Stable small-pore zeolites
11261097 · 2022-03-01
Assignee
Inventors
- Andreas Jan Hoffmann (Mechelen, BE)
- Michiel De Prins (Heverlee, BE)
- Sam Smet (Kessel-Lo, BE)
- Sreeprasanth Pulinthanathu Sree (Oud-Heverlee, BE)
- Elke Jane June Verheyen (Heverlee, BE)
- Johan Adriaan Martens (St-Joris-Weert, BE)
- Leen Van Tendeloo (Lier, BE)
- Frank-Walter Schuetze (Aschaffenburg, DE)
Cpc classification
B01J29/743
PERFORMING OPERATIONS; TRANSPORTING
B01D53/9418
PERFORMING OPERATIONS; TRANSPORTING
F01N2370/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2570/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C01B39/02
CHEMISTRY; METALLURGY
F01N3/2825
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2330/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/2066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01J29/763
PERFORMING OPERATIONS; TRANSPORTING
International classification
F01N3/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C01B39/02
CHEMISTRY; METALLURGY
Abstract
The present invention provides crystalline aluminosilicate zeolites having a maximum pore size of eight tetrahedral atoms, wherein the zeolite has a total proton content of less than 2 mmol per gram. The zeolite may comprise 0.1 to 10 wt.-% of at least one transition metal, calculated as the respective oxide and based on the total weight of the zeolite. It may furthermore comprise at least one alkali or alkaline earth metal in a concentration of 0 to 2 wt.-%, calculated as the respective metal and based on the total weight of the zeolite. The zeolites may be used for the removal of NOx from automotive combustion exhaust gases.
Claims
1. A crystalline aluminosilicate zeolite having a maximum pore size of eight tetrahedral atoms, wherein the zeolite has a total proton content of less than 2 mmol per gram, and wherein the zeolite framework type material is chosen from AEI, CHA, LEV, ETL, ESV, and DDR.
2. The crystalline aluminosilicate zeolite according to claim 1, wherein the SAR is between 5 and 50.
3. The crystalline aluminosilicate zeolite according to claim 1, wherein the zeolite comprises at least one transition metal in a concentration of 0.1 to 10 wt.-%, calculated as the respective oxides and based on the total weight of the zeolite.
4. The crystalline aluminosilicate zeolite according to claim 3, wherein the at least one transition metal is chosen from copper, iron, and mixtures thereof.
5. The crystalline aluminosilicate zeolite according to claim 3, wherein the at least one transition metal is introduced into the zeolite during the synthesis of said zeolite by an organic structure-directing agent comprising said at least one transition metal.
6. The crystalline aluminosilicate zeolite according to claim 1, wherein the zeolite comprises at least one alkali and/or alkaline earth metal in a concentration of 0 to 2 wt.-%, calculated as the respective metals and based on the total weight of the zeolite.
7. The crystalline aluminosilicate zeolite according to claim 6, wherein the at least one alkali or alkaline earth metal is selected from sodium, potassium, and mixtures thereof.
8. The crystalline aluminosilicate zeolite according to claim 1, wherein the transition metal to aluminium atomic ratio is in the range of between 0.003 to 0.5.
9. The crystalline aluminosilicate zeolite according to claim 1, wherein the mean crystal size is between 0.3 to 7 μm.
10. The crystalline aluminosilicate zeolite according to claim 1, wherein the zeolite is present in the form of a washcoat on a carrier substrate.
11. A process for the removal of NOx from automotive combustion exhaust gases wherein a zeolite according to claim 1 is used as the SCR catalytically active material for the conversion of NOx.
12. A catalysed substrate monolith comprising an SCR catalytically active material for the conversion of NOx for use in treating automotive combustion exhaust gases, wherein said SCR catalytically active material for the conversion of NOx is a zeolite according to claim 1.
13. A catalysed substrate monolith according to claim 12, wherein the zeolite is present in the form of a washcoat on a carrier substrate.
14. The catalysed substrate monolith according to claim 13, wherein the carrier substrate is a flow-through substrate or a wall-flow filter.
15. A catalysed substrate monolith according to claim 12, wherein the catalysed substrate monolith is an extruded catalysed substrate monolith.
16. An exhaust gas purification system comprising a particulate filter coated with an SCR catalyst, wherein the SCR catalytically active material is a crystalline aluminosilicate zeolite according to claim 1.
17. An exhaust gas purification system comprising a PNA catalyst, wherein the PNA catalytically active material comprises a crystalline aluminosilicate zeolite according to claim 1 and at least one platinum group metal selected from ruthenium, rhodium, palladium, osmium, iridium, platinum, and mixtures thereof.
18. An exhaust gas purification system according to claim 17, wherein the platinum group metal is palladium, and the palladium is present in a concentration of 0.5 to 5 wt.-%, calculated as Pd and based on the total weight of the zeolite.
19. An exhaust gas purification system comprising an ASC catalyst, wherein the ASC catalytically active material comprises a crystalline aluminosilicate zeolite according to claim 1 and at least one platinum group metal selected from ruthenium, rhodium, palladium, osmium, iridium, platinum, and mixtures thereof.
20. An exhaust gas purification system according to claim 19, wherein the platinum group metal is platinum, and the platinum is added in the form of a precursor salt to a washcoat slurry and applied to the carrier monolith, and the platinum is present in a concentration of 0.1 to 1 wt.-%, calculated as Pt and based on the total weight of the washcoat loading.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The
(2) HV=high vacuum
(3) CBS=concentric backscatter detector
(4) WD=working distance
(5) mag=magnification
(6) HFW=horizontal field width
(7) In all embodiments, a CBS was used as the detector.
(8)
(9) SEM image of embodiment 1: AEI zeolite (GV 116)
(10) Maximum hydrothermal stability: 800° C.
(11) HV: 1.00 kV
(12) WD: 4.6 mm
(13) Mag: 159 960×
(14) HFW: 1.87 μm
(15)
(16) SEM image of embodiment 2: AEI zeolite (MD155)
(17) Maximum hydrothermal stability: 850° C.
(18) HV: 2.00 kV
(19) WD: 4.5 mm
(20) Mag: 12 000×
(21) HFW: 24.9 μm
(22)
(23) SEM image of embodiment 3: AEI zeolite (GV191)
(24) Maximum hydrothermal stability: 900° C.
