US 7,645,718 B2Grant

Microporous crystalline material comprising a molecular sieve or zeolite having an 8-ring pore opening structure and methods of making and using same

Issue Date:2010-01-12

•30 Claims

•7 Drawing Sheets

Abstract

There is disclosed a hydrothermally stable microporous crystalline material comprising a molecular sieve or zeolite having an 8-ring pore opening structure, such as SAPO-34 or aluminosilicate zeolite, able to retain a specific percentage of its surface area and micropore volume after treatment with heat and moisture, such as at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 volume percent water vapor for a time ranging from 1 to 16 hours. Methods of using the disclosed crystalline material, such as in the SCR of NO_xin exhaust gas are also disclosed, as are methods of making such materials.

Metadata

Assignee

PQ Corporation

Inventors

Hong-Xin Li
William E. Cormier
Bjorn Moden

Application Information

Application Number:US 12/055,639

Filing Date:2008-03-26

Priority Date:2007-03-26

Art Unit:1793

Classifications

IPC:

B01J27/182

Patent Drawings (7 sheets)

Description

[0001] This application claims the benefit of domestic priority to U.S. Provisional Patent Application No. 60/907,206, filed Mar. 26, 2007, which is herein incorporated by reference in its entirety.

[0002] The present disclosure is related to hydrothermally stable microporous crystalline materials comprising a molecular sieve or zeolite having an 8-ring pore opening structure, such as SAPO-34 or aluminosilicate zeolite, that is able to retain a specific percentage of its surface area and micropore volume after treatment with heat and moisture. The present disclosure is also related to a method of making and methods of using the disclosed crystalline materials, such as in reducing contaminants in exhaust gases. Such methods include the selective catalytic reduction (“SCR”) of exhaust gases contaminated with nitrogen oxides (“NO_x”).

[0003] Microporous crystalline materials and their uses as catalysts and molecular sieve adsorbents are known in the art. Microporous crystalline materials include crystalline aluminosilicate zeolites, metal organosilicates, and aluminophosphates, among others. One catalytic use of the materials is in the SCR of NO_xwith ammonia in the presence of oxygen and in the conversion process of different feed stocks, such as an oxygenate to olefin reaction system.

[0004] Medium to large pore zeolites containing metals, such as ZSM-5 and Beta, are also known in the art for SCR of NO_xusing reductants, such as ammonia.

[0005] A class of silicon-substituted aluminophosphates, which are both crystalline and microporous and exhibit properties characteristic of both aluminosilicate zeolites and aluminophosphates, are known in the art and disclosed in U.S. Pat. No. 4,440,871. Silicoaluminophosphates (SAPOs) are synthetic materials having a three-dimensional microporous aluminophosphate crystalline framework with silicon incorporated therein. The framework structure consists of PO₂⁺, AlO₂⁻, and SiO₂tetrahedral units. The empirical chemical composition on an anhydrous basis is:
mR:(Si_xAl_yP_z)O₂
wherein, R represents at least one organic templating agent present in the intracrystalline pore system; m represents the moles of R present per mole of (Si_xAl_yP_z)O₂and has a value from zero to 0.3; and x, y, and z represent the mole fractions of silicon, aluminum, and phosphorous, respectively, present as tetrahedral oxides.

[0006] U.S. Pat. No. 4,961,917 discloses a method for the reduction of NO_xwith ammonia using a certain class of zeolite catalysts that are sulfur-tolerant, especially when the zeolites are promoted with a promoter such as iron or copper. The zeolites disclosed therein have pore diameters of at least 7 Angstroms and are selected from the groups including USY, Beta, and ZSM-20. The catalysts employed therein maintain good catalytic properties under high temperature conditions of use, from about 250-600° C.

[0007] U.S. Pat. No. 5,451,387 discloses a method for improving the reduction activity of the zeolite catalyst at temperatures below 400° C., without adversely affecting the reduction capacity above 400° C., by introducing iron into an intermediate pore size zeolite, which are identified as ZSM-5 type zeolites. U.S. Pat. No. 6,914,026 discloses an iron-promoted aluminosilicate zeolite with improved hydrothermal stability and good catalytic activity under high temperatures, e.g., 400° C. and above, in the presence of sulfur compounds. U.S. Pat. Nos. 6,689,709 and 7,118,722 disclose stabilized iron and/or copper promoted zeolite catalysts for NO_xreduction, wherein the zeolites include USY, Beta, and/or ZSM-20, and have pore diameters of at least 7 Angstroms. U.S. Pat. No. 6,890,501 discloses Beta-zeolites loaded with iron for the SCR of NO_xand N₂O with ammonia, wherein the zeolite was prepared by ion-exchange or impregnation.

