Pacific Industrial Development Corporation

De Gao

Wei Wu

Yunkui Li

David Shepard

Jeffery Lachapelle

Geng Zhang

A method of forming AEI-type zeolites in a hydrothermal synthesis without the use of hydrogen fluoride (HF) and in the presence of an FAU zeolite NaY with SAR ≤5, a Y zeolite with a SAR ≥5, or a combination thereof. A gel composition formed upon using this method includes one or more sources of silica, alumina, organic structure directing agents (OSDA), and alkali metal ions; zeolite seeds; and water. This gel composition is defined by the molar ratios of: SiO/AIO18:1 to 100:1; MO/SiO0.15:1 to 0.30:1; ROH/SiO0.05:1 to 0.13:1; and HO/SiO5:1 to 20:1; wherein M is the alkali metal ion and R is an organic moiety derived from the OSDA. This gel composition, after reacting at a temperature between 135° C. to about 200° C. for 10 hours to 168 hours forms the crystalline AEI-type zeolite having a silica to alumina ratio (SiO:AIO) that is greater than 15:1.

Method of making AEI-type zeolites having a high silica to alumina molar ratio (SAR)

A method of forming an AEI-type zeolite in a hydrothermal synthesis without the use of hydrogen fluoride (HF) and in the absence of any FAU zeolite Y. A gel composition formed upon using this method includes one or more sources of silica; one or more sources of alumina, one or more organic structure directing agents (OSDA); a source of alkali metal ions; and water. This gel composition is defined by the molar ratios of: SiO/AIO16:1 to 100:1; MO/SiO0.15:1 to 0.30:1; ROH/SiO0.05:1 to 0.20:1; and HO/SiO5:1 to 20:1; wherein M is the alkali metal ion and R is an organic moiety derived from the OSDA. This gel composition, after reacting at a temperature between 135° C. to about 180° C. for 15 hours to 168 hours forms the crystalline AEI-type zeolite having a silica to alumina ratio (SiO:AIO) that is greater than 8:1.

Method of making AEI-type zeolites having a high silica to alumina ratio (SAR)

A method of forming an AFX zeolite in a hydrothermal synthesis that exhibits a silica to alumina (SiOAIO) molar ratio (SAR) that is between 8:1 and 26:1; has a morphology that includes one or more of cubic, spheroidal, or rhombic particles with a crystal size that is in the range of about 0.1 micrometer (μm) to 10 μm. This AFX zeolite also exhibits a Brönsted acidity that is in the range of 1.2 mmol/g to 3.6 mmol/g as measured by ammonia temperature programmed desorption. A catalyst formed by substituting a metal into the framework of the zeolite exhibits about a 100% conversion of NO emissions over the temperature range of 300° C. to 650° C.

Method of making AFX zeolites having high thermal stability

A method of forming an SSZ-13 zeolite in a hydrothermal synthesis yields an SSZ-13 zeolite that exhibits a silica to alumina (SiO:AlO) molar ratio (SAR) that is less than 16:1; has a morphology that includes one or more of cubic, spheroidal, or rhombic particles with a crystal size that is in the range of about 0.1 micrometer (μm) to 10 μm. This SSZ-13 also exhibits a Brönsted acidity that is in the range of 2.0 mmol/g to 3.4 mmol/g as measured by ammonia temperature programmed desorption. A catalyst formed by substituting a metal into the framework of the zeolite provides for low temperature light-off of the NOx conversion reactions, while maintaining substantial performance at higher temperatures demonstrating hydrothermal stability.

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Troy, MI, United States of America

De Gao