Basf Corporation

Basf Mobile Emissions Catalysts LLC

Eduard L Kunkes

Ahmad Moini

Maritza I Ortega

William Michael Jaglowski

Christopher R Castellano

Rajamani P Gounder

Jonelle Charmaine Thomas

John Rocco Di Iorio

Claire Townsend Nimlos

Subramanian Prasad

Casey Benjamin Jones

Vivek Vattipalli

Martitza I Ortega

Karl C Kharas

The present disclosure provides catalyst compositions capable of reducing nitrogen oxide (NO) emissions in engine exhaust. The catalyst compositions include metal ion-exchanged zeolites having a domain size of less than about 1500 Ångstroms (Å), a crystallographic strain of less than about 0.7%, or both. Further provided are catalyst articles coated with such compositions, processes for preparing such catalyst compositions and articles, an exhaust gas treatment system including such catalytic articles, and methods for reducing NOin an exhaust gas stream using such catalytic articles and systems.

Cu-CHA SCR catalysts having specific lattice strain and domain size characteristics

The disclosure provides methods of preparing small pore zeolites, the method including using a first organic structure-directing agent and a second organic structure-directing agent to crystallize the zeolites, wherein the first organic structure-directing agent is bis-quaternary ammonium cations, and the second organic structure-directing agent is mono-quaternary ammonium cations. Further disclosed are small pore zeolites having a controlled framework aluminum distribution, and selective catalytic reduction catalyst compositions, articles, and systems including such zeolites promoted with a metal.

Zeolite structure synthesized using mixtures of organic structure directing agents

The present disclosure provides methods of synthesizing a zeolite with a silica-to-alumina ratio (SAR) of 10 or greater comprising, e.g.: forming a reaction mixture including at least one alumina source, at least one silica source, and at least one organic structure directing agent, wherein the reaction mixture has a solids content of about 10% or greater, and crystallizing the reaction mixture at a temperature of 100° C. or less at atmospheric pressure to form a zeolite.

Zeolite synthesis

The disclosure generally provides zeolites having the CHA crystalline framework and methods of preparing the same. Provided herein are CHA zeolites containing intergrowths, a controlled framework aluminum distribution, or both. Further provided are CHA zeolites wherein crystals of the zeolite material have a predominantly flake-like morphology as determined by scanning electron microscopy (SEM). Further provided are catalyst compositions, articles, and systems including CHA zeolites promoted with a metal.

Chabazite synthesis method including organic and inorganic structure directing agents and chabazite zeolite with flake-like morphology

The present disclosure provides a method of making zeolite intergrowths. In one embodiment, the present disclosure provides a method of making an AEI-based material, including the steps of: preparing a mixture of water, an alumina source, a silica source, a CHA structure directing agent, and an AEI structure directing agent, wherein the molar ratio of the CHA structure directing agent to the AEI structure directing agent is from about 1:1 to about 1:15; heating the mixture at a temperature sufficient to promote formation of crystals; and calcining the crystals at a temperature of from about 450° C. to about 750° C. to obtain a product, wherein no halide-containing reagent is employed. The AEI-based materials of the present disclosure may find particular use in selective catalytic reduction of NOin exhaust gas streams.

Aluminosilicate zeolite intergrowths

The invention provides a method of synthesizing a zeolite having the CHA crystalline framework, the method including forming a reaction mixture comprising an alumina source comprising a zeolite having an FAU crystalline framework, a silica source, and an organic structure directing agent, the reaction mixture&#x2014;having a combined molar ratio of M/Si+R/Si higher than the molar ratio OH/Si, wherein M is moles of alkali metal and R is moles of organic structure directing agent; and crystallizing the reaction mixture to form a product zeolite having the CHA crystalline framework, wherein the product zeolite has a mesopore surface area (MSA) of less than about 25 m/g. The invention also includes catalyst articles made using the product zeolite, exhaust gas treatment systems including the catalyst articles, and methods of treating exhaust gas using the catalyst articles.

CHA zeolite material and related method of synthesis

A method for crystallizing aluminosilicate zeolites, including the steps of preparing a mixture containing a silica source, a mineralizing agent, an organic structure directing agent; heating the mixture to form a heated mixture; and adding an alumina source to the heated mixture. The method steps described herein can provide an accelerated aluminosilicate zeolite crystallization process as compared to conventional processes.

Accelerated aluminosilicate zeolite crystallization

Disclosed herein are compositions including aluminosilicate zeolite crystals with an 8 ring pore size having a depth dependent silica to alumina molar ratio and processes of making aluminosilicate zeolite crystals with an 8 ring pore size having a depth dependent silica to alumina molar ratio.

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Iselin, NJ, United States of America

Eduard L Kunkes