[0008] U.S. Pat. No. 5,516,497 discloses a metal-promoted zeolite catalyst and a method for the catalytic reduction of NO_xwith ammonia using the catalysts in stages. The first catalyst is promoted with not more than about 1% by weight of iron and/or copper promoter, and the second catalyst is promoted with more than about 1% by weight of iron and/or copper promoter. The selectivity of the catalyst, favoring either reduction of NO_xor ammonia, can be tailored by controlling the content of the promoting metal. By utilizing suitable zeolite materials, high temperature gaseous streams, up to about 600° C., may be treated without seriously affecting the life or efficiency of the catalyst.

SUMMARY

[0009] Generally, the present disclosure provides a hydrothermally stable microporous crystalline material comprising a silicoaluminophosphate (SAPO) molecular sieve or aluminosilicate zeolite having an 8-ring pore opening structure, such as microporous crystalline compositions comprising SAPO-34, SAPO-18, and high-silica chabazite. The crystalline material according to one embodiment of the present disclosure is able to retain at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol. % water vapor for a time ranging from 1 to 16 hours.

[0010] In one embodiment, the microporous crystalline material comprises SAPO-34, having an initial surface area of at least 650 m²/g, wherein the surface area, after being treated at 700-900° C. and 10 vol. % water vapor for a time ranging from 1 to 16 hours, is at least 90% of the initial surface area.

[0011] In another aspect of the invention, a microporous crystalline material is chosen from SAPO molecular sieves and aluminosilicate zeolites having an 8-ring pore opening structure defined by the Structure Commission of the International Zeolite Association chosen from: AEI, AFT, AFX, CHA, DDR, ERI, ITE, ITW, KFI, LEV, LTA, PAU, RHO, and UFI, wherein the material retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol. % water vapor for a time ranging from 1 to 16 hours.

[0012] In another aspect of the present disclosure, the microporous crystalline materials are cation exchanged, for example exchanged with iron or copper. In one embodiment, the material, such as SAPO-34 and high-silica chabazite, is cation exchanged with iron, wherein the iron oxide comprises at least 0.20 weight percent of the total weight of the material. In another embodiment, the material, such as SAPO-34 and high-silica chabazite, is cation exchanged with copper, wherein copper oxide comprises at least 1.0 weight percent of the total weight of the material.

[0013] Other aspects of the present disclosure include methods of SCR of NO_xin exhaust gas. One such method comprises contacting, in the presence of ammonia or urea, exhaust gas with a hydrothermally stable microporous crystalline material comprising a molecular sieve or zeolite having an 8-ring pore opening structure, including SAPO-34, SAPO-18, and high-silica chabazite, wherein the crystalline material retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol. % water vapor for a time ranging from 1 to 16 hours.

[0014] Another aspect of the disclosed method comprises contacting, in the presence of ammonia or urea, exhaust gas with a microporous crystalline material chosen from molecular sieves and zeolites having an 8-ring pore opening structure defined by the Structure Commission of the International Zeolite Association chosen from: AEI, AFT, AFX, CHA, DDR, ERI, ITE, ITW, KFI, LEV, LTA, PAU, RHO, and UFI, wherein the material retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol. % water vapor for a time ranging from 1 to 16 hours.

[0015] Another aspect of the disclosed method comprises contacting, in the presence of ammonia or urea, exhaust gas with a hydrothermally stable microporous material comprising a molecular sieve or zeolite having an 8-ring pore opening structure, wherein the microporous material comprises iron and/or copper and retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol. % water vapor for up to 1 hour.

[0016] There is also disclosed a method for making a microporous crystalline material comprising a molecular sieve or zeolite having an 8-ring pore opening structure, the method comprising mixing sources of alumina, silica, and optionally phosphate in case of SAPOs, with a TEAOH solution or an organic structural directing agent (SDA) and water to form a gel, heating the gel in an autoclave at a temperature ranging from 150 to 180° C. for a time ranging from 12-60 hours to form a product, cooling and optionally washing the product in water, calcining the product to form a molecular sieve or zeolite having an 8-ring pore opening structure, wherein the crystalline material retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol. % water vapor for a time ranging from 1 to 16 hours.

