WO2004022229A1 - Novel catalyst for selective nox reduction using hydrocarbons - Google Patents

Abstract

A two phase catalyst is disclosed with one or more transition metals such as Cu, Co, Fe, Ag and Mo supported on a molecular sieve having a pore size not greater than 8 Å along with a stabilized oxide of one or more of the oxides of Zr, Mo, V, Nb or the rare earths coating the molecular sieve. A method of preparing the two phase catalyst and using same to remediate NOx in combustion gases is also described.

Description

NOVEL CATALYST FOR SELECTIVE NO_x

REDUCTION USING HYDROCARBONS

CONTRACTUAL ORIGIN OF THE INVENTION

The United States Government has rights in this invention pursuant to Contract No. W-31-109-ENG-38 between the U.S. Department of Energy (DOE) and The University of Chicago representing Argonne National Laboratory.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application serial no.09/975,708 filed October 11 , 2001.

FIELD OF THE INVENTION

The present invention relates to the reduction of nitrogen oxides (NO_x) present in a lean burn exhaust by the selective catalyst reduction of NO_x by a hydrocarbon with a bifunctional catalyst.

BACKGROUND OF THE INVENTION

The combustion of fossil fuels unavoidably leads to the formation of nitrogen oxides (NO_x) which, if released to the atmosphere, can lead to acid rain and detrimental interactions with ozone. Increasing government regulations around the world have called for continued NO_x emission reductions from both stationary and mobile sources, requiring new and improved technologies that can remove NO_x from exhaust streams. While three-way catalysts have been optimized to reduce NO_x emissions in rich-burn exhaust as from consumer automobiles, these catalysts are ineffective under lean-burn conditions, as usually observed with stationary sources or diesel engines. Reduction of NO_x with ammonia has been used industrially for stationary sources. However, it is less desirable (especially in transportation systems) due to the toxic nature of the ammonia which must be stored locally. Alternative catalytic processes have been investigated for operation under lean burn conditions, with the selective catalytic reduction (SCR) of NO_x with hydrocarbons being one of the most promising. These hydrocarbons are more readily available and pose less of a emission problem.

A large number of materials have been found to be catalyticly active for SCR. By far, the most widely reported in the open literature are metal-exchanged zeolites, such as Cu-ZSM-5, Co-ZSM-5, and Fe-ZSM-5. These have been found to be very active for SCR using C₃ hydrocarbons, with Cu-ZSM-5 being the most active. However, the zeolite-based materials lose much of their activity when water (common in exhaust streams) is added to the exhaust stream. The exact effects of water are not well known; it is speculated that either dealumination of the zeolite framework occurs which reduces the number of active sites, or that the metal sites agglomerate or are over-oxidized and lose their activity. While other catalysts that possess greater water stability have been found, such as metal-supported oxides, these tend to lack the desired activity seen by the metal zeolites, and produce large amounts of N₂O (also a major pollutant).

Patents which have varying relationships to the inventions at issue are, for instance, U.S. patent no. 5,116,586 issued to Baacke et al., May 26, 1992. This patent relates to a zeolite catalyst and a method for reduction of nitrogen oxides by mixing the waste gas with ammonia. As previously discussed in the background of this invention, the use of ammonia in the reduction of nitrogen oxide requires entirely different conditions than the present invention which is an NOx reduction catalyst utilizing hydrocarbons. The Baacke et al. patent does not show or suggest a two phase catalyst or the method of making the inventive two phase catalyst, nor obviously, the present catalysts themselves in which the stabilizing oxide coats the molecular sieve or zeolite material. Moreover, the use of ammonia itself presents a hazard.

The Green et al. U.S. patent no. 4,962,075 issued October 9, 1990 discloses a single phase catalyst obtained by intimately mixing the powders of the oxide binder and the metal salts so that although a physical mixture is formed, the inventive two phase catalyst is not made. This patent teaches mixing particles of a metal exchanged zeolite with an oxide. In this case, both particles are usually quite large (500 nm to 50,000 nm) and although the particles physically contact each other, no two phase catalyst with intimate contact between the phases such as produced by the methods of Examples 1-3 hereafter.

The Green et al. U.S. patent no. 5,276,249 issued January 4, 1994 relates to a catalyst composition for the destruction of halogenated organics. The Green et al. '249 patent like the Green et al. '075 patent does not show or suggest the inventive method of making the two phase catalyst of the present invention, and therefore, does not show or suggest the present inventive catalyst. Although the '075 patent does disclose the use of cerium oxide, the Green et al. '249 patent does not, neither patent teaches the present invention which uses metal oxide sols for creating the second phase.