(25) HV: 2.00 kV
(26) WD: 4.6 mm
(27) Mag: 50 000×
(28)
(29) SEM image of embodiment 4: AEI zeolite (GV198)
(30) Maximum hydrothermal stability: 900° C.
(31) HV: 2.00 kV
(32) WD: 4.2 mm
(33) Mag: 24 000×
(34)
(35) SEM image of embodiment 5: AEI zeolite (GV228)
(36) Maximum hydrothermal stability: 900° C.
(37) HV: 2.00 kV
(38) WD: 4.9 mm
(39) Mag: 100 000×
(40) HFW: 2.98 μm
(41)
(42) SEM image of embodiment 6: CHA zeolite (ZS5-GH008)
(43) Maximum hydrothermal stability: 800° C.
(44) HV: 2.00 kV
(45) WD: 4.4 mm
(46) Mag: 50 000×
(47) HFW: 5.97 μm
(48)
(49) SEM image of embodiment 7: CHA zeolite (ZS5-GH0087) Maximum hydrothermal stability: 850° C.
(50) HV: 2.00 kV
(51) WD: 4.2 mm
(52) Mag: 60 000×
(53) HFW: 4.97 μm
(54)
(55) SEM image of embodiment 8: CHA zeolite (GV251)
(56) Maximum hydrothermal stability: 900° C.
(57) HV: 2.00 kV
(58) WD: 4.6 mm
(59) Mag: 40 000×
(60)
(61) SEM image of embodiment 9: LEV zeolite (MD101)
(62) Maximum hydrothermal stability: 700° C.
(63) HV: 1.00 kV
(64) WD: 5.2 mm
(65) Mag: 60 000×
(66) HFW: 4.97 μm
(67)
(68) SEM image of embodiment 10: LEV zeolite (GV118)
(69) Maximum hydrothermal stability: 750° C.
(70) HV: 1.00 kV
(71) WD: 5.6 mm
(72) Mag: 80 102×
(73) HFW: 3.73 μm
(74)
(75) SEM image of embodiment 11: LEV zeolite (GV175)
(76) Maximum hydrothermal stability: 900° C.
(77) HV: 1.00 kV
(78) WD: 4.6 mm
(79) Mag: 5 000×
(80) HFW: 59.7 μm
(81)
(82) SEM image of embodiment 12: ERI/CHA zeolite (ZS5-GH0023) Maximum hydrothermal stability: 800° C.
(83) HV: 2.00 kV
(84) WD: 4.2 mm
(85) Mag: 50 000×
(86) HFW: 5.97 μm
(87)
(88) SEM image of embodiment 13: ETL zeolite (SK120) Maximum hydrothermal stability: 850° C.
(89) HV: 1.00 kV
(90) WD: 4.7 mm
(91) Mag: 79 996×
(92)
(93) SEM image of embodiment 16: KFI zeolite (GV009) Maximum hydrothermal stability: 800° C.
(94) HV: 1.00 kV
(95) WD: 5.4 mm
(96) Mag: 28 775×
(97) HFW: 10.4 μm
(98)
(99) SEM image of embodiment 17: UFI zeolite (GV051)
(100) Maximum hydrothermal stability: 800° C.
(101) HV: 2.00 kV
(102) WD: 3.9 mm
(103) Mag: 100 000×
(104) HFW: 2.98 μm
(105)
(106) SEM image of embodiment 18: AFX zeolite (SPSS076)
(107) Maximum hydrothermal stability: 800° C.
(108) HV: 2.00 kV
(109) WD: 5.2 mm
(110) Mag: 100 000×
(111) HFW: 2.98 μm
(112)
(113) Hydrothermal stability versus the proton content for embodiments 1 to 18.
(114)
(115) Silanol protons (Si—OH) and hydrothermal stability of the Embodiments 1 to 18.
(116)
(117) Aluminol protons (Al—OH) and hydrothermal stability of the Embodiments 1 to 18.
(118)
(119) Bronsted acid sites (BAS) and hydrothermal stability of the Embodiments 1 to 18.
EMBODIMENTS
Embodiment 1: Synthesis of AEI Zeolite (GV116)
(120) A synthesis gel with composition 37.1 SiO.sub.2: 1 Al.sub.2O.sub.3: 5.6 SDA:32.2 NaOH:1115 H.sub.2O was prepared by mixing 19.48 g of N,N-dimethyl, 3,5-dimethylpiperidinium hydroxide (18 wt % in H.sub.2O) with 2.21 g NaOH pellets, 44.38 g deionized H.sub.2O, 27.51 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2) and 2.19 g CBV-500 (Zeolyst) upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 135° C. for 7 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an AEI framework type with a SAR of 12.3.
(121) The SEM image of embodiment 1 is shown in
Embodiment 2: Synthesis of AEI Zeolite (MD155))
(122) A synthesis gel with composition 79.4 SiO.sub.2: 1 Al.sub.2O.sub.3: 13.8 SDA:44 NaOH:2216 H.sub.2O was prepared by mixing 24.1 g of N,N-dimethyl, 3,5-dimethylpiperidinium hydroxide (18 wt % in H.sub.2O) with 0.128 g NaOH pellets, 37.8 g deionized H.sub.2O, 32.5 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2) and 1.11 g CBV-500 (Zeolyst) upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 135° C. for 7 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an AEI framework type with a SAR of 15.6.
(123) The SEM image of embodiment 2 is shown in
Embodiment 3: Synthesis of AEI Zeolite (GV191)
(124) A synthesis gel with composition 79.4 SiO.sub.2:1 Al.sub.2O.sub.3:13.8 SDA:44.1 NaOH:3835 H.sub.2O was prepared by mixing 13.02 g of N,N-dimethyl,3,5-dimethylpiperidinium hydroxide (20.46 wt % in H.sub.2O) with 0.079 g NaOH pellets, 60.49 g deionized H.sub.2O, 20 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2) and 0.684 g CBV-500 (Zeolyst) upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 135° C. for 7 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an AEI framework type with a SAR of 17.
