High temperature catalyst and process for selective catalytic reduction of NOx in exhaust gases of fossil fuel combustion

A process for preparing a catalyst for reduction of NOx in combustion exhaust, comprising:

• a) steam treating a zeolite material at about 500° C.-600° C. for about 5-15 hours in air with about 10-25% water vapor;
• b) adding iron to the zeolite material at a loading between 0.01% and 10% iron;
• and
• c) calcining the zeolite material at about 500° C.-1100° C.;
• wherein the order of steps a) and b) may vary, followed by step c).

A process for preparing a catalyst for reduction of NOx in combustion exhaust, comprising:

• a) adding iron to an alumino-silicate zeolite material;
• b) steam treating the zeolite material at a temperature of 500° C.-600° C. for about 5-15 hours in air with about 10-25% water vapor such that said steam treating is sufficient for partial de-alumination of the zeolite material to approximately a steady state, but not sufficient to fully collapse the chemical structure of the zeolite material;
• c) calcining the zeolite material at a temperature, humidity, and duration sufficient to stabilize the zeolite material;
• and
• wherein the order of steps a) and b) may vary, followed by step c)
• whereby the process creates a stable and efficient catalyst for converting NO to N2 and H20 in combustion exhaust at temperatures from 300° C. to over 700° C.