Also cited in the parent case is the Sachtler et al. U.S. patent no. 6,143,681 issued November 7, 2000. The Sachtler et al. patent uses an entirely different means of introducing the metal into the zeolite, such as by metal vapor deposition, which leaves the metal in a different state and the addition of cerium into the matrix is by ion exchange not by a sol as taught in the present invention. Moreover, the '681 patent does not show or suggest the addition of a rare earth oxide by the use of a sol as opposed to a salt. Therefore, the '681 patent as the other patents cited in the prior case do not show the method of the present invention and therefore do not show the two phase catalyst of the present invention.

SUMMARY OF THE INVENTION

The present invention is the development of bifunctional catalysts that combine active metal-exchanged molecular sieves along with a separate metal oxide stabilizing phase from a sol precursor forming an oxide coating thereon that offers hydrothermal stability with sustained activity at low temperature for lean burn or rich burn exhaust with or without water present under SCR conditions.

Accordingly, it is a principal object of this invention to provide an effective method and catalyst for the reaction of NO_x in lean burn or rich burn exhaust with or without water present.

Yet another object of the invention is to provide a two phase catalyst comprising one or more transition metals supported on a molecular sieve and one or more stabilizing oxides coating the molecular sieve material.

A further object of the present invention is to provide a two phase catalyst comprising contacting a molecular sieve material having a pore size less than about 8 A with a sol of oxide particles having average diameters of greater than 8 A and less than about 100 nanometers to coat the molecular sieve particles with the oxide particles and loading the molecular sieve before and/or after the oxide coating with one or more transition metals.

Another object of the invention is to provide a two phase catalyst comprising a zeolite supported transition metal and a stabilizing oxide coated on the zeolite.

Still another object of this invention is to provide a method of remediating the concentration of nitrogen oxides (NO_x) in the exhaust from lean burn or rich burn combustion in the presence of water in which the exhaust containing water and NO_x is contacted with one or more of an organic reductant or mixtures thereof at a temperature of not greater than about 600°C with a two-part catalyst including a molecular sieve supported transition metal and a stabilizing metal oxide.

A final object of the present invention is to provide a method of remediating the concentration of nitrogen oxides (NO_x) in a combustion exhaust stream by contacting the exhaust stream with one or more organic reductants in the presence of water at a temperature not greater than 600°C over a two phase catalyst comprising one or more transition metals of Cu, Co, Fe, Ag and Mo supported on a molecular sieve having a pore size not less than 8 A, preferably between 4 A and 8A and a stabilizing oxide of one or more of the oxides of Zr, Mo, V, Nb or the rare earths.

The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.

FIGURE 1 is a graphical representation of the conversion of NO_x and propene as a function of temperature for a Cu-ZSM-5 catalyst and a CeO₂/Cu-ZSM-5 catalyst. Closed symbols represent conversions under dry conditions, while open symbols represent conversions under wet (10% water) conditions;

FIG. 2 is a graphical representation of the conversion of NO_x and propene over a zeolite supported copper catalysts stabilized with ceria illustrating various silicon to aluminum ratios;

FIG. 3 is a graphical representation of the conversion of NO_x and propene as a function of temperature for copper supported zeolite stabilized with ZrO₂ and a copper supported zeolite stabilized with molybdenum oxide;

FIG. 4 is a graphical representation of the conversion of NO_x and propene as a function of temperature for a cobalt supported zeolite and a cobalt supported zeolite stabilized with CeO₂;

FIG. 5 is a graphical representation of the conversion of NO_x and propene as a

function of temperature for copper supported zeolite stabilized with CeO₂ and ZrO₂ and a copper and cobalt supported zeolite;

FIG. 6 is a graphical representation of the conversion of NO_x and propene as a function of temperature for a copper supported mordenite and a copper supported mordenite stabilized with CeO₂;

FIG. 7 is a graphical representation of the conversion of NO_x and propene as a function of temperature for a physical mixture of Cu-ZSM-5 and CeO₂ and Cu-ZSM-5/CeO₂;

FIG 8 is a Scanning Electron Micrograph (SEM) Cu-ZSM-5 without the stabilizing oxide; and

FIG. 9 is a SEM of Cu-ZSM-5 with a coating of the stabilizing oxide (CeO₂). DESCRIPTION OF THE PREFERRED EMBODIMENT

