Iron-loaded Small Pore Aluminosilicate Zeolites and Method of Making Metal Loaded Small Pore Aluminosilicate Zeolites

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This invention relates to an improved iron-loaded small pore aluminosilicate zeolite catalyst (such as Fe-SSZ-13), which is produced through a specific post-synthesis process that introduces mesoporosity and allows homogeneous iron distribution. The resulting material shows a high proportion of isolated iron sites, which enhances its performance as a catalyst, particularly in selective catalytic reduction (SCR) of nitrogen oxides (NOx) in exhaust gases. The patent also describes a method for manufacturing such metal-loaded zeolites from pre-existing zeolites and their applications in exhaust treatment systems.

Use CasesContent extracted from patent full text and abstract with AI.

• Selective catalytic reduction (SCR) of NOx in diesel and other engine exhaust systems to reduce harmful emissions.
• Catalysts in stationary source emission controls, such as power plants or industrial facilities, for NOx abatement.
• Catalytic decomposition of nitrous oxide (N2O), a potent greenhouse gas.
• Direct oxidation of benzene to phenol in chemical synthesis.
• As an active component in washcoat compositions for monolithic catalyst substrates in automotive and industrial exhaust systems.
• Integration into exhaust after-treatment systems in commercial vehicles, ships, and locomotives.

BenefitsContent extracted from patent full text and abstract with AI.

• Provides improved NOx conversion due to a high proportion of isolated iron sites, enhancing selective catalytic reduction efficiency.
• Allows for a homogeneous and stable distribution of iron within the zeolite framework, avoiding inactive iron oxide agglomerates and maximizing catalyst activity.
• Can be produced from commercially available or natural pre-existing zeolites with scalable post-synthetic treatments, making it practical for industrial production.
• Enhanced catalyst durability and hydrothermal stability due to robust zeolite framework and optimized preparation methods.
• Potentially reduces the generation of undesired by-products (such as N2O) compared to copper-based alternatives at high temperatures.
• Broad applicability for both vehicle and stationary emission control, as well as in chemical processing industries.

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Patent Abstract

The present invention provides an iron-loaded aluminosilicate zeolite having a maximum pore opening defined by eight tetrahedral atoms and having the framework type CHA, AEI, AFX, ERI or LTA, wherein the iron (Fe) is present in a range of from about 0.5 to about 5.0 wt. % based on the total weight of the iron-loaded aluminosilicate zeolite, wherein an ultraviolet-visible absorbance spectrum of the iron-loaded synthetic aluminosilicate zeolite comprises a band at approximately 280 nm, wherein a ratio of an integral, peak-fitted ultraviolet-visible absorbance signal measured in arbitrary units (a.u.) for the band at approximately 280 nm to an integral peak-fitted ultraviolet-visible absorbance signal measured in arbitrary units (a.u.) for a band at approximately 340 nm is >about 2. 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.