[0017] Aside from the subject matter discussed above, the present disclosure includes a number of other exemplary features such as those explained hereinafter. It is to be understood that both the foregoing description and the following description are exemplary only.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The accompanying figures are incorporated in, and constitute a part of this specification.

[0019] FIG. 1 is a SEM of the SAPO-34 material described in Example 1, before aging or cation-exchange.

[0020] FIG. 2 is a SEM of the SAPO-34 material described in Example 2, before aging or cation-exchange.

[0021] FIG. 3 is a XRD of the SAPO-34 material described in Example 1, before aging or cation-exchange.

[0022] FIG. 4 is a XRD of the SAPO-34 material described in Example 2, before aging or cation-exchange.

[0023] FIG. 5 is a XRD of the Cu-exchanged SAPO-34 material described in Example 1 after hydrothermal aging at 800° C.

[0024] FIG. 6 is a XRD of the Cu-exchanged SAPO-34 material described in Example 2 after hydrothermal aging at 800° C.

[0025] FIG. 7 is a SEM of the SAPO-34 material described in Comparative Example 2, before aging or cation-exchange.

DEFINITIONS

[0026] “Hydrothermally stable” means having the ability to retain a certain percentage of initial surface area and/or microporous volume after exposure to elevated temperature and/or humidity conditions (compared to room temperature) for a certain period of time. For example, in one embodiment, it is intended to mean retaining at least 80%, such as at least 85%, at least 90%, or even at least 95%, of its surface area and micropore volume after exposure to conditions simulating those present in an automobile exhaust, such as temperatures ranging up to 900° C. in the presence of up to 10 volume percent (vol %) water vapor for times ranging from up to 1 hour, or even up to 16 hours, such as for a time ranging from 1 to 16 hours.

[0027] “Initial Surface Area” means the surface area of the freshly made crystalline material before exposing it to any aging conditions.

[0028] “Initial Micropore Volume” means the micropore volume of the freshly made crystalline material before exposing it to any aging conditions.

[0029] “Direct synthesis” (or any version thereof) refers to a method that does not require a metal-doping process after the zeolite has been formed, such as a subsequent ion-exchange or impregnation method.

[0030] “Defined by the Structure Commission of the International Zeolite Association,” is intended to mean those structures included but not limited to, the structures described in “Atlas of Zeolite Framework Types,” ed. Baerlocher et al., Sixth Revised Edition (Elsevier 2007), which is herein incorporated by reference in its entirety.

[0031] “Selective Catalytic Reduction” or “SCR” refers to the reduction of NO_x(typically with ammonia) in the presence of oxygen to form nitrogen and H₂O.

[0032] “Exhaust gas” refers to any waste gas formed in an industrial process or operation and by internal combustion engines, such as from any form of motor vehicle.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The microporous crystalline materials comprising a molecular sieve or zeolite having an 8-ring pore opening structure of the present invention exhibit good hydrothermal properties, as evidenced by the stability of the surface area and micropore volume after exposure to high temperatures and humidity. For example, after being treated at up to 900° C. in the presence of up to 10 vol % water vapor for a time ranging from 1 to 16 hours, the microporous crystalline materials of the present invention maintain at least 80% of their initial surface area. Likewise, after the treatment, the microporous crystalline materials of the present invention maintain at least 80% of their initial micropore volume.

[0034] Microporous crystalline materials of the present invention may have an initial surface area of at least 650 m²/g, such as at least 700 m²/g, or even up to 800 m²/g.

[0035] Microporous crystalline materials of the present invention may have an initial micropore volume of at least 0.25 cc/g, such as 0.30 cc/g.

[0036] The microporous crystalline materials of the present invention comprise molecular sieves or zeolites, including SAPO-34, high-silica chabazite, or those having a structure defined by the Structure Commission of the International Zeolite Association as CHA. The SAPO-34 structure of the present invention may contain SiO₂in an amount ranging from 1-20% and may have a crystal size greater than 0.3 microns. In another embodiment, the high-silica chabazite of the present invention may have a silica-to-alumina ratio (“SAR”) greater than 15, such as ranging from 15-60.