While the preferred embodiment is generally illustrated by reference to examples involving a catalyst composed of a zeolite supported copper metal impregnated with a ceria stabilizing oxide, it should be understood that a variety of molecular sieve materials are satisfactory including zeolites. Specifically, zeolite Y, zeolite beta, mordenite, ferrierite, ZSM-5, and ZSM-12 are preferred. The molecular sieve preferably should have a pore size of at least about 4 A. Moreover, any transition metal would be adequate to be supported by a molecular sieve in a wide variety of concentrations. However, commonly used transition metals are copper, cobalt, iron, silver, molybdenum, vanadium and various combinations thereof. Also, the supporting oxides can be any one or more of the rare earth oxides such as cerium oxide and transition metal oxides, such as zirconium oxide, molybdenum oxide, vanadium oxide and niobium oxide. Cerium oxide alone or in combination with one or more of the other rare earth oxides is preferred. All of the preferred oxides are added in the form of metal oxide sols.

Specifically, a wide variety of pore size zeolites has been investigated and it is preferred that the pore size be in the range of from about 4 A and up to about 8 A. In the art, these are referred to as medium pore and wide pore zeolites. Investigations have been conducted using various water concentrations up to about 20% by volume. It is believed that the stabilizing oxide may be present in the catalyst in the range of from about 0.1 % by weight to in excess of about 40% by weight including the molecular sieve, with about 5% by weight being the minimum preferred and about 20% by weight being most preferred. It is also believed that the typical exchange levels for the transition metal may be anywhere from about 25-200% with 100% being preferred. Moreover, a variety of ratios of silicon to aluminum have been tested in zeolites and found to be satisfactory. Silicon to aluminum ratios found to be satisfactory are generally between about 238 and about 17 to one. While the reductions herein use organics such as propylene (C₃H₆) or hexane, any alkane or alkene between C₁ and C₁₆ is acceptable but C₁ to C₈ are preferred. In addition, non- organic reductants such as ammonia or urea are applicable as are organics such as alcohols.

Most of the examples investigated have been using the Cu-ZSM-5 and CeO₂ system. Besides physically mixing these catalysts, the bifunctional catalysts were synthesized in two distinct ways to vary the way the phases were mixed. The methods used here can be easily extended to incorporate a number of oxides, such as the rare earth oxides, zirconium oxide, vanadium oxide, the molybdenum oxides, the niobium oxides or combinations thereof, onto any transition metal-exchanged zeolite, including but not limited to Co-ZSM-5, Fe-ZSM-5, or Cu-ZSM-5, Ag-ZSM-5, Mo-ZSM-5 as well as the multimetallic-exchanged zeolites. Furthermore, it is believed that other zeolites besides ZSM-5, such as zeolite Y, Beta zeolite, the others synthetic or natural zeolites, or other molecular-sieve-like materials, such as silica-aluminophosphate (SAPO) or MCM-41 , could be used as the primary component of the metal support.

EXAMPLE 1

Preparation of CeO^Cu-ZSMS: Copper was ion exchanged with a ZSM-5 zeolite via typical means. A 0.01 M solution of Cu(NO₃)₂ was prepared, and 2 g of H- ZSM-5 (SiO₂/AI₂O₃ = 80) was stirred into 40 ml of the solution. The slurry was stirred overnight at room temperature, then filtered, washed with distilled water, dried at 100°C in a vacuum oven, then calcined in air at 500°C for 3 hrs. Copper loadings can be adjusted by changing the concentration of the solution, the pH of mixing, or by repeated exchanges with the solution. Ceria was introduced by first diluting a ceria sol from 20 wt% to 0.01 M. Two grams of the Cu-ZSM-5 was mixed with 40ml of the ceria solution, and was stirred overnight at room temperature. The slurry was filtered, washed, dried, and then calcined using the same conditions above. This catalyst will be referred to as "CeO₂/Cu-ZSM-5".

EXAMPLE 2

Preparation of Cu-ZSM-5/Ce0₂: High surface area ceria was first prepared following traditional procedures. Five grams of cerium carbonate was slowly mixed with 4.5 ml of glacial acetic acid to produce cerium acetate. The sample was dried in a vacuum over at 100°C, the calcined in air at 425°C to produce cerium oxide. The ceria was coated with a layer of AI₂O₃ to act as a template by mixing 2 g of the ceria with 40 ml of a 0.01 M AI₂O₃ sol (diluted from a 20wt% sol), stirring overnight, then filtering, washing, drying, and calcining in air at 500°C as above. The zeolite precursor solution was prepared by mixing a solution containing NaOH, dissolved Al foil, and H₂O with tetraethylorthosilicate (TEOS) and tetrapropylammonium hydroxide (TPAOH) such that the molar concentrations in the final solution was 4:0.06:571 :6:1 NaOH:AI:H₂O:TEOS:TPAOH. The solution was stirred at room temperature overnight, then approximately 40 ml was added to 2 g of the AI₂O₃ coated ceria in an autoclave. The autoclave was heated to 175°C for 6 hrs under autogenic pressure. After rapid cooling, the sample was filtered, washed, dried, then calcined for 6 hrs in air at 500°C to remove residual organic compounds. Copper was exchanged with the zeolite film/ceria following the methods listed above for CeO₂/Cu-ZSM-5. The final catalyst will be referred to as "Cu-ZSM-5/CeO₂".