(125) The SEM image of embodiment 3 is shown in
Embodiment 4: Synthesis of AEI Zeolite (GV198)
(126) A synthesis gel with composition 79.4 SiO.sub.2:1 Al.sub.2O.sub.3:13.8 SDA:44.1 NaOH:148 glycerol:3835 H.sub.2O was prepared by mixing 13.02 g of N,N-dimethyl,3,5-dimethylpiperidinium hydroxide (20.46 wt % in H.sub.2O) with 0.079 g NaOH pellets, 60.49 g deionized H.sub.2O, 20 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2), 0.684 g CBV-500 (Zeolyst) and 16.5 g glycerol (Sigma-Aldrich) upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 135° C. for 7 days under static conditions.
(127) The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an AEI framework type with a SAR of 18.7.
(128) The SEM image of embodiment 4 is shown in
Embodiment 5: Synthesis of AEI Zeolite (GV228)
(129) A synthesis gel with composition 79.3 SiO.sub.2:1 Al.sub.2O.sub.3:13.8 SDA:44.0 NaOH:2450 H.sub.2O was prepared by mixing 20.33 g of N,N-dimethyl,3,5-dimethylpiperidinium hydroxide (20.46 wt % in H.sub.2O) with 0.12 g NaOH pellets, 47.24 g deionized H.sub.2O, 31.24 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2) and 1.07 g CBV-500 (Zeolyst). The gel was stirred at room temperature for 20 minutes, and then heated at 135° C. for 7 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an AEI framework type with a SAR of 11.6.
(130) The SEM image of embodiment 5 is shown in
Embodiment 6: Synthesis of CHA Zeolite (ZS5-GH0088)
(131) The Cu-tetraethylenepentamine complex (Cu-TEPA) was synthesized by adding 37.9 g tetraethylenepentamine (0.2 mole, Sigma-Aldrich) to a solution consisting of 50 g CuSO.sub.4.5H.sub.2O (0.2 mole, Sigma-Aldrich) in 200 g of H.sub.2O (1 M solution) upon stirring. This solution continued stirring for 2 h at room temperature as described in WO 20170/80722 A1).
(132) 62 g of zeolite Y with SAR=30 (Si/Al=15) (CBV-720, Zeolyst International) was suspended in 335 mL of a 2.0 M solution of sodium hydroxide. To this solution 31 mL of a 1 M Cu-TEPA solution was added. This suspension was stirred for 15 min and then kept static at 95° C. for 48 h in a closed PP bottle and is referred to as aluminosilicate solution 1.
(133) Aluminosilicate solution 2 was prepared as follows. 5.79 g aluminum-tri-sec-butoxide (Fluka) was added upon stirring to 256.87 g tetraethylammonium hydroxide (35 wt. %, Sigma-Aldrich) in a PP bottle. This mixture was stirred mechanically for 10 minutes. To this solution, 112.81 g Ludox AS-40 (Sigma-Aldrich) was added drop wise upon stirring. 5.19 g of potassium chloride (LabChem) was added slowly. This solution remained stirring for 24 h in the closed PP bottle at room temperature and forms a liquid gel. This gel was aged for another 48 h at room temperature without stirring. After the aging step, aluminosilicate solution 2 was added at once to aluminosilicate solution 1. The final gel has the following molar ratios: 1 SiO.sub.2/0.025 Al.sub.2O.sub.3/0.39 NaOH/0.041 KCl/0.02 CuTEPA/0.36 tetraethylammonium hydroxide (TEAOH)/20.75 H.sub.2O. The resulting mixture was homogenized by vigorous stirring for 15 minutes and afterwards transferred to a stainless steel autoclave. This mixture was heated for 4 days at 150° C. under dynamic conditions. The solid product was recovered by filtration and washing, and was dried at 60° C. for 16 h. The zeolite was calcined at 550° C. for 8 hours with a temperature ramp of 1° C./min.
(134) The SEM image of embodiment 6 is shown in
Embodiment 7: Synthesis of CHA Zeolite (ZS5-GH0087)
(135) The Cu-tetraethylenepentamine complex (Cu-TEPA) was synthesized by adding 37.9 g tetraethylenepentamine (0.2 mole, Sigma-Aldrich) to a solution consisting of 50 g CuSO.sub.4.5H.sub.2O (0.2 mole, Sigma-Aldrich) in 200 g of H.sub.2O (1 M solution) upon stirring. This solution continued stirring for 2 h at room temperature as described in WO 2017/080722 A1). 61.99 g of zeolite Y with SAR=30 (Si/Al=15) (CBV-720, Zeolyst International) was suspended in 335 mL of a 2.0 M solution of sodium hydroxide. To this solution 31 mL of a 1 M Cu-TEPA solution was added. This suspension was stirred for 15 min and then kept static at 95° C. for 48 h in a closed PP bottle and is referred to as aluminosilicate solution 1.
(136) Aluminosilicate solution 2 was prepared as follows. 5.80 g aluminum-tri-sec-butoxide (Fluka) was added upon stirring to 256.92 g tetraethylammonium hydroxide (35 wt. %, Sigma-Aldrich) in a PP bottle. This mixture was stirred mechanically for 10 minutes. To this solution, 112.84 g Ludox AS-40 (Sigma-Aldrich) was added drop wise upon stirring. This solution remained stirring for 24 h in the closed PP bottle at room temperature and forms a liquid gel. This gel was aged for another 48 h at room temperature without stirring. After the aging step, aluminosilicate solution 2 was added at once to aluminosilicate solution 1. The final gel has the following molar ratios: 1 SiO.sub.2/0.025 Al.sub.2O.sub.3/0.39 NaOH/0.02 Cu-TEPA/0.36 TEAOH/20.75 H.sub.2O. The resulting mixture was homogenized by vigorous stirring for 15 minutes and afterwards transferred to a stainless steel autoclave. This mixture was heated for 4 days at 150° C. under dynamic conditions. The solid product was recovered by filtration and washing, and was dried at 60° C. for 16 h. The zeolite was calcined at 550° C. for 8 hours with a temperature ramp of 1° C./min. The SEM image of embodiment 7 is shown in
Embodiment 8: Synthesis of CHA Zeolite (GV251)
(137) The Cu-tetraethylenepentamine complex (Cu-TEPA) was synthesized by adding 37.9 g tetraethylenepentamine (0.2 mole, Sigma-Aldrich) to a solution consisting of 50 g CuSO.sub.4.5H.sub.2O (0.2 mole, Sigma-Aldrich) in 200 g of H.sub.2O (1 M solution) upon stirring. This solution continued stirring for 2 h at room temperature as described in WO 2017/080722 A1).