[0037] The microporous crystalline materials of the present invention also comprise SAPO molecular sieves and aluminosilicate zeolites having an 8-ring pore opening structure defined by the Structure Commission of the International Zeolite Association chosen from: AEI, AFT, AFX, CHA, DDR, ERI, ITE, ITW, KFI, LEV, LTA, PAU, RHO, and UFI. These materials also exhibit the hydrothermal stability properties described herein, such as retaining at least 80% of their initial surface area and initial micropore volume after being treated at temperatures of up to 900° C. in the presence of up to 10 vol % water vapor for a time ranging from 1 to 16 hours. These materials may be an aluminosilicate having a SAR greater than 15, such as ranging from 20-60. Alternatively, these materials may also be SAPO molecular sieve structures containing SiO₂in an amount ranging from 1-20%.

[0038] SAPO-34 compositions of the present invention exhibit good hydrothermal and thermal properties as identified herein. For example, after being treated at temperatures up to 900° C. in the presence of up to 10 vol % water vapor for 16 hours, the SAPO-34 compositions of the present invention maintain at least 80% of their initial surface area, such as at least 85%, at least 90%, or even at least 95%. Likewise, after the treatment, the SAPO-34 compositions of the present invention maintain at least 80% of their initial micropore volume, such as 85%, and even 90% of their initial micropore volume.

[0039] The microporous crystalline materials of the present invention may comprise iron and/or copper. In one embodiment, the iron and/or copper are introduced into the microporous crystalline material by liquid-phase or solid ion-exchange or incorporated by direct-synthesis.

[0040] The present invention also is directed to hydrothermally stable microporous materials comprising a molecular sieve or zeolite having an 8-ring pore opening structure for SCR of NO_xwith urea or ammonia, wherein the microporous material comprises iron and/or copper and retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. and up to 10% water for up to 1 hour. The iron oxide may comprise at least 0.20 weight percent of the total weight of the material, and the copper oxide may comprise at least 1.0 weight percent of the total weight of the material.

[0041] In SAPO-34 compositions resulting from iron cation exchange, iron oxide comprises at least 0.20 weight percent of the total weight of the composition, such as 0.25 weight percent, or even 0.30 weight percent. The resulting iron cation-exchanged SAPO-34 compositions have a surface area of at least 250 m²/g, such as at least 400 m²/g, and even at least 600 m²/g.

[0042] In SAPO-34 compositions resulting from copper cation-exchange, copper oxide comprises at least 1.90 weight percent of the total weight of the composition, such as 1.95 weight percent, and even 2.00 weight percent. The resulting copper cation-exchanged SAPO-34 compositions have a surface area of at least 550 m²/g, such as at least 600 m²/g, and even at least 650 m²/g.

[0043] The resulting cation-exchanged SAPO-34 compositions also exhibit good hydrothermal and thermal properties, as evidenced by the stability of the surface area after exposure to high temperatures and humidity. For example, after being treated at temperatures up to 900° C. in the presence of up to 10 vol % water vapor for up to 1 hour, the iron cation-exchanged SAPO-34 compositions of the present invention maintain at least 20% of their initial surface area, such as at least 40%, and even at least 60%.

[0044] The microporous crystalline materials of the present invention are useful as exhaust catalysts, such as for reduction of NO_xin automotive exhaust, in part because of their good thermal and hydrothermal stability. Under extreme conditions, automotive exhaust catalysts are exposed to heat up to and in excess of 900° C. Therefore, some automotive exhaust catalysts are required to be stable at temperatures up to and in excess of 900° C.

[0045] The present invention is also directed to a method for reduction, typically prior to discharge, of exhaust gas. As mentioned, reference to “exhaust gas” refers to any waste gas formed in an industrial process or operation and by internal combustion engines, the composition of which varies. Non-limiting examples of the types of exhaust gases that may be treated with the disclosed materials include both automotive exhaust, as well as exhaust from stationary sources, such as power plants, stationary diesel engines, and coal-fired plants.

[0046] For example, the present invention is directed to a method for SCR of exhaust gases contaminated with NO_x. The nitrogen oxides of exhaust gases are commonly NO and NO₂; however, the present invention is directed to reduction of the class of nitrogen oxides identified as NO_x. Nitrogen oxides in exhaust are reduced with ammonia to form nitrogen and water. As previously mentioned, the reduction can be catalyzed to preferentially promote the reduction of the NO_xover the oxidation of ammonia by the oxygen, hence “selective catalytic reduction.”

