# US 10,245,582 B2 · Zeolite catalyst containing metals

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 10,245,582 B2
- Document ID: US10245582B2
- Status: Granted
- Kind: B2
- Application number: 14/394,230
- Filed: 2013-04-11
- Published: 2015-03-19
- Granted: 2019-04-02
- Earliest claimed: 2012-04-11
- Assignees: Johnson Matthey Public Limited Company
- Applicants: Johnson Matthey Public Limited Company
- Inventors: Joseph Michael Fedeyko; Hai-Ying Chen
- Web page: https://patentgrep.com/patent/US10245582B2

## CPC

- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas}
- B01J 23/78: with alkali- or alkaline earth metals
- B01J 29/723: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 35/396: {Distribution of the active metal ingredient}
- B01J 37/031: {Precipitation}
- B01J 37/036: {to form a gel or a cogel}
- B01J 37/038: {to form slurries or suspensions, e.g. a washcoat}
- B01J 37/30: Ion-exchange
- F01N 3/10: by thermal or catalytic conversion of noxious components of exhaust
- B01D 2255/202: Alkali metals
- B01D 2255/204: Alkaline earth metals
- B01D 2255/20738: Iron
- B01D 2255/20761: Copper
- B01D 2255/50: Zeolites
- B01D 2257/40: Nitrogen compounds
- B01D 2257/404: Nitrogen oxides other than dinitrogen oxide
- B01D 2258/012: Diesel engines and lean burn gasoline engines
- B01J 2229/186: not in framework positions
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)

## Abstract

Provided is catalyst material useful for the selective catalytic reduction of NOx in lean burn exhaust gas, wherein the catalyst material is a hydrothermally stable, low SAR aluminosilicate zeolite loaded with a synergistic combination of one or more transition metals, such as copper, and one or more alkali or alkaline earth metals, such as calcium or potassium.

## Claims

### Claim 1

A catalyst composition comprising:
a. an aluminosilicate zeolite material comprising silica and alumina in a CHA framework and having a silica-to-alumina mole ratio (SAR) of about 10 to about 25;
b. about 1 to about 5 weight percent of a base metal (“BM”), based on the total weight of the zeolite material, wherein said base metal disposed in said zeolite material as free and/or extra-framework exchanged metal;
c. an alkali or alkaline earth metal (collectively “AM”) disposed in said zeolite material disposed in said zeolite material as free and/or extra-framework exchanged metal,
wherein the BM and AM are present, respectively, in a molar ratio of about 15:1 to about 1:1,
wherein the alumina contains aluminum (Al) that is part of the zeolite framework and the catalyst composition has a (BM+AM):Al mole ratio of about 0.1 to about 0.4, and
wherein AM is calcium; and
d. about 1 to about 10 weight percent of cerium in said zeolite material, based on the total weight of the zeolite, wherein said cerium is present in a form selected from exchanged cerium ions, monomeric ceria, oligomeric ceria, and combinations thereof, provided that said oligomeric ceria has a particle size of less than 5 μm.

### Claim 2 (depends on 1)

The catalyst composition of claim 1, wherein a molar ratio of BM to Al is less than 0.25:1.

### Claim 3 (depends on 1)

The catalyst composition of claim 1, wherein a molar ratio of BM to AM is about 10:1 to about 3:1.

### Claim 4 (depends on 1)

The catalyst composition of claim 1, wherein said aluminosilicate zeolite material has an SAR of about 15 to about 20 and a BM:Al mole ratio of about 0.1 to about 0.24.

### Claim 5 (depends on 1)

The catalyst composition of claim 1, wherein said base metal is selected from chromium, manganese, iron, cobalt, nickel, and copper, and mixtures thereof.

### Claim 6 (depends on 1)

The catalyst composition of claim 1, wherein said base metal is selected from the group consisting of Cu, Fe, and combinations thereof, and a molar ratio of BM:Al is about 0.17 to about 0.24.

### Claim 7 (depends on 6)

The catalyst composition of claim 6, wherein said base metal is Cu.

### Claim 8 (depends on 1)

The catalyst composition of claim 1, wherein said zeolite is an SSZ-13 isotype.

### Claim 9 (depends on 2)

The catalyst composition of claim 2, wherein said zeolite has a mean crystal size of about 1 μm to about 5 μm.

### Claim 10 (depends on 1)

The catalyst composition of claim 1, wherein said catalyst composition is substantially free of Zr, ZrO, Ti, and TiO.

### Claim 11 (depends on 1)

A catalytically active washcoat composition comprising:
a. a catalyst composition according to claim 1, and
b. one or more stabilizers and/or binders selected from ceria, alumina, silica, (non-zeolite) silica-alumina, naturally occurring clays, TiO2, ZrO2, and SnO2,
wherein the catalyst composition and the one or more stabilizers and/or binders are present together in a slurry.

### Claim 12 (depends on 1)

A catalyst article comprising:
a. a catalyst composition according to claim 1, and
b. a substrate,
wherein the catalyst composition is disposed on the surface of the substrate, permeates at least a portion of the substrate, or a combination thereof.

### Claim 13 (depends on 12)

The catalyst article of claim 12, wherein said substrate is a flow-through monolith.

### Claim 14 (depends on 12)

The catalyst article of claim 12, wherein said substrate is a wall-flow monolith.

### Claim 15 (depends on 1)

A method for reducing NOx in an exhaust gas comprising:
contacting an exhaust gas stream derived from a lean-burn combustion process and containing NOx and a reducing agent with a catalyst composition according to claim 1; and
converting at a portion of said NOx to N2 and H2O.