Johnson Matthey Public Limited Company

Johnson Matthey Catalysts (germany) Gmbh

Joerg Werner Muench

Ralf Dotzel

Juergen Bauer

Rainer Leppelt

Joerg Walter Jodlauk

Wilhelm Schwieger

Ralitsa Purova

Ameen Shahid

Irene Piras

Paul Richard Phillips

Guy Richard Chandler

John Leonello Casci

Gudmund Smedler

Thangaraj Selvam

Diana Biskupski

Tobias Weissenberger

Selvam Thangaraj

Andrew Peter Walker

Alexander Nicholas Michael Green

Neil Robert Collins

Neil Greenham

Matthew Eben Harris

Maria Theresia Brandmair

Yannick Bidal

Daniel Avis

Rodney Foo

Sofia Lopez-Orozco

Nikki Jane Amos-Reichert

The present invention further provides a method of making an metal-loaded aluminosilicate zeolite having a maximum pore opening defined by eight tetrahedral atoms from pre-existing aluminosilicate zeolite crystallites, wherein the metal is present in a range of from 0.5 to 5.0 wt. % based on the total weight of the metal-loaded aluminosilicate zeolite.

Iron-loaded small pore aluminosilicate zeolites and method of making metal loaded small pore aluminosilicate zeolites

The present disclosure relates to a method for forming a catalyst article comprising: (a) forming a plastic mixture having a solids content of greater than 50% by weight by mixing together a crystalline small pore or medium pore molecular sieve in an Hor NHform, an insoluble active metal precursor, an inorganic matrix component, an organic auxiliary agent, an aqueous solvent and optionally inorganic fibres; (b) moulding the plastic mixture into a shaped article; and (c) calcining the shaped article to form a solid catalyst body. The present disclosure further relates to a catalyst article, particularly a catalyst article which is suitable for use in the selective catalytic reduction of nitrogen oxides, and to an exhaust system.

Method for forming a catalyst article

The present invention provides an iron-loaded aluminosilicate zeolite having a maximum pore opening defined by eight tetrahedral atoms and having the framework type CHA, AEI, AFX, ERI or LTA, wherein the iron (Fe) is present in a range of from about 0.5 to about 5.0 wt. % based on the total weight of the iron-loaded aluminosilicate zeolite, wherein an ultraviolet-visible absorbance spectrum of the iron-loaded synthetic aluminosilicate zeolite comprises a band at approximately 280 nm, wherein a ratio of an integral, peak-fitted ultraviolet-visible absorbance signal measured in arbitrary units (a.u.) for the band at approximately 280 nm to an integral peak-fitted ultraviolet-visible absorbance signal measured in arbitrary units (a.u.) for a band at approximately 340 nm is &#x3e;about 2. The present invention further provides a method of making an metal-loaded aluminosilicate zeolite having a maximum pore opening defined by eight tetrahedral atoms from pre-existing aluminosilicate zeolite crystallites, wherein the metal is present in a range of from 0.5 to 5.0 wt. % based on the total weight of the metal-loaded aluminosilicate zeolite.

In order to specify a catalytic converter, especially SCR catalytic converter, with maximum catalytic activity, this catalytic converter has at least one catalytically active component and additionally at least one porous inorganic filler component having meso- or macroporosity. The organic porous filler component has a proportion of about 5 to 50% by weight. More particularly, a diatomaceous earth or a pillared clay material is used as the porous inorganic filler component.

Catalytic converter

To be able to produce an SCR catalyst (), in particular one having a zeolite fraction (Z) as catalytically active fraction, in a reliable process and at the same time achieve good catalytic activity of the catalyst (), an inorganic binder fraction (B) which is catalytically inactive in the starting state and has been treated to develop catalytic activity is mixed into a catalyst composition (). The inorganic binder component for the binder fraction (B) is, in the starting state, preferably porous particles (), in particular diatomaceous earth, which display mesoporosity. To effect catalytic activation, the individual particles () are either coated with a catalytically active layer () or transformed into a catalytically active zeolite () with maintenance of the mesoporosity.

