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.

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.

AFX Zeolite for Use as a Support of NH3-SCR Catalyst Mining through AICE Joint Research Project of Industries–Academia–Academia

This paper introduces a joint industries–academia–academia research project started by researchers in several automobile companies and universities working on a single theme. Our first target was to find a zeolite for NH3-SCR, that is, zeolite mining. Zeolite AFX, having the same topology of SSZ-16, was found to be the one of the zeolites. SSZ-16 can be synthesized by using an organic structure-directing agent such as 1,1′-tetramethylenebis(1-azonia-4-azabicyclo[2.2.2]octane; Dab-4, resulting in the formation of Al-rich SSZ-16 with Si/Al below five. We found that AFX crystallized by use of N,N,N′,N′-tetraethylbicyclo[2.2.2]oct-7-ene-2,3:5,6-dipyrrolidinium ion, called TEBOP in this study, had the same analog as SSZ-16 having Si/Al around six and a smaller particle size than SSZ-16. The AFX demonstrated a high performance for NH3-SCR as the zeolitic support to load a large number of divalent Cu ionic species with high hydrothermal stability.

Ultrafast and continuous-flow synthesis of AFX zeolite via interzeolite conversion of FAU zeolite

Continuous-flow synthesis of AFX zeolite is achieved with the residence time of 10 min, using FAU zeolite as the silica and alumina source, and acid-leached seeds which promote secondary nucleation of AFX.

Selective catalytic reduction of NO with NH3 over Cu-exchanged CHA, GME, and AFX zeolites: a density functional theory study

Density functional theory calculations have been applied to study the selectivity caused by the cage size during the selective catalytic reduction of NO by NH₃ over the Cu-exchanged zeolites with cha, gme, and aft cages.

Selective catalytic reduction of NO over Cu-AFX zeolites: mechanistic insights from in situ/operando spectroscopic and DFT studies

In situ/operando spectroscopic experiments and DFT calculations unravel the redox mechanism of NH₃-SCR over Cu-AFX 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.

High-quality synthesis of a nanosized CHA zeolite by a combination of a starting FAU zeolite and aluminum sources

A chabazite (CHA zeolite) was synthesized using high-silica faujasite (FAU) zeolites with a Si/Al ratio of 93, an additional alumina source (aluminum hydroxide) combined with seed crystals, and N,N,N-trimethyl-1-adamantammonium hydroxide. We compared the crystallization behavior of the starting material (HSY + Al) with that of other combinations of silica/alumina sources (high-silica and low-silica FAU, fumed silica, and aluminum hydroxide). HSY + Al rapidly yielded nanosized CHA zeolites with a crystal size of approximately 70 nm, exhibited high product crystallinity and high yield and offered a wide synthesis window. A combination of analytic experiments using electrospray-ionization mass spectrometry and nuclear magnetic resonance (NMR) suggested that in the early stage, the pre-introduced CHA seeds provide a crystal nucleus and the FAU zeolites decompose to form oligomer species in the liquid phase. Meanwhile, aluminum hydroxide retains its solid phase. Subsequent crystallization of the zeolites is accelerated by the liquid silicate oligomer and solid aluminate sources, resulting in a high yield and rapid synthesis of nanosized CHA zeolites. We observed that phosphorus-modified CHA zeolites synthesized using HSY + Al perform well as a catalyst for ethanol conversion reactions. Controlled Si/Al ratios and additional phosphorus modifications improve catalytic durability, thereby exhibiting a higher propylene yield from the reaction within the zeolite pore system.

Mechanistic insights into the oxidation of copper(i) species during NH3-SCR over Cu-CHA zeolites: a DFT study

DFT calculations suggest that Cu(i) oxidation with O₂ as the sole oxidant plays a major role in the oxidation half cycle of standard NH₃-SCR over Cu-CHA zeolites.

Ultrafast synthesis of AFX-Type zeolite with enhanced activity in the selective catalytic reduction of NOx and hydrothermal stability

Shortening the synthesis time of SSZ-16 (AFX type) zeolite from several days to 2 h has been achieved using an ultrafast synthesis route involving N,N,N′,N′-tetraethylbicyclo[2.2.2]oct-7-ene-2,3:5,6-dipyrrolidinium (TEBOP) as an organic structure-directing agent (OSDA) in a tubular reactor assisted by seed crystals. Recently, copper exchanged SSZ-16 has been looked upon as one of the few equivalents to SSZ-13 for the selective catalytic reduction of NOx with ammonia (NH₃-SCR) from automobile exhausts. Hydrothermal stability is one of the crucial properties for any zeolites that compete for automobile applications. All the samples prepared were analyzed using sophisticated physio-chemical techniques and those prepared from TEBOP were subjected to SCR of NOx reactions. The rapid crystal growth induced by high synthesis temperature bestowed the ultrafast prepared SSZ-16 with high crystallinity and hydrothermal stability as well as enhanced SCR of NOx activity even when aged at 800 °C. Compared to 1,1′-(1,4-butanediyl)bis-4-aza-1-azoniabicyclo[2.2.2]octane dibromide (DABCO), TEBOP was found to be desirable as an OSDA for high crystallinity and hydrothermal stability.

SSZ-16 (AFX-type) zeolite prepared in 2 h, so far the fastest, shows enhanced hydrothermal-stability and activity in selective-catalytic-reduction of NOx.