Facile Synthesis of KFI-type Zeolite and Its Application to Selective Catalytic Reduction of NOx with NH3

Acceleration of Zeolite Crystallization: Current Status, Mechanisms, and Perspectives

Zeolites are important classes of crystalline materials and possess well-defined channels and cages with molecular dimensions. They have been extensively employed as heterogeneous catalysts and gas adsorbents due to their relatively large specific surface areas, high pore volumes, compositional flexibility, definite acidity, and hydrothermal stability. The zeolite synthesis normally undergoes high-temperature hydrothermal treatments with a relatively long crystallization time, which exhibits low synthesis efficiency and high energy consumption. Various strategies, e.g., modulation of the synthesis gel compositions, employment of special silica/aluminum sources, addition of seeds, fluoride, hydroxyl (·OH) free radical initiators, and organic additives, regulation of the crystallization conditions, development of new approaches, etc., have been developed to overcome these obstacles. And, these achievements make prominent contributions to the topic of acceleration of the zeolite crystallization and promote the fundamental understanding of the zeolite formation mechanism. However, there is a lack of the comprehensive summary and analysis on them. Herein, we provide an overview of the recent achievements, highlight the significant progress in the past decades on the developments of novel and remarkable strategies to accelerate the crystallization of zeolites, and basically divide them into three main types, i.e., chemical methods, physical methods, and the derived new approaches. The principles/acceleration mechanisms, effectiveness, versatility, and degree of reality for the corresponding approaches are thoroughly discussed and summarized. Finally, the rational design of the prospective strategies for the fast synthesis of zeolites is commented on and envisioned. The information gathered here is expected to provide solid guidance for developing a more effective route to improve the zeolite crystallization and obtain the functional zeolite-based materials with more shortened durations and lowered cost and further promote their applications.

Efficient Pt/KFI zeolite catalysts for the selective catalytic reduction of NOx by hydrogen

Aiming at purification of NOx from hydrogen internal combustion engines (HICEs), the hydrogen selective catalytic reduction (H2-SCR) reaction was investigated over a series of Pt/KFI zeolite catalysts. H2 can readily reduce NOx to N2 and N2O while O2 inhibited the deNOx efficiency by consuming the reductant H2. The Pt/KFI zeolite catalysts with Pt loading below 0.1 wt.% are optimized H2-SCR catalysts due to its suitable operation temperature window since high Pt loading favors the H2-O2 reaction which lead to the insufficient of reactants. Compared to metal Pt0 species, Ptδ+ species showed lower activation energy of H2-SCR reaction and thought to be as reasonable active sites. Further, Eley-Rideal (E-R) reaction mechanism was proposed as evidenced by the reaction orders in kinetic studies. Last, the optimized reactor was designed with hybrid Pt/KFI catalysts with various Pt loading which achieve a high NOx conversion in a wide temperature range.

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.

Insights into SO2 Poisoning Mechanisms of Fresh and Hydrothermally Aged Cu-KFI Catalysts for NH3-SCR Reaction

The complex poisoning of Cu-KFI catalysts by SO₂ and hydrothermal aging (HTA) was investigated. The low-temperature activity of Cu-KFI catalysts was restrained by the formation of H₂SO₄ and then CuSO₄ after sulfur poisoning. Hydrothermally aged Cu-KFI exhibited better SO₂ resistance than fresh Cu-KFI since HTA significantly reduced the number of Brønsted acid sites, which were considered to be the H₂SO₄ storage sites. The high-temperature activity of SO₂-poisoned Cu-KFI was basically unchanged compared to the fresh catalyst. However, SO₂ poisoning promoted the high-temperature activity of hydrothermally aged Cu-KFI since it triggered CuOx into CuSO₄ species, which was considered as an important role in the NH₃-SCR reaction at high temperatures. In addition, hydrothermally aged Cu-KFI catalysts were more easily regenerated after SO₂ poisoning than fresh Cu-KFI on account of the instability of CuSO₄.

Si/Al Ratio Determines the SCR Performance of Cu-SSZ-13 Catalysts in the Presence of NO2

A comparative study was performed to investigate the NH₃-selective catalytic reduction (SCR) reaction activity of Cu-SSZ-13 zeolites having Si/Al ratios (SARs) of 5, 18, and 30. Remarkably, the Cu-SSZ-13 zeolite catalysts exhibited completely opposite behaviors as a function of SAR under standard SCR (SSCR) and fast SCR (FSCR) reaction atmospheres. Under SSCR conditions, the NO_x conversion increased as expected with the decreasing SAR. Under FSCR conditions, however, the NO_x conversion decreased as the SAR decreased, contrary to expectations. In this study, based on characterization of the catalysts by X-ray diffraction, transmission electron microscopy, electron paramagnetic resonance, H₂-temperature-programmed reduction, temperature-programmed desorption, and diffuse reflectance infrared Fourier transform spectroscopy, together with theoretical calculations, the authors found that the amount of Brønsted acid sites goes up while the SAR goes down, leading to an increase in the accumulation of NH₄NO₃ under FSCR reaction conditions. Moreover, the accumulated NH₄NO₃ is of greater stability for those low SAR Cu-SSZ-13 catalysts. These two reasons cause the FSCR performance of Cu-SSZ-13 to decrease with a decrease in SAR. As a result, the NO₂ effect on SCR activity changes from promotion to inhibition as the SAR decreases.

