Understanding the high hydrothermal stability and NH3-SCR activity of the fast-synthesized ERI zeolite

Synthesis and Structural Analysis of High-Silica ERI Zeolite with Spatially-Biased Al Distribution as a Promising NH3-SCR Catalyst

Erionite (ERI) zeolite has recently attracted considerable attention for its application prospect in the selective catalytic reduction of NOx with NH3 (NH3-SCR), provided that the high-silica (Si/Al > 5.5) analog with improved hydrothermal stability can be facilely synthesized. In this work, ERI zeolites with different Si/Al ratios (4.6, 6.4, and 9.1) are synthesized through an ultrafast route, and in particular, a high-silica ERI zeolite with a Si/Al ratio of 9.1 is obtained by using faujasite (FAU) as a starting material. The solid-state 29Si MAS NMR spectroscopic study in combination with a computational simulation allows for figuring out the atomic configurations of the Al species in the three ERI zeolites. It is revealed that the ERI zeolite with the highest Si/Al ratio (ERI-9.1, where the number indicates the Si/Al ratio) exhibits a biased Al occupancy at T1 site, which is possibly due to the presence of a higher fraction of the residual potassium cations in the can cages. In contrast, the Al siting in ERI-4.6 and ERI-6.4 proves to be relatively random.

Cu-OFF/ERI Zeolite: Intergrowth Structure Synergistically Boosting Selective Catalytic Reduction of NOx with NH3

Cu-SSZ-13 has been commercialized for selective catalytic reduction with ammonia (NH3-SCR) to remove NOx from diesel exhaust. As its synthesis usually requires toxic and costly organic templates, the discovery of alternative Cu-based zeolite catalysts with organotemplate-free synthesis and comparable or even superior NH3-SCR activity to that of Cu-SSZ-13 is of great academic and industrial significance. Herein, we demonstrated that Cu-T with an intergrowth structure of offretite (OFF) and erionite (ERI) synthesized by an organotemplate-free method showed better catalytic performance than Cu-ERI and Cu-OFF as well as Cu-SSZ-13. Structure characterizations and density functional theory calculations indicated that the intergrowth structure promoted more isolated Cu2+ located at the 6MR of the intergrowth interface, resulting in a better hydrothermal stability of Cu-T than Cu-ERI and Cu-OFF. Strikingly, the low-temperature activity of Cu-T significantly increased after hydrothermal aging, while that of Cu-ERI and Cu-OFF substantially decreased. Based on in situ diffuse reflectance infrared Fourier transform spectra analysis and density functional theory calculations, the reason can be attributed to the fact that NH4NO3 formed on the CuxOy species within ERI polymorph of Cu-T underwent a fast SCR reaction pathway with the assistance of Brønsted acid sites at the intergrowth interfaces under standard SCR reaction conditions. Significantly, Cu-T exhibited a wider temperature window at a catalytic activity of over 90% than Cu-SSZ-13 (175-550 vs 175-500 °C for fresh and 225-500 vs 250-400 °C for hydrothermal treatment). This work provides a new direction for the design of high-performance NH3-SCR catalysts in terms of the interplay of the intergrowth structure of zeolites.

One-Pot Synthesis of CHA/ERI-Type Zeolite Intergrowth from a Single Multiselective Organic Structure-Directing Agent

We report the one-pot synthesis of a chabazite (CHA)/erionite (ERI)-type zeolite intergrowth structure characterized by adjustable extents of intergrowth enrichment and Si/Al molar ratios. This method utilizes readily synthesizable 6-azaspiro[5.6]dodecan-6-ium as the exclusive organic structure-directing agent (OSDA) within a potassium-dominant environment. High-throughput simulations were used to accurately determine the templating energy and molecular shape, facilitating the selection of an optimally biselective OSDA from among thousands of prospective candidates. The coexistence of the crystal phases, forming a distinct structure comprising disk-like CHA regions bridged by ERI-rich pillars, was corroborated via rigorous powder X-ray diffraction and integrated differential-phase contrast scanning transmission electron microscopy (iDPC S/TEM) analyses. iDPC S/TEM imaging further revealed the presence of single offretite layers dispersed within the ERI phase. The ratio of crystal phases between CHA and ERI in this type of intergrowth could be varied systematically by changing both the OSDA/Si and K/Si ratios. Two intergrown zeolite samples with different Si/Al molar ratios were tested for the selective catalytic reduction (SCR) of NOx with NH3, showing competitive catalytic performance and hydrothermal stability compared to that of the industry-standard commercial NH3-SCR catalyst, Cu-SSZ-13, prevalent in automotive applications. Collectively, this work underscores the potential of our approach for the synthesis and optimization of adjustable intergrown zeolite structures, offering competitive alternatives for key industrial processes.

