Zeolite-Based Honeycomb Body

A method of making a zeolite-based honeycomb body, the method comprising:

• forming a mixture comprising a zeolite having a SiO2 to Al2O3 molar ratio in the range from 5 to 300;
• a secondary phase material having a coefficient of thermal expansion greater than 10×10−7/° C.;
• a permanent binder;
• and 1-80% superaddition of a poreformer agent;
• extruding the mixture to form a cellular body having a matrix of walls;
• and
• heating the cellular body to produce a zeolite-based honeycomb body.

A method of making a zeolite-based honeycomb body, the method comprising the steps of:

• forming a slurry mixture comprising a zeolite material;
• spray-drying the slurry mixture to form zeolite-based agglomerates;
• forming a batch formulation comprising the zeolite-based agglomerates, a binder and a poreformer agent;
• extruding the batch formulation to form a honeycomb body having a matrix of walls having the zeolite material homogenously distributed therein;
• and
• heating the honeycomb body to remove the poreformer agent to produce a median pore diameter greater than 1 micron and a porosity greater than 25% in the walls.

A zeolite-based honeycomb body filter comprising a matrix of walls defining channels through the body, at least a portion of said channels being plugged at one end only, said body comprising:

• a primary phase material comprising one or more zeolite material having a SiO2 to Al2O3 molar ratio in the range from 5 to 300;
• one or more secondary phase material having a coefficient of thermal expansion of at least 10×10-7/° C.;
• and
• a permanent binder;
• wherein the honeycomb body walls exhibit a median pore diameter measured by mercury intrusion of at least 1 micron, a porosity of 30-70% and a mean coefficient of thermal expansion in the range of 0 to +/−15×10-7/° C.