[0047] The inventive method for SCR of NO_xin exhaust gases comprises contacting, in the presence of ammonia or urea, exhaust gas with a hydrothermally stable microporous crystalline material comprising a molecular sieve or zeolite having an 8-ring pore opening structure, wherein the crystalline material retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol % water vapor for a time ranging from 1 to 16 hours. In one embodiment, the molecular sieves and zeolites having an 8-ring pore opening structure comprising the microporous crystalline material may be chosen from those structures defined by the Structure Commission of the International Zeolite Association as AEI, AFT, AFX, CHA, DDR, ERI, ITE, ITW, KFI, LEV, LTA, PAU, RHO, and UFI.

[0048] The inventive method of SCR of NO_xin exhaust gas also comprises contacting, in the presence of ammonia or urea, exhaust gas with a hydrothermally stable microporous material comprising a molecular sieve or zeolite having an 8-ring pore opening structure, wherein the microporous material comprises iron and/or copper and retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900° C. in the presence of up to 10 vol % water vapor for up to 1 hour.

[0049] In one embodiment, the inventive method for SCR of exhaust gases may comprise (1) adding ammonia or urea to the exhaust gas to form a gas mixture; and (2) contacting the gas mixture with a microporous crystalline composition comprising SAPO-34, having an initial surface area of at least 650 m²/g, wherein the surface area, after being treated at 700-900° C. in the presence of up to 10 vol % water vapor for a time ranging from 1 to 16 hours, is at least 80% of the initial surface area; such that the NO_xand ammonia of the gas mixture is converted to nitrogen and water. In one embodiment, the NO_xof the exhaust gas are substantially converted.

[0050] The inventive method may be performed using a microporous crystalline composition comprising SAPO-34 that has been cation exchanged with iron, wherein iron oxide is at least 0.20 weight percent of the total weight of the microporous crystalline composition, and wherein the SAPO-34 has an initial surface area of at least 250 m²/g, and wherein the surface area, after being treated at temperatures up to 900° C. in the presence of up to 10 vol % water vapor for up to 1 hour, is at least 10% of the initial surface area. Likewise, the inventive method may also be performed using a microporous crystalline composition comprising SAPO-34 cation exchanged with copper, wherein copper oxide is at least 1.0 weight percent of the total weight of the microporous crystalline composition, and wherein the SAPO-34 has an initial surface area of at least 500 m²/g, and wherein the surface area, after being treated at temperatures of up to 900° C. in the presence of up to 10 vol % water vapor for up to 1 hour, is at least 80% of the initial surface area.

[0051] It has been found that such methods result in the substantial conversion of NO_xand ammonia of the gas mixture to nitrogen and water. The microporous crystalline materials of the present invention show surprisingly high stability and high reduction of NO_xactivity over large pore zeolites.

[0052] The microporous crystalline materials of the present invention, including SAPO-34, may also be useful in the conversion of oxygenate-containing feedstock into one or more olefins in a reactor system. In particular, the compositions may be used to convert methanol to olefins.

[0053] There is also disclosed a method of making the crystalline material according to the present invention. In one embodiment, this includes mixing together an organic structural directing agent, such as a tetraethylammonium hydroxide solution (e.g., 35% TEAOH), a precursor of aluminum (e.g., pseudoboehmite alumina), and de-ionized water. To such a mixture, other known ingredients, including a source of iron or copper, if desired, and silica sol can be added while stirring, to form a gel. Crystallization seeds, such as a particular zeolite, may be added to the gel to form a desired molar composition.

[0054] The gel can then be heated in an autoclave for a time and temperature to provide a substantially pure phase composition after cooling, washing, and filtering the product. As one skilled in the art would appreciate, the product can achieve a desired SAR and/or remove organic residue upon calcination.

[0055] The present invention is also directed to a catalyst composition comprising the microporous crystalline material described herein. The catalyst composition may also be cation-exchanged, particularly with iron or copper.

[0056] In one embodiment, the present invention is directed to a catalyst composition comprising a microporous crystalline composition comprising SAPO-34 having an initial surface area of at least 650 m²/g, wherein the surface area, after being treated at temperatures of up to 900° C. in the presence of up to 10 vol % water vapor for up to 16 hours, is at least 80% of the initial surface area and a matrix material. In another aspect of the invention, the catalyst composition may comprise a cation-exchanged SAPO-34 composition, particularly with iron or copper.