Understanding the Anion-Templated, OSDA-Free, Interzeolite Conversion Synthesis of High Silica Zeolite ZK-5

High silica zeolite ZK-5 (framework Si/Al=4.8) has been prepared by interzeolite conversion from ultrastable zeolite Y via a co-templating route using alkali metal cations and nitrate anions but without organic structure directing agents. The mechanism, which involves zeolite framework - alkali metal cation - nitrate anion ordering, has been established by a combination of chemical and thermal analyses, Raman spectroscopy, computational modelling, and X-ray powder diffraction. Ammonium exchange gives ZK-5 with occluded ammonium nitrate and subsequent heating gives microporous zeolite ZK-5.

Metal Sites in Zeolites: Synthesis, Characterization, and Catalysis

Zeolites with ordered microporous systems, distinct framework topologies, good spatial nanoconfinement effects, and superior (hydro)thermal stability are an ideal scaffold for planting diverse active metal species, including single sites, clusters, and nanoparticles in the framework and framework-associated sites and extra-framework positions, thus affording the metal-in-zeolite catalysts outstanding activity, unique shape selectivity, and enhanced stability and recyclability in the processes of Brønsted acid-, Lewis acid-, and extra-framework metal-catalyzed reactions. Especially, thanks to the advances in zeolite synthesis and characterization techniques in recent years, zeolite-confined extra-framework metal catalysts (denoted as metal@zeolite composites) have experienced rapid development in heterogeneous catalysis, owing to the combination of the merits of both active metal sites and zeolite intrinsic properties. In this review, we will present the recent developments of synthesis strategies for incorporating and tailoring of active metal sites in zeolites and advanced characterization techniques for identification of the location, distribution, and coordination environment of metal species in zeolites. Furthermore, the catalytic applications of metal-in-zeolite catalysts are demonstrated, with an emphasis on the metal@zeolite composites in hydrogenation, dehydrogenation, and oxidation reactions. Finally, we point out the current challenges and future perspectives on precise synthesis, atomic level identification, and practical application of the metal-in-zeolite catalyst system.

Comparison of Industrial and Lab-Scale Ion Exchange for the DeNOx-SCR Performance of Cu Chabazites: A Case Study

The efficiency and robustness of selective catalytic reduction (SCR) by NH3 catalysts for exhaust gas purification, especially of heavy-duty diesel engines, will continue to play a major role, despite the increasing electrification of powertrains. With that in mind, the effect of the synthesis scale on commercially available Cu-exchanged chabazite catalysts for SCR was investigated through physicochemical characterizations and catalytic tests. During hydrothermal aging, both industrial and lab-scale prepared catalysts underwent structural dealumination of the zeolite framework and redistribution of the Al sites. Although both catalysts demonstrated similar NO conversion activity under SCR conditions, the lab-scale catalyst showed higher selectivity and lower activity in NH3 oxidation. Variations in N2O formation and NH3 oxidation rate were found to correlate with the formation of different copper species, and the compositions become less controllable in industrial-scale process. This case study focused on routes of ion exchange, and the results provide new insights into catalytic performance of the industrially-produced zeolites.

Selective catalytic reduction of NOx with ammonia (NH3-SCR) over copper loaded LEV type zeolites synthesized with different templates

LEV type zeolites were synthesized with four different structure-directing agents and converted to copper loaded NH₃-SCR catalysts. The synthesis recipe was found to impact the respective Al population in the two topologically different framework sites in double and single 6-rings, resolvable by ²⁷Al MAS NMR spectroscopy. Hydrothermal stability was found to be related to the silanol concentration, Si/Al ratio, particle size, crystal morphology, crystal defects, external surface area, and microporosity. Catalytic activity in NH₃-SCR was dependent on preferential Al siting in the double 6-rings. Levinite synthesized using adamantylamine showed the strongest preference for Al atoms sitting in double 6-ring sites, and showed the highest catalytic turnover frequency. Unfortunately, because of the large crystal size, copper loading of this sample was limited to 0.6 wt% while other samples could be loaded with copper up to 3.3 wt%. An optimum combination of hydrothermal stability and catalytic activity was obtained with N,N'-bis-dimethylpentanediyldiammonium dibromide as structure-directing agent.

