or Al atoms within the crystal lattice of the (metal) zeolite, and is dispersed throughout the (metal) zeolite crystal lattice. The metal oxide can substitute atoms within the crystal lattice of the (metal) zeolite.

The present disclosure features a high metal cation content zeolite-based binary catalyst (e.g., a high copper and/or iron content zeolite-based binary catalyst, where the zeolite can be a chabazite) for NO.sub.x reduction, having relatively low N.sub.2O make, and having low corresponding metal oxide content; where the metal in the metal oxide corresponds to the metal of the metal cation. The present disclosure also describes the synthesis of the zeolite-based binary catalyst having high metal cation content.

JMZ-1S, a silicoaluminophosphate molecular sieve having a CHA structure and containing a trimethyl(cyclohexylmethyl)ammonium cation cation is described. A calcined product, JMZ-1SC, formed from JMZ-1S is also described. Methods of preparing JMZ-1S, JMZ-1SC and metal containing calcined counterparts of JMZ-1SC are described along with methods of using JMZ-1SC and metal containing calcined counterparts of JMZ-1SC in treating exhaust gases and in converting methanol to olefines.

A composition of matter is provided comprising hierarchically ordered crystalline microporous material having well-defined long-range mesoporous ordering of lamellar symmetry. The composition possesses mesopores having walls of crystalline microporous material and a mass of mesostructure between mesopores of crystalline microporous material. Long-range ordering is defined by presence of secondary peaks in an X-ray diffraction (XRD) pattern and/or lamellar symmetry observable by microscopy.

A process for the calcination of a zeolitic material, wherein the process contains the steps of (i) providing a zeolitic material containing YO.sub.2 and optionally further containing X.sub.2O.sub.3 in its framework structure in the form of a powder and/or of a suspension of the zeolitic material in a liquid, wherein Y stands for a tetravalent element and X stands for a trivalent element; (ii) atomization of the powder and/or of the suspension of the zeolitic material provided in (i) in a gas stream for obtaining an aerosol; and (iii) calcination of the aerosol obtained in (ii) for obtaining a calcined powder, a zeolitic material obtained by the above process, and its use as a molecular sieve, as an adsorbent for ion-exchange, as a catalyst, and/or as a catalyst support.

The invention provides methods and compositions for precursors and for the synthesis of zeolites. The invention makes use of intimately homogeneous precursors which avoid the formation of a difficult to work with gel stage in zeolite formation. This allows for the synthesis of zeolite in a much shorter period of time and with much lower amounts of structure directing agents.

The invention provides methods and compositions for precursors and for the synthesis of zeolites. The invention makes use of intimately homogeneous precursors which avoid the formation of a difficult to work with gel stage in zeolite formation. This allows for the synthesis of zeolite in a much shorter period of time and with much lower amounts of structure directing agents.

A zeolite synthesis sol includes particles of an aluminum source with a mean particle diameter of 5 to 500 nm, and a solvent in which the particles are dispersed, the solvent being water that contains a phosphorus source, a structure-directing agent, and a carboxylic acid.