(138) 22.74 g tetraethylammonium hydroxide (35 wt. %, Sigma-Aldrich) was added to a glass beaker. To this solution, 8.51 g Ludox AS-40 (Sigma-Aldrich) was added drop wise upon stirring. Afterwards 3.03 g hexamethonium bromide (Acros), 29.4 g of a 0.21 M potassium chloride solution (LabChem), 30 g of a 1.13 M sodium hydroxide solution (Fisher Scientific), 1.79 g CBV-500 (Zeolyst) and 2.75 g of a 1 M Cu-TEPA solution was added slowly upon stirring. The final gel has the following molar ratios: SiO.sub.2/0.043 Al.sub.2O.sub.3/0.46 NaOH/0.08 KCl/0.04 Cu-TEPA/0.73 TEAOH/0.11 RBr/62 H.sub.2O where R is the hexamethonium organic template. The resulting mixture was homogenized by vigorous stirring for 10 minutes and afterwards heated for 168 h at 160° C. under dynamic conditions. The solid product was recovered by centrifugation and washing with deionized H.sub.2O, and was dried at 60° C. for 16 h. The zeolite produced has an CHA framework type with a SAR of 17.2.
(139) The SEM image of embodiment 8 is shown in
Embodiment 9: Synthesis of LEV Zeolite (MD101)
(140) A synthesis gel with composition 30.9 SiO.sub.2: 1 Al.sub.2O.sub.3: 17.5 SDA:7.0 NaOH:186 H.sub.2O was prepared by mixing 2.13 g deionized H.sub.2O with 1.31 g NaCl (Fisher Scientific), 14.71 g choline hydroxide (46 wt % in H.sub.2O) and 6.9 g CBV-720 (Zeolyst) upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 125° C. for 7 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an LEV framework type with a SAR of 16.8.
(141) The SEM image of embodiment 9 is shown in
Embodiment 10: Synthesis of LEV Zeolite (GV118)
(142) A synthesis gel with composition 20.3 SiO.sub.2: 1 Al.sub.2O.sub.3: 10.1 SDA:1 NaOH:101 H.sub.2O was prepared by mixing 14.9 g diethyldimethylammonium hydroxide (Aldrich, 40 wt % in H.sub.2O) with 0.2 g NaOH pellets, 0.77 g aluminum hydroxide (BDH) and 6 g silica (Cab-O-Sil M5) upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 150° C. for 3 days under dynamic conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an LEV framework type with a SAR of 18.7.
(143) The SEM image of embodiment 10 is shown in
Embodiment 11: Synthesis of LEV Zeolite (GV175)
(144) A synthesis gel with composition 27.5 SiO.sub.2:1 Al.sub.2O.sub.3:8.8 SDA:3.4 NaOH:1090 H.sub.2O was prepared by mixing 25.32 g Ludox SM-30 (Aldrich) with 6.31 g 1-adamantylamine (97 wt %, Aldrich), 68.48 g deionized H.sub.2O, 0.87 g sodiumaluminate (Riedel-de Haen, 41% Na.sub.2O, 54% Al.sub.2O.sub.3) and 0.16 g NaOH in 3.94 g deionized H.sub.2O upon stirring. The gel was stirred at room temperature for 30 minutes, and then heated at 180° C. for 6 days under dynamic conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an LEV framework type with a SAR of 23.6.
(145) The SEM image of embodiment 11 is shown in
Embodiment 12: Synthesis of ERI/CHA Zeolite (ZS5-GH0023)
(146) The Cu-tetraethylenepentamine complex (Cu-TEPA) was synthesized by adding 37.9 g tetraethylenepentamine (0.2 mole, Sigma-Aldrich) to a solution consisting of 50 g CuSO.sub.4.5H.sub.2O (0.2 mole, Sigma-Aldrich) in 200 g of H.sub.2O (1 M solution) upon stirring. This solution continued stirring for 2 h at room temperature as described in WO 2017/080722 A1).
(147) 310 g of zeolite Y with SAR=30 (Si/Al=15) (CBV-720, Zeolyst International) was suspended in 1674 mL of a 2.0 M solution of sodium hydroxide. To this solution 155 mL of a 1 M Cu-TEPA solution was added. This suspension was stirred for 15 min and then kept static at 95° C. for 48 h in a closed PP bottle and is referred to as aluminosilicate solution 1. Aluminosilicate solution 2 was prepared as follows. 29.09 g aluminum-tri-sec-butoxide (Fluka) was added upon stirring to 1284.4 g tetraethylammonium hydroxide (35 wt. %, Sigma-Aldrich) in PP bottle. This mixture was stirred mechanically for 10 minutes. To this solution, 564.20 g Ludox AS-40 (Sigma-Aldrich) was added drop wise upon stirring and afterwards 170.60 g hexamethonium bromide (Acros) was added at once. Another 25.83 g of potassium chloride (LabChem) This solution remained stirring for 24 h in the closed PP bottle at room temperature and forms a liquid gel. This gel was aged for another 48 h at room temperature without stirring.
(148) After the aging step, aluminosilicate solution 2 was added at once to aluminosilicate solution 1. The final gel has the following molar ratios: 1 SiO.sub.2/0.025 Al.sub.2O.sub.3/0.39 NaOH/0.041 KCl/0.02 Cu-TEPA/0.36 TEAOH/0.18 RBr/20.75 H.sub.2O where R is the hexamethonium organic template. The resulting mixture was homogenized by vigorous stirring for 15 minutes and afterwards transferred to a stainless steel autoclave. This mixture was heated for 4 days at 150° C. under dynamic conditions. The solid product was recovered by filtration and washing, and was dried at 60° C. for 16 h. The zeolite was calcined at 750° C. for 8 hours with a temperature ramp of 1° C./min.
(149) The SEM image of embodiment 12 is shown in
Embodiment 13: Synthesis of ETL Zeolite (SK120)
(150) A synthesis gel with composition 30 SiO.sub.2:1 Al.sub.2O.sub.3: 5.1 SDA:11.7 RbOH:1394 H.sub.2O was prepared by mixing 0.52 g aluminum hydroxide (BDH) with 8 mL of RbOH solution (50 wt % in H.sub.2O), 6 g silica (Cab-O-Sil M5), 75 g deionized H.sub.2O and 6.2 g tetramethylammonium hydroxide (TMAOH) (25 wt % in H.sub.2O) upon stirring. The gel was stirred at room temperature for 30 minutes, and then heated at 180° C. for 5 days under dynamic conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an ETL framework type with a SAR of 15.6.