[0057] Any suitable physical form of the catalyst may be utilized, including, but not limited to: a channeled or honeycombed-type body; a packed bed of balls, pebbles, pellets, tablets, extrudates or other particles; microspheres; and structural pieces, such as plates or tubes.

[0058] The invention will be further clarified by the following non-limiting examples, which are intended to be purely exemplary of the invention.

EXAMPLES

Example 1

SAPO 34—Medium, Non-Uniform Crystals

[0059] Pseudoboehmite alumina, phosphoric acid, silica sol (Ludox LS30), TEAOH solution, and deionized water were mixed together to form a gel. The gel was stirred at room temperature for about 30 min before charged to an autoclave. The autoclave was heated to 150° C. and maintained at the temperature for 60 hours. After cooling, the product was recovered by filtration and washed with deionized water. The product was then dried and calcined to remove any organic residue. The resulting product was medium, non-uniform crystals. The resulting properties are listed below in Table 1.

Example 2

SAPO-34—Large, Uniform Crystals

[0060] Pseudoboehmite alumina, phosphoric acid, silica sol (Nyacol 20₄0NH₄), TEAOH solution, and deionized water were mixed together to form a gel. The gel was stirred at room temperature for about 30 min before charged to an autoclave. The autoclave was heated to 180° C. and maintained at the temperature for 12 hours. After cooling, the product was recovered by filtration and washed with deionized water. The product was then dried and calcined to remove organic. The resulting product was large, uniform crystals. The resulting properties are listed below in Table 1.

Example 3

High-Silica Chabazite

[0061] High-silica chabazite (structure code CHA) was synthesized according to examples in U.S. Pat. No. 4,544,538, which is herein incorporated by reference. Pure CHA materials, with SAR of 30-40 were obtained. After filtering, washing, and drying, the product was calcined at 550° C. for 10 hours. To remove residual sodium, the product was slurried in 2 liters of 2 M NH₄NO₃solution and stirred at 80° C. for 2 hours. The resulting properties are listed below in Table 1.

Example 4

SAPO-18

[0062] SAPO-18 (structure code AEI) was synthesized according to the procedure outlined in J. Chen et al., Catal. Lett. 28 (1994) 241, which is herein incorporated by reference. Pseudoboehmite alumina, phosphoric acid, silica sol, N,N-diisopropylethylamine (DIPEA), and deionized water were mixed to form a gel. The gel was stirred at room temperature for 120 min before being charged to an autoclave. The autoclave was heated to 190° C. and maintained at this temperature for 48 hours. After cooling, the product was recovered by filtration and washed with deionized water. The product was then dried and calcined at 550° C. to remove organic. The resulting properties are listed below in Table 1.

Comparative Example 1

Low-Silica Chabazite

[0063] Low-silica chabazite (structure code CHA) was synthesized according to examples of U.S. Pat. No. 5,026,532, which is herein incorporated by reference. After filtering, washing, and drying, the product was calcined at 550° C. To remove residual sodium and potassium, the product was then washed in a solution containing 0.25 M HNO₃and 4 M NH₄NO₃at 80° C. for 2 hours. The resulting properties are listed below in Table 1.

Comparative Example 2

SAPO 34—Small, Non-Uniform Crystals

[0064] Al isopropoxide, phosphoric acid, tetraethyl orthosilicate, TEAOH solution, and deionized water were mixed together to form a gel with the following composition:
0.33 SiO₂: 1.0 Al₂O₃: 1.0 P₂O₅: 1.0 TEAOH:51 H₂O

[0065] The gel was stirred at room temperature for about 30 min before charged to an autoclave. The autoclave was heated to 180° C. and maintained at the temperature for 12 hours. After cooling, the product was recovered by filtration and washed with deionized water. The product was then dried and calcined to remove any organic. The resulting product was small crystals (less than 0.2 micron in size). The resulting properties are listed below in Table 1.