Process for producing a catalyst and catalyst as such

A composite material comprises a macroporous silicate-based material at least partially substituted with at least one microporous zeolite, wherein the microporous zeolite is functionalised with either copper, iron or both copper and iron, and wherein the composite material is in the form of particles. The composite material can be obtained using a method comprising the steps of: (i) providing a mixture comprising a silicate-containing scaffold having a macroporous structure, an aluminium source and an organic template; (ii) hydrothermally treating the mixture to form a microporous zeolite-containing structure substantially retaining the macroporous structure of the silicate-containing scaffold; (iii) incorporating copper, iron or both copper and iron into the zeolite. The silicate-containing scaffold can be a diatomaceous earth.

Composite material

A selective catalytic reduction catalyst composition for converting oxides of nitrogen (NO) in an exhaust gas using a nitrogenous reductant, which catalyst composition comprising a mixture of a first component and a second component, wherein the first component is the H-form of an aluminosilicate chabazite zeolite (CHA); or an admixture of the H-form of an aluminosilicate mordenite zeolite (MOR) and the H-form of an aluminosilicate chabazite zeolite (CHA); and the second component is a vanadium oxide supported on a metal oxide support, which is titania, silica-stabilized titania or a mixture of titania and silica-stabilized titania, wherein the weight ratio of the first component to the second component is 10:90 to 25:75.

Selective catalytic reduction catalyst

An extruded, solid honeycomb body comprises a copper-promoted, small pore, crystalline molecular sieve catalyst for converting oxides of nitrogen in the presence of a reducing agent, wherein the crystalline molecular sieve contains a maximum ring size of eight tetrahedral atoms, which extruded, solid honeycomb body comprising: 20-50% by weight matrix component comprising diatomaceous earth, wherein 2-20 weight % of the extruded, solid honeycomb body is diatomaceous earth; 80-50% by weight of the small pore, crystalline molecular sieve ion-exchanged with copper; and 0-10% by weight of inorganic fibres.

Catalytic extruded, solid honeycomb body

A selective catalytic reduction catalyst composition for converting oxides of nitrogen (NO) in an exhaust gas using a nitrogenous reductant comprises a mixture of a first component and a second component, wherein the first component is an admixture of the H-form of an aluminosilicate mordenite zeolite (MOR) and an iron-promoted aluminosilicate MFI zeolite; and the second component is a vanadium oxide supported on a metal oxide support, which is titania, silica-stabilized titania or a mixture of both titania and silica-stabilized titania, wherein the weight ratio of the first component to the second component is 10:90 to 25:75.

An extruded honeycomb catalyst for nitrogen oxide reduction according to the selective catalytic reduction (SCR) method in exhaust gases from motor vehicles includes an extruded active carrier in honeycomb form having a first SCR catalytically active component and with a plurality of channels through which the exhaust gas flows during operation, and a washcoat coating having a second SCR catalytically active component being applied to the extruded body, wherein the first SCR catalytically active component and the second SCR catalytically active component are each independently one of:

Extruded honeycomb catalyst

Provided is a catalyst composition for treating exhaust gas comprising a blend of a first component and second component, wherein the first component is an aluminosilicate or ferrosilicate molecular sieve component wherein the molecular sieve is either in H+ form or is ion exchanged with one or more transition metals, and the second component is a vanadium oxide supported on a metal oxide support selected from alumina, titania, zirconia, cella, silica, and combinations thereof. Also provided are methods, systems, and catalytic articles incorporating or utilizing such catalyst blends.

Zeolite promoted V/TiW catalysts

An extruded, solid honeycomb body comprises a copper-promoted, small pore, crystalline molecular sieve catalyst for converting oxides of nitrogen in the presence of a reducing agent, wherein the crystalline molecular sieve contains a maximum ring size of eight tetrahedral atoms, which extruded, solid honeycomb body comprising: 20-50% by weight matrix component comprising diatomaceous earth, wherein 2-20 weight % of the extruded, solid honeycomb body is diatomaceous earth; 80-50% by weight of the small pore, crystalline molecular sieve ion-exchanged with copper; and 0-10% by weight of inorganic fibers.

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Redwitz, Germany

Joerg Werner Muench