Exclusive SAPO-seeded synthesis of ZK-5 zeolite for selective synthesis of methylamines

ZK-5 zeolite with superior selectivity for monomethylamine (MMA) plus dimethylamine (DMA) is fast synthesized using the exclusive silicoaluminophosphate SAPO-34 seed and K+ and Na+ cations.

Selective catalytic reduction of NO x with NH3: opportunities and challenges of Cu-based small-pore zeolites

Zeolites, as efficient and stable catalysts, are widely used in the environmental catalysis field. Typically, Cu-SSZ-13 with small-pore structure shows excellent catalytic activity for selective catalytic reduction of NO _x with ammonia (NH₃-SCR) as well as high hydrothermal stability. This review summarizes major advances in Cu-SSZ-13 applied to the NH₃-SCR reaction, including the state of copper species, standard and fast SCR reaction mechanism, hydrothermal deactivation mechanism, poisoning resistance and synthetic methodology. The review gives a valuable summary of new insights into the matching between SCR catalyst design principles and the characteristics of Cu²⁺-exchanged zeolitic catalysts, highlighting the significant opportunity presented by zeolite-based catalysts. Principles for designing zeolites with excellent NH₃-SCR performance and hydrothermal stability are proposed. On the basis of these principles, more hydrothermally stable Cu-AEI and Cu-LTA zeolites are elaborated as well as other alternative zeolites applied to NH₃-SCR. Finally, we call attention to the challenges facing Cu-based small-pore zeolites that still need to be addressed.

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.

Recent progress in the improvement of hydrothermal stability of zeolites

Zeolites have been successfully employed in many catalytic reactions of industrial relevance. The severe conditions required in some processes, where high temperatures are frequently combined with the presence of steam, highlight the need of considering the evolution of the catalyst structure during the reaction. This review attempts to summarize the recently developed strategies to improve the hydrothermal framework stability of zeolites.

Simple physical mixing of zeolite prevents sulfur deactivation of vanadia catalysts for NOx removal

NOx abatement has been an indispensable part of environmental catalysis for decades. Selective catalytic reduction with ammonia using V2O5/TiO2 is an important technology for removing NOx emitted from industrial facilities. However, it has been a huge challenge for the catalyst to operate at low temperatures, because ammonium bisulfate (ABS) forms and causes deactivation by blocking the pores of the catalyst. Here, we report that physically mixed H-Y zeolite effectively protects vanadium active sites by trapping ABS in micropores. The mixed catalysts operate stably at a low temperature of 220 °C, which is below the dew point of ABS. The sulfur resistance of this system is fully maintained during repeated aging/regeneration cycles because the trapped ABS easily decomposes at 350 °C. Further investigations reveal that the pore structure and the amount of framework Al determined the trapping ability of various zeolites.

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.

Promoting Effect of Mn on In Situ Synthesized Cu-SSZ-13 for NH3-SCR

The effect of Mn impregnation on the NH3-SCR (selective catalytic reduction of NOx by NH3) activity of in situ synthesized Cu-SSZ-13 was investigated in this work. It was found that Mn addition could efficiently improve the low-temperature activity of Cu-SSZ-13. The optimal amount of Mn was 5 wt.%, and NOx conversion was improved by more than 20% over a temperature range of 120 °C to 150 °C. SEM (scanning electron microscopy), XRD (X-ray diffraction), N2 adsorption-desorption, H2-TPR (temperature programmed reduction of H2), NH3-TPD (temperature programmed desorption of NH3) and in situ DRIFTS (diffuse reflectance infrared Fourier transform spectroscopy) experiments were conducted to investigate the changes in the zeolite structure, active sites, acid sites and reaction mechanism. The impregnated MnOx species caused a decline in the crystallinity of Cu-SSZ-13 but markedly improved the redox ability. Nitrate and nitrite species were observed in the Mn-modified Cu-SSZ-13, and the formation of these species was thought to cause the observed increase in low-temperature NH3-SCR activity. The results show that the addition of Mn is a promising method for promoting the low-temperature catalytic activity of Cu-SSZ-13.

Single-Atom Catalysts Supported by Crystalline Porous Materials: Views from the Inside

Single-atom catalysts (SACs) have recently emerged as an exciting system in heterogeneous catalysis showing outstanding performance in many catalytic reactions. Single-atom catalytic sites alone are not stable and thus require stabilization from substrates. Crystalline porous materials such as zeolites and metal-organic frameworks (MOFs) are excellent substrates for SACs, offering high stability with the potential to further enhance their performance due to synergistic effects. This review features recent work on the structure, electronic, and catalytic properties of zeolite and MOF-protected SACs, offering atomic-scale views from the "inside" thanks to the subatomic resolution of synchrotron X-ray absorption spectroscopy (XAS). The extended X-ray absorption fine structure and associated methods will be shown to be powerful tools in identifying the single-atom site and can provide details into the coordination environment and bonding disorder of SACs. The X-ray absorption near-edge structure will be demonstrated as a valuable method in probing the electronic properties of SACs by analyzing the white line intensity, absorption edge shift, and pre-/postedge features. Emphasis is also placed on in situ/operando XAS using state-of-the-art equipment, which can unveil the changes in structure and properties of SACs during the dynamic catalytic processes in a highly sensitive and time-resolved manner.