(151) The SEM image of embodiment 13 is shown in
Embodiment 14: Synthesis of ESV Zeolite (SKES009)
(152) A synthesis gel with composition 25 SiO.sub.2:1 Al.sub.2O.sub.3: 6.2 SDA:20.6 NaOH:999 H.sub.2O was prepared by mixing 5.81 g SDA (N,N-dimethylpiperidiniumbromide) with 1.20 g NaOH pellets, 26.62 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2), 3.19 g aluminumsulfate (Vel, Al.sub.2(SO.sub.4).sub.3.18H.sub.2O) and 68.89 g deionized H.sub.2O upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 170° C. for 6 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an ESV framework type with a SAR of 17.3.
Embodiment 15: Synthesis of DDR Zeolite (GV176)
(153) A synthesis gel with composition 30.5 SiO.sub.2:1 Al.sub.2O.sub.3: 12.9 SDA:3.8 NaOH:1528 H.sub.2O was prepared by mixing 20.37 g Ludox SM-30 (Aldrich) with 6.71 g 1-adamantylamine (97 wt %, Aldrich), 73.07 g deionized H.sub.2O, 0.63 g sodiumaluminate (Riedel-de Haen, 41% Na.sub.2O, 54% Al.sub.2O.sub.3) and 0.17 g NaOH in 4.23 g deionized H.sub.2O upon stirring. The gel was stirred at room temperature for 30 minutes, and then heated at 180° C. for 6 days under dynamic conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an DDR framework type with a SAR of 29.1.
Embodiment 16: Synthesis of KFI Zeolite (GV009)
(154) A synthesis gel with composition 11 SiO.sub.2:1 Al.sub.2O.sub.3:5.2 K:0.1 Sr:152 H.sub.2O was prepared by mixing 3.96 g aluminum hydroxide (BDH), 7.46 g of KOH (VWR), 12.54 g deionized H.sub.2O, 41.98 g Ludox HS-40 (Aldrich) and 0.52 g Sr(NO.sub.3).sub.2 (Acros) dissolved in 31.92 g deionized H.sub.2O upon stirring. The gel was stirred at room temperature for 20 minutes, and then heated at 150° C. for 7 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h.
(155) The zeolite produced has a KFI framework type with a SAR of 8.2.
(156) The SEM image of embodiment 16 is shown in
Embodiment 17: Synthesis of UFI Zeolite (GV051)
(157) A synthesis gel with composition 16.2 SiO.sub.2:1 Al.sub.2O.sub.3:16.4 triethanolamine (TEA): 2.2 trimethylaluminium (TMA): 361 H.sub.2O was made by first preparing a mixture of 17.43 g TEAOH (35 wt % in H.sub.2O, Aldrich), 1.25 g aluminum-sec-butoxide (Fluka), 6.16 g Ludox As-40 (Aldrich) and 0.21 g deionized H.sub.2O which is heated at 95° C. for 18 h under static conditions. Afterwards, 0.6 g TMACI in 1.16 g deionized H.sub.2O is added to the first mixture upon stirring. The gel was stirred at room temperature for 30 minutes, and then heated at 150° C. for 4 days under static conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an UFI framework type with a SAR of 17.4.
(158) The SEM image of embodiment 17 is shown in
Embodiment 18: Synthesis of AFX Zeolite (SPSS076)
(159) A synthesis gel with composition 30.8 SiO.sub.2:1 Al.sub.2O.sub.3: 2.9 SDA:23.4 Na:939 H.sub.2O was prepared by mixing 48.86 g deionized H.sub.2O, 1.32 g NaOH pellets, 20.95 g sodiumsilicate (Merck, 7.5-8.5 wt % Na.sub.2O, 25.5-28.5 wt % SiO.sub.2), 2.09 g CBV-500 (Zeolyst) and 5.05 g 1,4-diazabicyclo[2.2.2]-octane-C4-diquat dibromide upon stirring. The gel was stirred at room temperature for 40 minutes, and then heated at 150° C. for 5 days under dynamic conditions. The solid product was recovered by filtration and washing with deionized water, and was dried at 60° C. for 16 h. The zeolite produced has an AFX framework type with a SAR of 8.9.
(160) The SEM image of embodiment 18 is shown in
Embodiment 19: Determination of Proton Content
(161) The as made zeolite was calcined in air at 550° C. for 8 hours with a heating rate of 1° C./min. Afterwards the calcined zeolite was suspended in a 0.5 M NH.sub.4Cl solution (100 ml per g of sample) and kept under reflux conditions for 4 hours. This procedure is repeated twice and followed by a drying step at 60° C. in air for 16 h. Subsequently, the zeolite is calcined in air at 650° C. for 8 hours with a heating rate of 1° C./min. Finally, the samples were packed in a 4 mm zirconia solid state NMR rotor and dried under vacuum (1 mbar) at 90° C. for 30 min and at 200° C. for 16 h. After flushing with N.sub.2 gas, the rotor was sealed.
(162) .sup.1H MAS NMR experiments were performed at 295 K on a Bruker Ultrashield Plus 500 MHz spectrometer (static magnetic field of 11.7 T) equipped with a 4 mm H/X/Y magic angle spinning (MAS) solid-state probe. Samples were spun at 10 kHz. .sup.1H spectra were recorded using a π/2 flip angle with a pulse length of 2.95 μs and a repetition delay of 5 s. Adamantane was used as an external secondary reference for the chemical shift referencing to TMS. The .sup.1H spectra were integrated between 20 and −8 ppm (between 2 and −8 ppm) using Bruker Topspin 3.5 software. Absolute quantification of the integrated areas was performed as described in M Houlleberghs, A Hoffmann, D Dom, C E A Kirschhock, F Taulelle, J A Martens and E Breynaert: “Absolute Quantification of Water in Microporous Solids with .sup.1H Magic Angel Spinning NMR and Standard Addition”, Anal Chem 2017, 89, 6940-6943”.