EXAMPLE 3

In addition to the catalysts above, additional catalysts tested included: a Cu-ZSM-5 prepared similarly to CeO₂/Cu-ZSM-5 but without ceria addition, and a quantity of the Cu-ZSM-5 catalyst mixed in a equal weight ratio with the high surface area ceria prepared above. This latter catalyst was mixed by gentle grinding in a mortar for about 10 minutes.

EXAMPLE 4

Preparation of Cu-ZSM-5 and Ce0₂/Cu-ZSM-5 of various Si0₂/Al₂0₃ ratios: These materials were prepared similarly to the Cu-ZSM-5 and CeO₂/Cu-ZSM-5 materials of Example 1 , but using H-ZSM-5 precursor materials with SiO₂/Al₂O₃ molar ratios of 280, 55, and 30.

EXAMPLE 5

Preparation of ZrO Cu-ZSM-δ: This material was prepared similarly to the CeO₂/Cu-ZSM-5 material of Example 1 , but using a nanoparticle ZrO₂ sol in place of the CeO₂ sol.

EXAMPLE 6

Preparation of MoO^Cu-ZSM-5: This material was prepared similarly to the CeO₂/Cu-ZSM-5 material of Example 1 , but standard incipient wetness of ammonium heptamolybdate salt was used instead of the slurry method.

EXAMPLE 7

Preparation of (Ce0₂,ZrO^/Cu-ZSM-5: This material was prepared similarly to the CeO₂/Cu-ZSM-5 material of Example 1 , but using a 50:50 (by weight) mixture of the CeO₂ and ZrO₂ sols. EXAMPLE 8

Preparation of Co-ZSM-5: This material was prepared similarly to the Cu-ZSM- 5 sample of Example 1 , but using Co(NO₃)₂ salt as the cobalt precursor. Additionally, the slurry was gently warmed during the exchange process to ca. 50°C.

EXAMPLE 9

Preparation of CeO^Co-ZSM-δ: This material was prepared similarly to the CeO₂/Cu-ZSM-5 sample of Example 8, but starting with the Co-ZMS-5 sample from Example 7.

EXAMPLE 10

Preparation of CeO fCu^oj-ZSM-δ: This material was prepared similarly to the CeO₂/Cu-ZSM-5 material of Example 1 , but instead of only Cu(NO₃)₂ solution for the exchange process, a solution containing 0.005M Cu(NO₃)₂ and 0.005M Co(NO₃)₂ was used for co-exchange.

EXAMPLE 11

Preparation of Cu-MOR and CeO Cu-MOR: These materials were prepared similarly to the Cu-ZSM-5 and CeO₂/Cu-ZSM-5 materials from Example 1 , but instead of H-ZSM-5 as the precursor material, H-MOR (SiO₂/AI₂O₃ molar ratio of 20) was used as the precursor.

EXAMPLE 12 Preparation of Cu-ZSM-5. Cu-ZSM-5 material was prepared from the ammonium form of ZSM-5 via the exchange of Cu(NO₃)₂. A 0.01 M solution of Cu(NO₃)₂ was prepared from . Approximately 20g of NH₄-ZSM-5 (SiO₂/AI₂O₃ = 50) was massed into a beaker, and the Cu(NO₃)₂ solution was added at a ratio of 10ml/g (ca. 200ml). The slurry was then stirred vigorously while monitoring its pH, typically in the range of pH 2-4. A 0.1 M solution of NH₄OH was slowly added drop-wise to the slurry until the pH remained stable near 8.0. The solution was left to stir overnight (>18hrs). After stirring, the solution was filtered then rinsed with distilled water. The collected solids were then dried in an oven at ca. 110°C to remove the bulk of the moisture, then transferred to a calcination oven at 500°C for 3 hours. The sample was then removed and collected. The above process (starting with Cu(NO₃)₂ solution addition) was repeated twice more to increase the exchange level on the Cu-ZSM-5 to about 100%.