Effects of SO2 on Cu-SSZ-39 catalyst for the selective catalytic reduction of NOx with NH3

The impact of SO₂ on Cu-SSZ-39 was firstly investigated, and sulfation mechanism at different temperature was proposed.

Direct Synthesis of Aluminosilicate SSZ-39 Zeolite Using Colloidal Silica as a Starting Source

For the first time, SSZ-39 zeolite has been directly prepared using conventional colloidal silica and sodium aluminate instead of using FAU zeolite as the raw material in the alkaline media. The adjustment of the Si/Al ratios in the starting materials to the suitable values is a key factor to prepare the aluminosilicate SSZ-39 zeolite. Various characterizations (for instance, X-ray diffraction, scanning electron microscopy, nitrogen sorption, solid ²⁷Al NMR, and NH₃-temperature-programmed desorption) display that the aluminosilicate SSZ-39 zeolite owns high crystallinity, uniform cuboid morphology, large surface area, four-coordinated aluminum species, and strong acidic sites. Inductively coupled plasma analysis shows that the SiO₂/Al₂O₃ ratios of the SSZ-39 products are ranged from 12.8 to 16.8. Considering the special framework of the SSZ-39 zeolite, the yield of this synthesis is not higher than 21.3%. Moreover, the catalytic performance of Cu-SSZ-39 catalyst synthesized from this route is excellent in the selective catalytic reduction of NO _x with NH₃ (NH₃-SCR).

Strategies to control zeolite particle morphology

Methods to synthesize zeolites with different crystal habits and assemble zeolite crystals into specific structures are reviewed for the rational design of zeolite particle morphologies.

Cu-exchanged RTH-type zeolites for NH3-selective catalytic reduction of NOx: Cu distribution and hydrothermal stability

The Cu-exchanged RTH-type zeolites (Cu-RTH) were applied in ammonia-selective catalytic reduction (NH₃-SCR) of NO_x.

Barium-promoted hydrothermal stability of monolithic Cu/BEA catalyst for NH3-SCR

As a promising candidate for NOx elimination from the emission of diesel engines, the enhancement effect of Ba on the hydrothermal stability of cordierite supported CuBa/BEA at 600 °C for 48 h was investigated by XRD, NH3-TPD, H2-TPR, XPS, EPR, TEM and in situ DRIFTS. Different properties and amounts of active species are significant factors contributing to the enhanced hydrothermal stability of CuBa/BEA-HT. CuBa/BEA-HT has more Cu2+/Cu+ redox-couples and stronger interactions than Cu/BEA-HT, indicating an excellent redox property of the active species in CuBa/BEA-HT. The better redox property of CuBa/BEA-HT produces more nitrates that easily participate in the NH3-SCR reaction, which enhances the low-temperature activity. Furthermore, as observed from EPR and H2-TPR, the appearance of more isolated Cu2+ species and fewer CuO species also contribute to the higher hydrothermal stability of CuBa/BEA-HT.

Small-Pore Zeolites: Synthesis and Catalysis

In the past decade or so, small-pore zeolites have received greater attention than large- and medium-pore molecular sieves that have historically dominated the literature. This is primarily due to the commercialization of two major catalytic processes, NOx exhaust removal and methanol conversion to light olefins, that take advantage of the properties of these materials with smaller apertures. Small-pore zeolites possess pores that are constructed of eight tetrahedral atoms (Si⁴⁺ and Al³⁺), each time linked by a shared oxygen These eight-member ring pores (8MR) provide small molecules access to the intracrystalline void space, e.g., to NOx during car exhaust cleaning (NOx removal) or to methanol en route to its conversion into light olefins, while restricting larger molecule entrance and departure that is critical to overall catalyst performance. In total, there are forty-four structurally different small-pore zeolites. Forty-one of these zeolites can be synthesized, and the first synthetic zeolite (KFI, 1948) was in fact a small-pore material. Although the field of 8MR zeolite chemistry has expanded in many directions, the progress in synthesis is framework-specific, leaving insights and generalizations difficult to realize. This review first focuses on the relevant synthesis details of all 8MR zeolites and provides some generalized findings and related insights. Next, catalytic applications where 8MR zeolites either have been commercialized or have dominated investigations are presented, with the aim of providing structure-activity relationships. The review ends with a summary that discusses (i) both synthetic and catalytic progress, (ii) a list of opportunities in the 8MR zeolite field, and (iii) a brief future outlook.