Embodiment 20: Determination of Hydrothermal Stability
(163) The as made zeolite was calcined in air at 550° C. for 8 hours with a heating rate of 1° C./min. A 0.5 M NH.sub.4Cl solution is made by dissolving 13.4 g NH.sub.4Cl (MP Biomedicals LLC) in 500 mL deionized H.sub.2O. The calcined zeolite is suspended in the 0.5 M NH.sub.4Cl solution (1 g zeolite in 100 mL) and heated under reflux conditions for 4 hours upon stirring, followed by centrifugation. The combination of ion-exchange and centrifugation was performed three times. The solid product was recovered by centrifugation after washing with deionized water and was dried at 60° C. for 24 hours. A solution of 300 mL deionized water and 0.28 g copper acetate (Sigma-Aldrich) was prepared in a PP bottle.
(164) 3 grams of the zeolite is added to this solution. The suspension is stirred at room temperature in a closed PP bottle for 20 hours. Afterwards, the zeolite in its copper exchanged form is recovered by centrifugation. This procedure is repeated twice. The final material is then washed with deionized water by centrifugation and dried at 60° C. for 48 hours. The hydrothermal stability was determined by heating Cu loaded zeolite catalyst pellets to 900° C. in a quartz tube under air flow (2 mL/min) with an absolute humidity of 12 vol. % for 3 h with a heating rate of 5° C./min. Cooling was performed under a 40 mL/min dry nitrogen flow. Prior to this experiment, the powder was pelletized to a particle size between 125 and 250 μm to avoid pressure build-up in the quartz tube.
(165) Proton Content—Decomposition
(166) When decomposing the spectrum, the baseline is corrected through a cubic spline interpolation method incorporated in the Topspin 3.5 software. The decomposition is performed using the DmFit Software (Version Amfit/release #20180327′) using Lorentzian curves. The signals fitted between 1 and 2 ppm are defined as silanol species, the signals between 2 and 3.5 ppm are defined as aluminol species or other defect-related sites and the signals between 3.5 and 5 ppm are defined as Brønsted acid sites.
(167) Absolute quantification of the Si—OH region was ensured with the combination of .sup.1H MAS NMR detection with standard addition of water. The dried spectrum was used to derive the total spectrum surface area and the Si—OH region surface area. The dried sample within the rotor was then hydrated with known amounts of water by adding a known mass of water to the packed rotor and afterwards equilibrating the capped rotor overnight at 333 K to ensure homogeneous distribution of water throughout the sample. A sample-dependent linear correlation function (y=Ax+B) was obtained showing the integrated .sup.1H NMR signals of the (de)hydrated zeolite samples (y) plotted against water addition (x). The absolute Si—OH content can be derived using the slope A and the Si—OH surface area, corrected for sample weight and number of scans. Probe tuning and matching was carried out using a vectorial Network Analyzer to ensure comparable Q factors between the (de)hydrated states as to maximize accuracy and reproducibility when acquiring the linear correlation function for each sample (M Houlleberghs, A Hoffmann, D Dom, C E A Kirschhock, F Taulelle, J A Martens and E Breynaert: “Absolute Quantification of Water in Microporous Solids with .sup.1H Magic Angel Spinning NMR and Standard Addition”, Anal Chem 2017, 89, 6940-6943″).
(168) TABLE-US-00003 TABLE 2 Hydrothermal stability of the Cu loaded zeolites from Embodiment 1 to 18 Embodi- Maximum ment Framework Proton content Cu content hydrother- number type code (mmol/g) (Wt. %) mal stability (° C.) 1 AEI 2.4 3.8 800 2 AEI 2.3 3.2 850 3 AEI 1.6 2.9 900 4 AEI 1.5 3.1 900 5 AEI 1.3 2.9 900 6 CHA 2.3 4.1 800 7 CHA 2.0 3.9 850 8 CHA 1.8 2.8 900 9 LEV 3.3 4.1 700 10 LEV 3.1 4.1 750 11 LEV 1.5 0.8 900 12 ERI/CHA 3.0 4.3 800 13 ETL 1.6 1.2 850 14 ESV 1.0 4.1 900 15 DDR 1.3 1.6 900 16 KFI 2.8 4.2 800 17 UFI 2.8 3.8 800 18 AFX 2.2 5.6 800
(169)
(170) The Cu content is calculated as CuO.
(171) TABLE-US-00004 TABLE 3 Composition of the synthesis gels from Embodiment 1 to 18 Frame- Proton Hydrothermal Embodi- work SiO.sub.2 Al.sub.2O.sub.3 SDA 1 SDA 2 Me 1 Me 2 RBr H.sub.2O Content Cu Stability ment No. Type (mol) (mol) (mol) (mol) (mol) (mol) (mol) (mol) (mmol/g) (wt.-%) (° C.) 1 AEI 1 0.027 0.15 0.87 30.1 2.4 3.8 800 2 AEI 1 0.012 0.17 0.55 27.9 2.3 3.2 850 3 AEI 1 0.012 0.17 0.56 48.3 1.6 2.9 900 4 AEI 1 0.012 0.17 1.86 0.56 48.3 1.5 3.1 900 5 AEI 1 0.013 0.17 0.55 30.6 1.3 2.9 900 6 CHA 1 0.025 0.02 0.36 0.39 0.041 20.75 2.3 4.1 800 7 CHA 1 0.025 0.02 0.36 0.39 20.75 2.0 3.9 850 8 CHA 1 0.043 0.04 0.73 0.46 0.08 0.11 62.0 1.8 2.8 900 9 LEV 1 0.032 0.57 0.23 6.0 3.3 4.1 700 10 LEV 1 0.049 0.50 0.05 5.0 3.1 4.1 750 11 LEV 1 0.036 0.32 0.12 39.6 1.5 0.8 900 12 ERI/CHA 1 0.025 0.02 0.36 0.39 0.41 0.18 20.75 3.0 4.3 800 13 ETL 1 0.033 0.39 0.39 46.5 1.6 1.2 850 14 ESV 1 0.04 0.25 1.03 40.0 1.0 4.1 900 15 DDR 1 0.033 0.42 0.12 50.1 1.3 1.6 900 16 KFI 1 0.09 0.47 0.009 13.8 2.8 4.2 800 17 UFI 1 0.062 1.01 0.14 22.3 2.8 3.8 800 18 AFX 1 0.032 0.094 0.76 30.5 2.2 5.6 800
(172) All embodiments 1 to 18 indicate the respective gel composition. In table 3, the molar amounts of the respective components of the gels have been referred to 1 mol of SiO.sub.2. SDA1 is the first named SDA (structure directing agent) of the gel composition of the respective embodiment, and SDA2—if present—is the second one.