EXAMPLE 13

Preparation of CeO/Cu-ZSM-5 (Forward, ca. 20wt% loading). The Cu-ZSM-5 material from Example 12 was used as a precursor to the preparation of the two- phase catalyst. A CeO₂ sol from Nyacol (20% wt) was used as the CeO₂ precursor. Approximately 2g of Cu-ZSM-5 was put into a pyrex dish. CeO₂ sol was added drop- wise into the solid, with vigorous stirring after each drop, until the solid-liquid mixture became paste-like, and the solid material was completely wetted, typically obtained after about 2ml of sol addition. The mixture was placed into an oven at ca. 110°C to remove the bulk of the moisture, and then the remaining solid was collected and transferred to a calcination oven at 500°C for 3 hours. The sample was then removed and collected. This method was called the "forward" method with respect to the order of the copper and ceria loading.

EXAMPLE 14

Preparation of CeO Cu-ZSM-δ (Forward, ca. 40% loading). A sample was prepared following the methods of Example 13. This precursor material was then subjected to the same medication as outlined in Example 13 as to double the loading of the ceria.

EXAMPLE 15

Preparation of CeθχCu-ZSM-δ (Forward, ca. 10% loading). This material was prepared similarly to Example 13, but prior to addition, the CeO₂ sol was diluted in half by the addition of an equal amount of water as to reduce the sol concentration to ca. 10w%. This diluted sol was then added in the same fashion as outlined in Example 13. EXAMPLE 16

Preparation of CeθχZSM-δ (20% loading). This material was prepared similarly to Example 13, but using the NH₄-ZSM-5 form of the zeolite provided as the reagent as opposed to the Cu-ZSM-5 material.

EXAMPLE 17

Preparation of CeO/Cu-ZSM-δ (Reverse, 20% loading). This material was prepared similarly to Example 12, but using the CeO₂/H-ZSM-5 material of Example 16 as the initial precursor. Three Cu exchange steps were performed as per Example 12. This method was called the 'reverse' method with respect to the order of the copper and ceria loading.

EXAMPLE 18

Preparation of CeO Cu-ZSM-δ (Reverse, 40% loading). Material was prepared as per Example 16. The resulting material was then impregnated again with CeO₂ sol following the sample procedure of Example 16 to increase the ceria loading. Copper was then exchanged onto this material as per Example 17.

EXAMPLE 19

Preparation of CeO Cu-ZSM-δ (Reverse, 10% loading). Initial material was prepared similarly to Example 16, but using the diluted sol as per Example 15. Copper was then exchanged onto this material as per Example 17.

EXAMPLE 20

Preparation of Ce₀₈Sm₀₂O₂ sol. A 0.08M solution of Ce(NO₃)₃and a 0.08M solution of Sm(NO₃)₃ were mixed in the appropriate ratio to achieve the desired metal oxide composition; for the ratio of Ce:Sm of 4 in the present example, 65ml of the Ce(NO₃)₃ solution were combined with 16mL of the Sm(NO₃)₃ solution. The metal hydroxides were coprecipitated as a gel by the drop-wise addition of concentrated ammonium hydroxide until a pH above 9 was maintained. The gel material was filtered and then washed twice with ca. 100mL distilled water followed by one washing with ca. 50mL ethanol. The collected solid was then placed into an oven at 110°C under reduced pressure for 4 hours, which caused the gel to collapse into a glass-like form. The pulverized product was peptized in acetic acid and diluted in distilled water to the desired concentration (20wt% in the present example).

EXAMPLE 21

Preparation of Ce₀₈Sm₀₂O₂-/Cu-ZSM-δ (Forward, 20% loading). This material was prepared similarly to Example 13, but using the sol from Example 20 as the sol precursor material.

EXAMPLE 22

Preparation of Ce₀₈Zr₀₂O₂ sol. This material was prepared similarly to Example 20, except a 0.08M solution of ZrO(NO₃)₂ was used instead the Sm(NO₃)₃ solution. Additionally, after the vacuum drying, the sample was peptized by dilute nitric acid in a digestion bomb overnight at 135°C; the concentration of the nitric acid was determined based on a ratio of NO₃ to total metal content (Ce and Zr) of 0.25. The suspension obtained was air-dried first and then placed in an oven at 110°C for 30 minutes. The powder was re-dispersed in distilled water and passed through a 0.2 μ filter. The concentration of the sol was adjusted to 20 wt % oxide.

EXAMPLE 23

Preparation of Ce₀₈Zr₀₂θ₂/Cu-ZSM-δ (Forward, 20% loading). This material was prepared similar to Example 13, but using the sol from Example 22 as the sol precursor material.