[0066]

	TABLE 1

					Comparative	Comparative
	Example 1	Example 2	Example 3	Example 4	Example 1	Example 2


Gel	0.4 SiO₂:	0.6 SiO₂:		0.6 SiO₂:		0.33 SiO₂:
Composition	1.0 Al₂O₃:	1.0 Al₂O₃:		1.0 Al₂O₃:		1.0 Al₂O₃:
	1.0 P₂O₅:	1.0 P₂O₅:		0.9 P₂O₅:		1.0 P₂O₅:
	1.0 TEA	0.7 TEA		1.6 DIPEA		1.0 TEA
Fresh Crystals
SiO₂/Al₂O₃			28		6.3
molar ratio
(SAR)
Surface area	677	745	798	696	577	566
(m2/g)
Micropore	0.27	0.29	0.30	0.25	0.21	0.18
volume (cc/g)
Acidity (mmol/g)	1.00	1.00	0.75		1.54	0.72
After 900° C.
10 vol % water
16 hr aging
Surface area	607	698	663			409
(m²/g)
Micropore	0.22	0.27	0.24			0.13
volume (cc/g)
Acidity (mmol/g)	0.40	0.57	0.05			0.01
Fe Ion-
exchange
Fe₂O₃wt %	0.32	0.27	1.4
Surface area	306	686	793
(m²/g)
After 900° C.
10 vol % water
16 hr aging:
Surface area	39	444	780
(m²/g)
NO_xConversion	10.7	10.2	88.7
(%) at 300° C.
NO_xConversion	25.8	35.3	90.4
(%) at 400° C.
Cu Ion-
exchange
CuO wt %	2.08	1.97	2.2	1.8	2.0
Surface area	558	681	747	669	557
(m²/g)
After 900° C.
10 vol % water
16 hr aging
Surface area	13	4	669
(m²/g)
After 700° C.
10 vol % water
16 hr aging
Surface area	544	683	762	639	10
(m²/g)

Hydrothermal Aging Tests

[0067] The foregoing samples were hydrothermally aged at temperatures ranging from 700-900° C. in the presence of 10 vol % water vapor for between 1 and 16 hours to simulate automotive exhaust aging conditions. The activities of the hydrothermally aged materials for NO_xconversion, using NH₃as reductant, were tested with a flow-through type reactor. Powder zeolite samples were pressed and sieved to 35/70 mesh and loaded into a quartz tube reactor. The gas stream conditions are set forth in Table 2. Reactor temperature was ramped and NO_xconversion was determined with an infrared analyzer at each temperature interval. The results are set forth in Table 2 below.

[0068]

TABLE 2

Ion-exchange with Cu and NO_xreduction with NH₃
	Exam-		Exam-	Exam-
	ple 1	Example 2	ple 3	ple 4

After 700° C., 10 vol % water vapor, 16 hr aging
Surface area (m²/g)	544	683	762	639
NO_xConversion at 200° C.*			97.6	92.0
NO_xConversion at 250° C.*	91.2	92.2
NO_xConversion at 300° C.*	91.3	91.8	97.9	94.2
NO_xConversion at 400° C.*	90.5	92.8	93.7	90.6
* NH₃-SCR of NO_xreaction	500 ppm NO_x; NH₃/NO = 1.0; 5 vol %
conditions:	O₂; balance N₂; SV = 50,000 h⁻¹.
After 800° C., 10 vol % water vapor, 16 hr aging
Surface area (m²/g)	517	657
NO_xConversion at 250° C.**	84.7	89.8
NO_xConversion at 300° C.**	88.9	91.3
NO_xConversion at 400° C.**	88.0	86.3
** NH₃-SCR of NO_xreaction	500 ppm NO_x; NH₃/NO = 1.0; 5 vol %
conditions:	O₂; balance N₂; SV = 100,000 h⁻¹.
After 900° C., 10 vol % water vapor, 1 hr aging
Surface area (m²/g)		632	669
NO_xConversion at 200° C.***		83.1	90.7
NO_xConversion at 300° C.***		90.6	86.9
NO_xConversion at 400° C.***		83.1	79.9
*** NH₃-SCR of NO_xreaction	500 ppm NO; NH₃/NO = 1.0; 5 vol %
conditions:	O₂; balance N₂; SV = 50,000 h⁻¹.

[0069] Unless otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention.

[0070] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope of the invention being indicated by the following claims.

Claims

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The claims shown below may not include correction changes. Use the corrected PDF for authoritative text.

What we claim is:

1. A hydrothermally stable microporous crystalline material comprising SAPO-34 having a crystal size greater than 0.3 microns, which after exposure to temperatures ranging from 700 to 900° C. in the presence of up to 10 volume percent water vapor for a time of 16 hours, retains at least 80% of its surface area and micropore volume and an acidity of at least 0.35 mmol/g.