(173) Me1 refers to the molar amount of the first listed metal hydroxide Me(OH). In the embodiments 1 to 18, Me(OH) always dealt with an alkali metal hydroxide. Thus, the molar amount of Me1 is identical to that of the respective alkali metal hydroxide.
(174) Me2 refers to the molar amount of the metal of the second listed alkali or alkaline earth metal component.
(175) RBr represents hexamethonium bromide.
(176) The Cu content is calculated as CuO.
Embodiment 21: Determination of NH.SUB.3.—SRC Catalytic Activity
(177) NH.sub.3—SCR activity after hydrothermal ageing at 900° C. as described in Embodiment 21 are measured for zeolites from Embodiment 3, 5, 8, 13 and 15 (see Table 2). Catalyst pellets (125-250 μm) consisting of compressed zeolite powder are loaded in a quartz fixed bed tubular continuous flow reactor with on-line reaction product analysis. The catalyst first undergoes a pretreatment under simulated air flow conditions, i.e. 5% 02 and 95% N.sub.2, at 450° C., the highest temperature of the catalytic testing. After pretreatment, the catalyst temperature is decreased to 150° C. A typical gas composition for NH.sub.3—SCR performance evaluation consists of 500 ppm NO, 450 ppm NH.sub.3, 5% O.sub.2, 2% CO.sub.2, 2.2% H.sub.2O. The gas hourly space velocity (GHSV) will be fixed at 30 000 h.sup.−1, obtained with 0.5 cm.sup.3 catalyst bed and a gas flow of 250 mL/min. The temperature will be stepwise increased from 150 to 450° C. with fixed temperature ramps, and 50° C. intervals. Isothermal periods of 60 to 120 minutes are foreseen before reaction product sampling at each temperature plateau. A return point to 150° C. enables detection of degradation of catalytic performance during the testing.
(178) TABLE-US-00005 TABLE 4 NH.sub.3—SCR catalytic activity of Embodiment 3 (AEI), Embodiment 5 (AEI), Embodi- ment 8 (CHA), Embodiment 13 (ETL) and Embodiment 15 (DDR) NO.sub.x conversion (%) Temperature Embodiment Embodiment Embodiment Embodiment Embodiment (° C.) 3 (GV191) 5 (GV228) 8 (GV251) 13 (SK120) 15 (GV176) 150 55 52 81 8 22 175 75 72 95 12 40 200 88 85 92 17 48 250 87 92 88 36 70 300 85 88 88 53 65 350 84 87 87 57 57 400 81 85 85 53 49 450 79 84 83 48 35 150 54 51 81 9 21
Comparative Example 1
(179) 1122.2 mg of an aqueous solution of copper sulfate (CuSO.sub.4) was mixed with 266.2 mg of tetraethylenepentamine (TEPA) in order to prepare in-situ the copper organometallic complex, and the resulting mixture was stirred for 2 hours. Afterwards, 9487.3 mg of an aqueous solution of tetraethylammonium hydroxide (TEAOH) (35 wt.-% in water) and 1150.1 mg of an aqueous solution of 20 wt.-% NaOH were added, and the resulting mixture was stirred for 15 minutes. Lastly, 3608.5 mg of a zeolite with a FAU structure (CBV-720, SAR=21) was introduced into the synthesis mixture and stirred for the time required to evaporate the excess water until the desired gel concentration was achieved.
(180) The final composition of the gel is SiO.sub.2: 0.047 Al.sub.2O.sub.3: 0.022 Cu(TEPA).sup.2+: 0.4 TEAOH: 0.1 NaOH:4 H.sub.2O. The resulting gel was transferred to an autoclave with Teflon liner. The crystallization was carried out at 160° C. for 7 days under static conditions. The solid product was filtered, rinsed with plenty of water, dried at 100° C. and then calcined in air at 550° C. for 4 hours in order to remove the organic residues.
(181) Proton content: 2.2 mmol/g
(182) The zeolite obtained was not hydrothermally stable after 900° C. hydrothermal aging.
Comparative Example 2
(183) 380.2 mg of an aqueous solution of 20 wt.-% of CuSO.sub.4 was mixed with 90.2 mg of tetraethylenepentamine (TEPA) and stirred for 2 hours. Then, 1578.0 mg of an aqueous solution of tetraethylammoniumhydroxide (TEAOH) (35 wt.-%) and 230.1 mg of an aqueous solution of NaOH (20 wt.-% in H.sub.2O) were added, and the resulting mixture was stirred for 15 min. Lastly, 601.3 mg of a zeolite with a FAU structure (CBV-720, SAR=21) was introduced into the synthesis mixture and stirred for the time required to evaporate the excess water until the desired gel concentration was achieved. The final composition of the gel is SiO.sub.2: 0.047 Al.sub.2O.sub.3: 0.045 Cu(TEPA).sup.2+:0.4 TEAOH:0.1 NaOH:4 H.sub.2O. The resulting gel was transferred to an autoclave with Teflon liner.
(184) The crystallization was carried out at 160° C. for 7 days under static conditions. The solid product was filtered, rinsed with plenty of water, dried at 100° C. and then calcined in air at 550° C. for 4 hours in order to remove the organic residues.
(185) Proton content: 2.5 mmol/g
(186) The zeolite obtained was not hydrothermally stable after 900° C. hydrothermal aging.
Comparative Example 3
(187) 234.0 mg of an aqueous solution of 20 wt.-% of CuSO.sub.4 was mixed with 53.2 mg of tetraethylenepentamine (TEPA) and stirred for 2 hours. Then, 959.1 mg of an aqueous solution of tetraethylammoniumhydroxide (TEAOH) (35 wt.-%) and 225.1 mg of an aqueous solution of NaOH (20 wt.-% in H.sub.2O) were added, and the resulting mixture was stirred for 15 min. Lastly, 365.3 mg of a zeolite with a FAU structure (CBV-720, SAR=21) was introduced into the synthesis mixture and stirred for the time required to evaporate the excess water until the desired gel concentration was achieved. The final composition of the gel is SiO.sub.2:0.047 Al.sub.2O.sub.3:0.045 Cu(TEPA).sup.2+:0.4 TEAOH:0.2 NaOH:13 H.sub.2O. The resulting gel was transferred to an autoclave with Teflon liner.