EXAMPLE 24

DeNO_x Activity of Samples. The samples prepared in Examples 1-11 were tested for deNOx activity and the results are illustrated on Figures 1-7. The samples prepared in Examples (12-23) were tested for deNO_x as described below hereafter and the conversion of NO to N₂ over the temperature range of 250-400°C is listed in Table 1. TABLE 1

Material Example NO to N₂ Conversion (%)

250°C 300°C 350°C 400°C

Cu-ZSM-5 12 6 18 47 60

CeO₂/Cu-ZSM-5 13 40 35 26 20

(Forward, 20%)

CeO₂/Cu-ZSM-5 14 45 34 22 14

(Forward, 40%)

CeO₂/Cu-ZSM-5 15 22 50 37 25

(Forward, 10%)

CeO₂/Cu-ZSM-5 17 22 64 52 43

(Reverse, 20%)

CeO₂/Cu-ZSM-5 18 22 55 37 26

(Reverse, 40%)

CeO₂/Cu-ZSM-5 19 17 59 45 35

(Reverse, 10%)

Ce₀₈Sm₀₂O₂/Cu-ZSM-5 21 13 46 38 N/A

(Forward, 20%)

Ce₀₈Zr₀₂O₂/Cu-ZSM-5 23 20 48 30 24

(Forward, 20%)

The NO_x conversion activity was performed as follows. Approximately 150 mg

of sample was loaded into a quartz tube, and connected to a gas manifold system.

Prior to reaction, the sample was pretreated in He at 500°C for one hour. Gases

were available as 5.025% NO in He, 3.0% C₃H₆ in He, 4.96% O₂ in He, and pure He.

The gases were controlled with Brooks 5850e mass flow controllers as to introduce a

gas flow of 1000 ppm NO, 1000 ppm C₃H₆, 2% O₂, and the balance He at a space

velocity of approximately 30,000 hr¹. For water tests, water was pumped into the

system with a syringe pump and the water and gas flows were adjusted to give the

same concentration of gases above and 10% H₂O. The reaction was allowed to proceed at 500°C for 3 hrs prior to taking any readings. The reaction temperature

was varied between 200°C and 600°C in 50°C increments, allowing for at least 30

minutes at temperature before analyzing the effluent. The reaction effluent was

analyzed using an MTI micro gas chromatograph with molecular sieve 5 A and

poropak Q columns for the stationary and hydrocarbon gases, or with a California

Analytical Instruments NO_x detector, model HCLD-400, for the NO and NO₂.

The reduction of NO_x and C₃H₆ over Cu-ZSM-5 and ceria on ZSM-5 are shown

on Figure 1. As can be seen, at about 350°C, the zeolite supported copper shows a

NO_x conversion under wet conditions of just under 20% whereas the ceria and

zeolite shows an NO_x conversion under wet conditions of just under 10%.

Referring to Fig. 2, it can be seen that the combination of a zeolite supported

copper and ceria catalyst provides NO_x conversions in the presence of water in

excess of 40% at about 350°C for both the silicon to aluminum ratios displayed in

Fig. 2, that is a silicon to aluminum ratio of 67 and a silicon to aluminum ratio of 45.

These conversions are outstanding. Only small amounts of NO₂ (< 10ppm) were

observed, and no other nitrogen oxide species was present. Carbon dioxide was the

only observable product from C₃H₆ oxidation. The Cu-ZSM-5/CeO₂ catalyst had

slightly lower maximum NOx activity than the Cu-ZSM-5. In all cases, the maximum

NO_x conversion approaches the temperature when the propene is nearly all

consumed.

Under wet conditions, the Cu-ZSM-5 catalyst shows significant loss in NO_x

and hydrocarbon conversion activity. The CeO₂/Cu-ZSM-5 catalyst shows improved

NOx activity under wet conditions, possessing NO_x conversion levels over 40%. After reaction, the used catalysts were examined in the reactor prior to

removal. It was noted that Cu-ZSM-5 catalyst showed significant discoloration

throughout the bed, indicative of coking. However, with the other catalysts tested, it

was observed that only a small fraction of the bed length was discolored, the rest of

the bed remaining the same color as the original sample.

The ceria improves the Cu-ZSM-5 in two ways. First, it provides necessary

water stability Ceria also aids the NO_x conversion reaction, based on improved activities with the CeO₂/Cu-ZSM-5.

Fig. 3 shows similar data for a catalyst comprised of a zeolite supported

copper with zirconia and a zeolite supported copper with molybdenum oxide. In

these data it is clear that the zirconia containing catalyst is a superior performer at

lower temperatures such as 400°C, whereas at 450°C, the molybdenum containing

catalyst is very good.

