# US 2013/0281284 A1 · Catalyst for nitrogen oxide removal

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- Number: US 2013/0281284 A1
- Document ID: US20130281284A1
- Status: Published application
- Kind: A1
- Application number: 13/997,894
- Filed: 2011-12-26
- Published: 2013-10-24
- Earliest claimed: 2010-12-27
- Assignees: Mitsubishi Plastics, Inc.
- Inventors: Takeshi Matsuo; Takahiko Takewaki; Kazunori Oshima; Haijun Chen; Daisuke Nishioka; Caio Tagusagawa
- Web page: https://patentgrep.com/patent/US20130281284A1

## CPC

- B01J 29/85: Silicoaluminophosphates [SAPO compounds]
- B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas}
- B01J 29/7065: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/743: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 35/393: {Metal or metal oxide crystallite size}
- B01J 35/395: {Thickness of the active catalytic layer}
- C01B 39/085: {Group IVB- metallosilicates}
- C01B 39/48: using at least one organic template directing agent
- C01B 39/54: Phosphates, e.g. APO or SAPO compounds
- B01D 2255/2092: Aluminium
- B01D 2255/50: Zeolites
- B01D 2255/707: Additives or dopants
- B01D 2255/9202: Linear dimensions
- B01D 2258/012: Diesel engines and lean burn gasoline engines
- B01D 2258/014: Stoichiometric gasoline engines
- B01J 2229/186: not in framework positions
- B01J 2229/42: Addition of matrix or binder particles
- B01J 2235/00: Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
- B01J 2235/15: X-ray diffraction
- 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)
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}

## Abstract

[Object] To provide a catalyst for nitrogen oxide removal having no degradation problem caused by adsorbed water when a temperature is raised sharply and exhibiting excellent nitrogen oxide removal performance and retentive characteristic thereof. [Solution] A catalyst for nitrogen oxide removal, containing a metal-loading zeolite, wherein the zeolite contains a silicon atom, an aluminum atom, and a phosphorus atom in a framework structure, and the amount of water adsorption of the catalyst at 25° C. and a relative vapor pressure of 0.5 is 0.05 to 0.2 (kg-water/kg-catalyst) or less. A method for manufacturing this catalyst for nitrogen oxide removal, the method including the steps of drying a mixed slurry containing a metal source, the zeolite, and metal oxide particles having an average particle diameter of 0.1 to 10 μm and/or an inorganic binder and calcining the resulting dry powder.

## Claims

### Claim 1

A catalyst comprising a zeolite and a metal loaded thereon, wherein the zeolite comprises a silicon atom, an aluminum atom, and a phosphorus atom in a framework structure, and wherein an amount of water adsorption of the catalyst at 25° C. and a relative vapor pressure of 0.5 is from 0.05 to 0.2 kg water/kg catalyst.

### Claim 2

A catalyst comprising a zeolite and a metal loaded thereon, the zeolite having a framework structure comprising a silicon atom, an aluminum atom, and a phosphorus atom,
wherein when an X-ray diffraction measurement by using Cu-Kα rays as an X-ray source is performed, a ratio of a diffraction peak intensity observed in a range of diffraction angle (2θ) of 21.0 to 21.4 degrees to a diffraction peak intensity observed in a range of 20.4 to 20.8 degrees is from 0.2 to 1.2.

### Claim 3 (depends on 1)

The catalyst of claim 1, wherein a molar ratio of Si to a sum of Si, Al and P in the framework structure of the zeolite is 0.10 or more.

### Claim 4 (depends on 1)

The catalyst of claim 1, wherein an amount of NH3 adsorption is 0.28 mmol/g-catalyst or more, wherein the amount of NH3 adsorption is measured by:
adsorbing ammonia to the catalyst at 200° C. until saturation is reached;
contacting the catalyst with a first gas consisting of 350 ppm NO, 385 ppm NH3, 15 vol % O2, 5 vol % H2O, and a remainder N2, to achieve an equilibrium state of a reduction reaction of NO by ammonia; and
contacting the catalyst with a second gas consisting of 350 ppm NO, 0 ppm NH3, 15 vol % O2, 5 vol % H2O, and a remainder N2, to determine the amount of NH3 adsorption, wherein
amount of NH3 adsorption=total amount of NO reduced/catalyst weight (g).

### Claim 5 (depends on 1)

The catalyst of claim 1, comprising (i) metal oxide particles having an average particle diameter of 0.1 to 10 μm, (ii) an inorganic binder, or both (i) and (ii).

### Claim 6 (depends on 5)

The catalyst of claim 5, comprising both (i) and (ii).

### Claim 7 (depends on 1)

The catalyst of claim 1, comprising the zeolite in an amount of 30 to 99 percent by weight.

### Claim 8 (depends on 1)

The catalyst of claim 1, wherein the zeolite has a structure of CHA on a cord defined by IZA.

### Claim 9 (depends on 1)

The catalyst of claim 1, wherein the loaded metal is copper, iron, or both copper and iron.

### Claim 10 (depends on 5)

The catalyst of claim 5, comprising the metal oxide particles, wherein the metal oxide particles comprise at least one metal selected from the group consisting of aluminum, silicon, titanium, cerium, and niobium.

### Claim 11 (depends on 5)

The catalyst of claim 5, comprising the inorganic binder, wherein the inorganic binder is an aggregate of inorganic oxide sols having an average particle diameter of 5 to 100 nm.

### Claim 12 (depends on 1)

A device comprising:
a honeycomb-shaped product, and
the catalyst of claim 1 coated on the product.

### Claim 13 (depends on 1)

A device formed by molding the catalyst of claim 1.

### Claim 14

A method for manufacturing a catalyst, the catalyst comprising a zeolite and a metal loaded thereon,
wherein the method comprises:
preparing dry powder by drying a mixed slurry comprising a metal source, the zeolite, and (i) metal oxide particles having an average particle diameter of 0.1 to 10 μm, (ii) an inorganic binder, or both (i) and (ii), and
calcining the dry powder.

### Claim 15 (depends on 14)

The method of claim 14, wherein the dry powder is calcined at a temperature of 400° C. or higher.

### Claim 16 (depends on 1)

The catalyst of claim 1, wherein when an X-ray diffraction measurement by using Cu-Kα rays as an X-ray source is performed, a ratio of a diffraction peak intensity observed in a range of diffraction angle (2θ) of 21.0 to 21.4 degrees to a diffraction peak intensity observed in a range of 20.4 degrees to 20.8 degrees is from 0.2 to 1.2.

### Claim 17 (depends on 1)

The catalyst of claim 1, which is suitable for nitrogen oxide removal.

### Claim 18 (depends on 2)

The catalyst of claim 2, which is suitable for nitrogen oxide removal.

### Claim 19 (depends on 2)

The catalyst of claim 2, wherein a molar ratio of Si to a sum of Si, Al and P in the framework structure of the zeolite is 0.10 or more.

### Claim 20 (depends on 1)

The catalyst of claim 1, comprising metal oxide particles having an average particle diameter of 0.1 to 10 μm.