(188) The crystallization was carried out at 160° C. for 7 days under static conditions. The solid product was filtered, rinsed with plenty of water, dried at 100° C. and then calcined in air at 550° C. for 4 hours in order to remove the organic residues.
(189) Proton content: 2.2 mmol/g
(190) The zeolite obtained was not hydrothermally stable after 900° C. hydrothermal aging.
Comparative Example 4
(191) a) Synthesis of Cu-Tetraethylenepentamine complex (Cu-TEPA): 37.9 g tetraethylenepentamine (0.2 mole) was added under stirring to a solution consisting of 50 g CuSO.sub.4.5H.sub.2O (0.2 mole) in 200 g of H.sub.2O (1 M solution) and left to stir for 2 h at room temperature.
(192) b) 3 g of zeolite Y with SAR=30 (Si/Al=15) (CBV720 supplied by Zeolyst International) was suspended in 27 mL of a 1.2 M solution of sodium hydroxide. To this solution 1.5 mL of a 1 M Cu-TEPA solution was added. The final gel had the following molar ratios: 1 SiO.sub.2/0.033 Al.sub.2O.sub.3/0.033 Cu-TEPA/0.70 NaOH/34 H.sub.2O. The suspension was stirred for 10 minutes at room temperature, before being transferred to an oven at 95° C. and left statically for 7 days. After cooling to room temperature, the powder was separated from the mother liquor by filtration, washed with demineralized water and dried at 60° C. for 12 h. The zeolite produced was determined to have the CHA framework type code according to X-ray diffraction (see
(193) Proton content: 4.02 mmol/g
(194) The zeolite obtained was not hydrothermally stable after 900° C. hydrothermal aging.
(195) TABLE-US-00006 TABLE 4 Gel compositions, ageing conditions, proton and Cu contents of the CHA examples Heating Proton Cu Hydro- SiO.sub.2 Al.sub.2O.sub.3 Cu(TEPA).sup.2+ TEAOH NaOH H.sub.2O KCl RBr Heating temp. Gel content cont. therm. Source (mol) (mol) (mol) (mol) (mol) (mol) (mol) (mol) time gel (gel) ageing (mmol/g) (wt.-%) stability CE 1 1 0.047 0.022 0.4 0.1 4 7 days 160° C. static 2.2 n.d. <900° C. CE 2 1 0.047 0.045 0.4 0.1 4 7 days 160° C. static 2.5 n.d. <900° C. CE 3 1 0.047 0.045 0.4 0.2 13 7 days 160° C. static 2.2 n.d. <900° C. CE 4 1 0.033 0.033 0.7 34 7 days 95° C. static 4.02 5.9 <900° C. Emb 6 1 0.025 0.02 0.36 0.39 20.75 4 days 150° C. dynamic 2.3 4.1 800° C. Emb 7 1 0.025 0.02 0.36 0.39 20.75 4 days 150° C. dynamic 2.0 3.9 850° C. Emb 8 1 0.043 0.04 0.73 0.46 62 0.08 0.11 7 days 160° C. dynamic 1.8 2.8 900° C. CE comparative example Emb embodiment RBr hexamethoniumbromide n.d. not detected
(196) All Cu contents were calculated as CuO.
(197) The Comparative Examples were tested for their hydrothermal stability at 900° C.
(198) Table 5 shows the total proton content, the hydrothermal stability, the Bronsted acid sites (BAS), the silanol protons (Si—OH), the aluminol protons (Al—OH) and the residual protons of the embodiments 1 to 18.
(199) The skilled person knows that zeolites comprise protons which can unambiguously assigned to a specific site, namely to Bronsted acid sites (BAS), or to silanol groups (SiOH), or to aluminol groups (Al—OH). In addition, there are protons which cannot be clearly assigned to a specific site. These protons are hereinafter referred to as “residual protons”.
(200) The data clearly show that the overall amount of protons, i.e. the sum of BAS, Si—OH, Al—OH and residual protons, has to be taken into account when assessing the hydrothermal stability of a zeolite.
(201) TABLE-US-00007 TABLE 5 Total proton content, the hydrothermal stability, the Bronsted acid sites (BAS), the silanol protons (Si—OH), the aluminol protons (Al—OH) and the residual protons of the embodiments 1 to 18 Frame- Sum BAS + Total Proton Embodi- work Al—OH + Si—OH + Residual Content Hydrothermal ment No. Type BAS Al—OH Si—OH Si—OH Al—OH protons (mmol/g) Stability (° C.) 1 AEI 0.336 1.734 0.072 1.806 2.143 0.257 2.4 800 2 AEI 0.634 0.751 0.111 0.863 1.497 0.803 2.3 850 3 AEI 0.498 0.742 0.095 0.837 1.335 0.265 1.6 900 4 AEI 0.524 0.604 0.132 0.736 1.260 0.240 1.5 900 5 AEI 0.322 0.570 0.059 0.629 0.951 0.349 1.3 900 6 CHA 0.700 1.054 0.263 1.317 2.017 0.283 2.3 800 7 CHA 0.677 0.925 0.197 1.123 1.799 0.201 2.0 850 8 CHA 0.280 0.284 0.031 0.315 0.596 1.204 1.8 900 9 LEV 0.377 0.365 0.134 0.498 0.875 2.425 3.3 700 10 LEV 0.732 0.574 0.316 0.890 1.622 1.478 3.1 750 11 LEV 0.349 0.410 0.009 0.418 0.767 0.733 1.5 900 12 ERI/CHA 0.338 1.688 0.280 1.968 2.306 0.694 3.0 800 13 ETL 0.523 0.470 0.248 0.718 1.240 0.360 1.6 850 14 ESV 0.026 0.496 0.170 0.667 0.693 0.307 1.0 900 15 DDR 0.182 0.199 0.084 0.283 0.465 0.835 1.3 900 16 KFI 0.393 1.481 0.651 2.132 2.525 0.275 2.8 800 17 UFI 0.588 1.221 0.622 1.842 2.430 0.370 2.8 800 18 AFX 0.604 0.907 0.317 1.224 1.829 0.371 2.2 800
(202) BAS, Si—OH, Al—OH, residual protons and the total proton content are indicated in mmol/g zeolite.