Fig. 4 shows a comparison of a cobalt and a combination of a zeolite

supported cobalt with ceria. As can be seen from the data, without the ceria present

there is little, if any, NO_x conversion under wet conditions whereas with the ceria

present there is substantial conversion at 450°C.

Fig. 5 shows data for a variety of catalyst, the first being a zeolite supported

copper with a combination of ceria and zirconia which shows excellent NO_x

conversions under wet conditions at about 400°C and acceptable but less

conversions at 350°C. Similarly, the copper cobalt supported zirconia with ceria

shows excellent NO_x conversions under wet conditions both at 400° and 350°C. Fig. 6 illustrates comparisons of a mordenite supported copper and a

mordenite supported copper with ceria under both wet and dry conditions. It is seen

that the inventive catalyst, that is the copper supported mordenite with ceria has

clearly superior activity at temperatures under 400° compared to the copper

supported mordenite.

Finally in Fig. 7, shows data for a physical mixture of ceria and Cu-ZSM-5 and

Cu-ZSM-5 on ceria. Note that these catalysts were tested at a space velocity of

10,000 Hr¹ and 20% water when present. The physical mixture of Cu-ZSM-5 and

CeO₂ showed no loss in activity, but only a slight shift in temperature where the

maximum activity occurred. In the case of Cu-ZSM-5/CeO₂, there is still some loss

of NO conversion, but not as great as the Cu-ZSM-5 alone, while hydrocarbon

conversion remained high.

Figures 8 and 9 are Scanning Electron Microscopy (SEM) of a zeolite without

the stabilizing oxide (see Fig. 8) and a zeolite with a coating of the stabilizing oxide

(Fig. 9). As seen from the two SEMs, the stabilizing oxide entirely coats the zeolite

applied by the method hereinbefore set forth adding the oxide in the form of colloidal

sol.

The possible concentration ranges for the metal salt solution in the range of

from 0.001 M to about 1 M solutions, but preferably in the range of 0.01 M to 0.1 M. The

pH of the zeolite/solution slurry will typically start in the pH range from 2 to 5; the pH

of the solution can be raised as high as 12 with ammonia hydroxide solution, but is

typically only raised to a pH between 6 and 8. Certain metal salts, such as Co(NO₃)₂,

will exchange better at higher temperatures; when used, the slurry is taken to temperatures between 50 and 80°C in a refluxing unit during the exchange process. All of these variables can be used to influence the rate, quantity, and quality of the metal exchange process on the zeolite.

Nanoparticle sols can be obtained through many industrial sources; however,

it is sometimes necessary to prepare these sols directly as illustrated in Example 2

and others, particularly in the case of mixed metal oxides. By nanoparticles, we mean

particles having an average diameter of less than about 100 nanometers and

preferably in the range of from about 20 to about 40 nanometers. In any event, the

oxides prepared from these sols should have diameters larger than the pore sizes of

the molecular sieves, so that the stabilizing oxides do not enter the sieve but coat

same. Generally, these sols are made by the peptization of a dry oxide gel in an

acidic medium. The oxide gel can be prepared by a number of procedures, most

commonly by (co) precipitation of the metal hydroxide from a solution of the metal

salts by ammonium hydroxide. For mixed metal sols, the desired metal ratio in the

final sol can be controlled by the appropriate mixing of the initial metal salts.

Additional information on sol formation can be found in D.-H. Tsai and TJ. Huang,

Appl. Catal. A., 223, 1-9 (2002), and J.L. Woodhead, U.K. Patent 2102780.

The data reported herein were for lean-burn combustion gases, that is

combustion gases in which air or oxygen was present in greater than stoichiometric

quantities. Moreover, all the data reported herein had between about 10 and 20% by

volume water present in the combustion gases. However, the inventive catalyst is

operable in either rich or lean burn conditions with or without water. Currently, the

best conditions for NO_x remediation is with C:N rations of from 1 :1 to 16:1. Gas mole to gas mole ratios of 1 :1 to 10:1 are preferred. Space velocities from 1 ,000 hr4 to

about 100,000 hr.^"1 are estimated with space velocities of 30,000 hr.^"1 having been

measured. Moreover, essentially all the remediated NO_x is converted to N₂ with little if any N₂O being produced.