Fabrication of wide temperature FexCe1-xVO4 modified TiO2-graphene catalyst with excellent NH3-SCR performance and strong SO2/H2O tolerance

Selective catalytic reduction of NO with NH₃ (NH₃-SCR) is one of the most common technique for elimination of NO_x. The promotional effect of Fe additive on the NH₃-SCR activity of the CeVO₄/TiO₂-graphene (GE) is systematically studied. The results exhibited that the low-temperature NO_x conversion could be enhanced dramatically via the addition of Fe and Fe_0.5Ce_0.5VO₄/TiO₂-GE displayed the highest conversion of NO_x in the wide temperature window (200-400 °C). It is because that Fe³⁺ + Ce³⁺ ↔ Fe²⁺ + Ce⁴⁺ facilitated the oxidization of NO to NO₂ at low temperature and led to the "Fast SCR," thereby raising the SCR performance. What is more, the introduction of Fe enhanced redox ability, the surface relative percentage of Ce³⁺, V⁵⁺ and the chemical adsorbed oxygen. Furthermore, the high surface concentration of Ce³⁺ species can produce more active oxygen and leads to the "Fast SCR" reaction. In addition, the Fe_0.5Ce_0.5VO₄/TiO₂-GE catalyst showed excellent H₂O/SO₂ tolerance, which may be due to the decomposition of ammonium bisulphite under high temperature and the hydrophobicity of graphene. What is more, it displayed outstanding the stability. This work would provide theoretical reference for the practical application of NO_x abatement via NH₃-SCR.

Physicochemical Features and NH3-SCR Catalytic Performance of Natural Zeolite Modified with Iron—The Effect of Fe Loading

In modern dual-pressure nitric acid plants, the tail gas temperature usually exceeds 300 °C. The NH3-SCR catalyst used in this temperature range must be resistant to thermal deactivation, so commercial vanadium-based systems, such as V2O5-WO3 (MoO3)-TiO2, are most commonly used. However, selectivity of this material significantly decreases above 350 °C due to the increase in the rate of side reactions, such as oxidation of ammonia to NO and formation of N2O. Moreover, vanadium compounds are toxic for the environment. Thus, management of the used catalyst is complicated. One of the alternatives to commercial V2O5-TiO2 catalysts are natural zeolites. These materials are abundant in the environment and are thus relatively cheap and easily accessible. Therefore, the aim of the study was to design a novel iron-modified zeolite catalyst for the reduction of NOx emission from dual-pressure nitric acid plants via NH3-SCR. The aim of the study was to determine the influence of iron loading in the natural zeolite-supported catalyst on its catalytic performance in NOx conversion. The investigated support was firstly formed into pellets and then impregnated with various contents of Fe precursor. Physicochemical characteristics of the catalyst were determined by XRF, XRD, low-temperature N2 sorption, FT-IR, and UV–Vis. The catalytic performance of the catalyst formed into pellets was tested on a laboratory scale within the range of 250–450 °C using tail gases from a pilot nitric acid plant. The results of this study indicated that the presence of various iron species, including natural isolated Fe3+ and the introduced FexOy oligomers, contributed to efficient NOx reduction, especially in the high-temperature range, where the NOx conversion rate exceeded 90%.

Dealumination of small-pore zeolites through pore-opening migration process with the aid of pore-filler stabilization

Small-pore zeolites are gaining increasing attention owing to their superior catalytic performance. Despite being critical for the catalytic activity and lifetime, postsynthetic tuning of bulk Si/Al ratios of small-pore zeolites has not been achieved with well-preserved crystallinity because of the limited mass transfer of aluminum species through narrow micropores. Here, we demonstrate a postsynthetic approach to tune the composition of small-pore zeolites using a previously unexplored strategy named pore-opening migration process (POMP). Acid treatment assisted by stabilization of the zeolite framework by organic cations in pores is proven to be successful for the removal of Al species from zeolite via POMP. Furthermore, the dealuminated AFX zeolite is treated via defect healing, which yields superior hydrothermal stability against severe steam conditions. Our findings could facilitate industrial applications of small-pore zeolites via aluminum content control and defect healing and could elucidate the structural reconstruction and arrangement processes for inorganic microporous materials.

Insight into the promoting effect of support pretreatment with sulfate acid on selective catalytic reduction performance of CeO2/ZrO2 catalysts

In this paper, sulfated ZrO₂ were synthesized via precipitation and impregnation method, and the promoting effects of support sulfation on selective catalytic reduction (SCR) performance of CeO₂/ZrO₂ catalysts were investigated. The results revealed that sulfated ZrO₂ could significantly enhance the SCR activity of CeO₂/ZrO₂ catalysts in a wide temperature range. Especially when S/Zr molar ratio was 0.1, CeO₂/ZrO₂-0.1S catalyst exhibited a large operating temperature window of 251 ∼ 500 °C and its N₂ selectivity was 100 % in the temperature range of 150 ∼ 500 °C. Moreover, CeO₂/ZrO₂-0.1S catalyst possessed a superior low-temperature activity over 0.1S-CeO₂/ZrO₂ catalyst. After exposing to 100 ppm SO₂ for 15 h, a high NO conversion efficiency of CeO₂/ZrO₂-0.1S catalyst (90.7 %) could still be reached. The characterization results indicated that ZrO₂ treated with a proper dosage of sulfate acid was beneficial to enlarge the specific surface area greatly. Sulfated ZrO₂ was also in favor of promoting the transformation of CeO₂ from crystalline state to highly-dispersed amorphous state, and inhibiting the transformation of ZrO₂ from tetragonal to monoclinic phase. It could also enhance the total surface acidity greatly with an increase in both Brønsted acid sites and Lewis acid sites, thus significantly improving NH₃ adsorption on catalyst surface. Besides, the promoting effect of support sulfation on SCR performance of CeO₂/ZrO₂ catalysts was also related with the enhanced redox property, higher Ce³⁺/(Ce³⁺+Ce⁴⁺) ratio and abundant surface chemisorbed labile oxygen. The in-situ DRIFTS results implied that nitrate species coordinated on the surface of CeO₂/ZrO₂-0.1S catalyst could participate in the Selective catalytic reduction with ammonia (NH₃-SCR) reactions at either medium or high temperature, suggesting that both Eley-Rideal (E-R) and Langmuir-Hinshelwood (L-H) mechanisms might be followed in SCR reactions.