2. A microporous crystalline material of claim 1, wherein said crystalline material comprises iron and/or copper.

3. A microporous crystalline material of claim 2, wherein said iron and/or copper are introduced into said solid by liquid-phase or solid ion-exchange or incorporated by direct-synthesis.

4. A microporous crystalline material of claim 1, wherein said SAPO-34 contains SiO₂in an amount ranging from 1-20%.

5. A microporous crystalline material of claim 1, wherein said SAPO-34 has a crystal size ranging from 0.3 to 5.0 microns.

6. A microporous crystalline material of claim 1, having an initial surface area of at least 650 m²/g.

7. A microporous crystalline material of claim 1, having an initial micropore volume of at least 0.25 cc/g.

8. A hydrothermally stable microporous crystalline material for SCR of NO_xwith urea or ammonia, wherein said crystalline material comprises iron and/or copper containing SAPO-34 having a crystal size greater than 0.3 microns which retains at least 80% of its surface area and micropore volume after exposure to temperatures of up to 900 ° C. in the presence of up to 10 volume percent water vapor for up to 1 hour.

9. A microporous crystalline material of claim 8, wherein the iron and/or copper are introduced into said material by liquid-phase or solid ion-exchange or incorporated by direct-synthesis.

10. A microporous crystalline material of claim 8, wherein said iron comprises at least 0.20 weight percent of the total weight of said material.

11. A microporous crystalline material of claim 8, wherein said copper comprises at least 1.0 weight percent of the total weight of said material.

12. A microporous crystalline material of claim 8, wherein said SAPO-34 contains 1-20% of SiO₂.

13. A method for making silicoaluminophosphate molecular sieve comprising SAPO-34, said method comprising:

mixing sources of alumina, silica, and phosphate with a TEAOH solution and water to form a gel;

heating said gel in an autoclave at a temperature ranging from 150 to 180° C. to form a product;

cooling and optionally washing said product in water;

calcining said product to form a molecular sieve comprising SAPO-34 having a crystal size greater than 0.3 microns and containing from 1-20% SiO₂, wherein said molecular sieve after exposure to temperatures ranging from 700 to 900° C. in the presence of up to 10 volume percent water vapor for 16 hours, retains at least 80% of its surface area and micropore volume and has an acidity of at least 0.35 mmol/g.

14. The method of claim 13, wherein said source of alumina is pseudoboehmite alumina.

15. The method of claim 13, wherein said source of silica is a silica sol.

16. The method of claim 13, wherein said source of phosphate is phosphoric acid.

17. The method of claim 13, further comprising a cation exchange step.

18. The method of claim 17, wherein said cation is chosen from iron and copper.

19. The method of claim 13, wherein said gel is heated in an autoclave at a temperature of 180° C.

20. A microporous crystalline material of claim 1, wherein said exposure comprises a temperature of 900° C.

21. A microporous crystalline material of claim 1, wherein said crystalline material has an acidity value of at least 0.4 mmol/g after exposure.

22. A microporous crystalline material of claim 21, wherein said crystalline material has an acidity value ranging from 0.4 to 1.00 mmol/g after exposure.

23. A microporous crystalline material of claim 1, wherein said SAPO-34 has a crystal size ranging from 0.3 to 5.0 microns.

24. A hydrothermally stable microporous crystalline material comprising SAPO-34, having a crystal size greater than 0.3 microns and an acidity of at least 0.35 mmol/g and retains at least 80% of its surface area and micropore volume after hydrothermal aging comprising exposure to temperatures ranging from 700 to 900° C. in the presence of up to 10 volume percent water vapor for a time of 1 to 16 hours.

25. A microporous crystalline material of claim 24, wherein said SAPO-34 contains SiO₂in an amount ranging from 1-20%.

26. A microporous crystalline material of claim 24, having an initial surface area of at least 650 m²/g.

27. A microporous crystalline material of claim 24, having an initial micropore volume of at least 0.25 cc/g.

28. A hydrothermally stable microporous crystalline material of claim 8, wherein said SAPO-34 has a crystal size ranging from 0.3 to 5.0 microns.

29. A microporous crystalline material of claim 2, wherein said copper comprises about 2.0 weight percent of the total weight of said material.

30. A microporous crystalline material of claim 8, wherein said copper comprises about 2.0 weight percent of the total weight of said material.

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Abstract