Accordingly, two phase catalysts prepared according to the methods of

Examples 1 to 11 herein are molecular sieves having pore sizes up to about 8 A

supporting one or more transition metals, with the molecular sieve particles coated by

a stabilizing oxide. Examples 12 to 23 herein illustrate additional formations of the

inventive two phase catalysts and method of making same. Not only are the

catalysts distinctive for their two phase formation, but the oxide coating herein

disclosed provides the unusual catalytic activity with layer oxide loadings than

heretofore available. Oxide loadings of 40% by weight are reported in Table 1 and it

is believed loadings of about 50% by weight can be obtained. Valuable catalytic

materials with oxide loadings of up to 10% by weight but preferably, up to about 20%

by weight have been used.

While there has been disclosed what is considered to be the preferred

embodiment of the present invention, it is understood that various changes in the

details may be made without departing from the spirit, or sacrificing any of the

advantages of the present invention.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A two phase catalyst comprising one or more transition metals

supported on a molecular sieve and one or more stabilizing oxides coating the molecular sieve.

2. The catalyst of claim 1 , wherein the molecular sieve has a pore size not

greater than 8 A.

3. The catalyst of claim 1 , wherein the molecular sieve is a zeolite.

4. The catalyst of claim 3, wherein the zeolite has a pore size between 4

and 8 A.

5. The catalyst of claim 3, wherein the zeolite is an aluminosilicate.

6. The catalyst of claim 5, wherein the zeolite includes one or more of

zeolite Y, zeolite beta, ZSM-5, ZSM-12, mordenite, or ferrerite.

7. The catalyst of claim 5, wherein the zeolite has a silicon-to-aluminum

ratio between about 17 and about 238.

8. The catalyst of claim 1 , wherein the transition metal includes one or

more of Cu, Co, Fe, Ag, and Mo.

9. The catalyst of claim 8, wherein the transition metal is Cu.

10. The catalyst of claim 8, wherein the transition metals are present in the

catalyst up 200% by weight.

11. The catalyst of claim 10, wherein the stabilizing oxides includes one or more of the oxides of Zr, Mo, V, Nb, or the rare earths.

12. The catalyst of claim 11 , wherein the stabilizing oxide is CeO₂.

13. The catalyst of claim 12, wherein the stabilizing oxides are present in the catalyst not less than about 20% by weight.

14. The catalyst of claim 1 , wherein the transition metal supported

molecular sieve and the stabilizing oxide are physically mixed when the stabilizing

oxide is in the form of a sol.

15. The catalyst of claim 14, wherein the stabilizing oxide coats the outside

of the molecular sieve.

16. The catalyst of claim 1 , wherein the molecular sieve is contacted by a

stabilizing oxide sol with particles between about 20 to about 40 nanometers in

diameter.

17. A two phase catalyst comprising one or more transition metals of Cu,

Co, Fe, Ag and Mo supported on a molecular sieve having a pore size not greater

than 8 A and a stabilizing oxide of one or more of the oxides of Zr, Mo, V, Nb or the

rare earths coating the molecular sieve.

18. The catalyst of claim 17, wherein the transition metal is Cu.

19. The catalyst of claim 17, wherein the stabilizing oxide is CeO₂.

20. The catalyst of claim 17, wherein the transition metal is Cu and the

stabilizing oxide is CeO₂ and the molecular sieve is ZSM-5.

21. The catalyst of claim 20, wherein the Cu is present up to about 10% by

weight of the catalyst and the CeO₂ is present up to about 40% by weight of the

catalyst.

22 A method of remediating the concentration of nitrogen oxides (NO_x) in a

combustion exhaust stream by contacting the exhaust stream with one or more

reductants at a temperature not greater than 600°C over a two-phase catalyst

comprising one or more transition metals supported on a molecular sieve and one or

more stabilizing oxides coating the molecular sieves.

23. A method of remediating the concentration of nitrogen oxides (NO_x) in a

combustion exhaust stream by contacting the exhaust stream with one or more

organic reductants in the presence of water at a temperature not greater than 600°C

over a two phase catalyst comprising one or more transition metals of Cu, Co, Fe, Ag

and Mo supported on a molecular sieve having a pore size not greater than about 8

A and a stabilizing oxide of one or more of the oxides of Zr, Mo, V, Nb or the rare

earths coating the molecular sieve and present in an amount of up to about 40% by

weight.

24. A method of preparing a two phase catalyst comprising contacting a

molecular sieve material having a pore size less than about 8 A with a sol of oxide

particles having average diameters of greater than 8 A and less than about 100

nanometers to coat the molecular sieve particles with the oxide particles and loading

the molecular sieve before and/or after the oxide coating with one or more transition

metals.

25. A two phase catalyst made according to the method of claim 24.