Fe and Mn mixed oxide catalysts supported on Sn-modified TiO2 for the selective catalytic reduction of NO with NH3 at low temperature

FeMn/SnxTiO2 catalysts were synthesized by introducing Sn as an additive to modify TiO2 supports, and the Sn doping could improve the SO2 tolerance and low-temperature SCR activity significantly.

Advances in Catalytic Applications of Zeolite-Supported Metal Catalysts

Zeolites possessing large specific surface areas, ordered micropores, and adjustable acidity/basicity have emerged as ideal supports to immobilize metal species with small sizes and high dispersities. In recent years, the zeolite-supported metal catalysts have been widely used in diverse catalytic processes, showing excellent activity, superior thermal/hydrothermal stability, and unique shape-selectivity. In this review, a comprehensive summary of the state-of-the-art achievements in catalytic applications of zeolite-supported metal catalysts are presented for important heterogeneous catalytic processes in the last five years, mainly including 1) the hydrogenation reactions (e.g., CO/CO₂ hydrogenation, hydrogenation of unsaturated compounds, and hydrogenation of nitrogenous compounds); 2) dehydrogenation reactions (e.g., alkane dehydrogenation and dehydrogenation of chemical hydrogen storage materials); 3) oxidation reactions (e.g., CO oxidation, methane oxidation, and alkene epoxidation); and 4) other reactions (e.g., hydroisomerization reaction and selective catalytic reduction of NO_x with ammonia reaction). Finally, some current limitations and future perspectives on the challenge and opportunity for this subject are pointed out. It is believed that this review will inspire more innovative research on the synthesis and catalysis of zeolite-supported metal catalysts and promote their future developments to meet the emerging demands for practical applications.

Insight into the Promoting Role of Er Modification on SO2 Resistance for NH3-SCR at Low Temperature over FeMn/TiO2 Catalysts

Er-modified FeMn/TiO2 catalysts were prepared through the wet impregnation method, and their NH3-SCR activities were tested. The results showed that Er modification could obviously promote SO2 resistance of FeMn/TiO2 catalysts at a low temperature. The promoting effect and mechanism were explored in detail using various techniques, such as BET, XRD, H2-TPR, XPS, TG, and in-situ DRIFTS. The characterization results indicated that Er modification on FeMn/TiO2 catalysts could increase the Mn4+ concentration and surface chemisorbed labile oxygen ratio, which was favorable for NO oxidation to NO2, further accelerating low-temperature SCR activity through the “fast SCR” reaction. As fast SCR reaction could accelerate the consumption of adsorbed NH3 species, it would benefit to restrain the competitive adsorption of SO2 and limit the reaction between adsorbed SO2 and NH3 species. XPS results indicated that ammonium sulfates and Mn sulfates formed were found on Er-modified FeMn/TiO2 catalyst surface seemed much less than those on FeMn/TiO2 catalyst surface, suggested that Er modification was helpful for reducing the generation or deposition of sulfate salts on the catalyst surface. According to in-situ DRIFTS the results of, the presence of SO2 in feeding gas imposed a stronger impact on the NO adsorption than NH3 adsorption on Lewis acid sites of Er-modified FeMn/TiO2 catalysts, gradually making NH3-SCR reaction to proceed in E–R mechanism rather than L–H mechanism.

High NH3-SCR reaction rate with low dependence on O2 partial pressure over Al-rich Cu-*BEA zeolite

Dependence of NH₃-SCR reaction rate on O₂ partial pressure was investigated at 473 K over Cu ion-exchanged MOR, MFI, CHA and *BEA zeolites with varying “Cu density in micropores”. Among the zeolites, Cu–*BEA zeolite demonstrated promising potential as an effective catalyst for NH₃-SCR over a wide range of O₂ partial pressure.

It was revealed that Al-rich Cu–*BEA zeolite exhibit high reaction rate for NH₃-SCR at 473 K in low P_O2 reaction condition.

Kinetic and spectroscopic insights into the behaviour of Cu active site for NH3-SCR over zeolites with several topologies

Zeolite topology has a great effect on the dependence of NH₃-SCR rates over Cu–zeolites at 473 K on Cu density. It is revealed by the time-resolved UV-vis measurements that zeolites mainly affect the oxidation property of Cu ion by O₂.