WO2024251821A1 - Catalytic materials comprising fe-containing zeolitic material for the treatment of an exhaust gas - Google Patents
Catalytic materials comprising fe-containing zeolitic material for the treatment of an exhaust gas Download PDFInfo
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- WO2024251821A1 WO2024251821A1 PCT/EP2024/065477 EP2024065477W WO2024251821A1 WO 2024251821 A1 WO2024251821 A1 WO 2024251821A1 EP 2024065477 W EP2024065477 W EP 2024065477W WO 2024251821 A1 WO2024251821 A1 WO 2024251821A1
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- catalytic
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- catalytic material
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- 239000000463 material Substances 0.000 title claims abstract description 256
- 230000003197 catalytic effect Effects 0.000 title claims abstract description 171
- 238000011282 treatment Methods 0.000 title claims abstract description 54
- 238000000034 method Methods 0.000 claims abstract description 72
- 230000008569 process Effects 0.000 claims abstract description 66
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 50
- 238000004400 29Si cross polarisation magic angle spinning Methods 0.000 claims abstract description 47
- 238000010531 catalytic reduction reaction Methods 0.000 claims abstract description 27
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 25
- 229910052681 coesite Inorganic materials 0.000 claims abstract description 23
- 229910052906 cristobalite Inorganic materials 0.000 claims abstract description 23
- 229910052682 stishovite Inorganic materials 0.000 claims abstract description 23
- 229910052905 tridymite Inorganic materials 0.000 claims abstract description 23
- 229910052742 iron Inorganic materials 0.000 claims abstract description 14
- 238000002485 combustion reaction Methods 0.000 claims abstract description 12
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 10
- 239000000203 mixture Substances 0.000 claims description 67
- 239000000306 component Substances 0.000 claims description 35
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 22
- 238000005342 ion exchange Methods 0.000 claims description 14
- -1 ammonium cations Chemical class 0.000 claims description 11
- 125000000008 (C1-C10) alkyl group Chemical group 0.000 claims description 10
- 229910052796 boron Inorganic materials 0.000 claims description 9
- 235000012239 silicon dioxide Nutrition 0.000 claims description 9
- 229910052733 gallium Inorganic materials 0.000 claims description 5
- 229910052738 indium Inorganic materials 0.000 claims description 5
- 238000004891 communication Methods 0.000 claims description 3
- 230000006854 communication Effects 0.000 claims description 3
- 239000012530 fluid Substances 0.000 claims description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 abstract description 78
- 239000004411 aluminium Substances 0.000 abstract 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 abstract 1
- 239000007789 gas Substances 0.000 description 87
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 80
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 80
- 239000003054 catalyst Substances 0.000 description 53
- 229910001657 ferrierite group Inorganic materials 0.000 description 48
- 239000010457 zeolite Substances 0.000 description 38
- 230000003647 oxidation Effects 0.000 description 32
- 238000007254 oxidation reaction Methods 0.000 description 32
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 28
- 229910021536 Zeolite Inorganic materials 0.000 description 27
- 239000002002 slurry Substances 0.000 description 27
- 229910021529 ammonia Inorganic materials 0.000 description 22
- 238000012360 testing method Methods 0.000 description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 20
- 238000001354 calcination Methods 0.000 description 19
- 229930195733 hydrocarbon Natural products 0.000 description 19
- 150000002430 hydrocarbons Chemical class 0.000 description 19
- 239000012298 atmosphere Substances 0.000 description 17
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 16
- 239000002245 particle Substances 0.000 description 16
- 230000032683 aging Effects 0.000 description 15
- 125000000217 alkyl group Chemical group 0.000 description 15
- VTLYFUHAOXGGBS-UHFFFAOYSA-N Fe3+ Chemical compound [Fe+3] VTLYFUHAOXGGBS-UHFFFAOYSA-N 0.000 description 14
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 14
- 238000002360 preparation method Methods 0.000 description 14
- 239000000758 substrate Substances 0.000 description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 13
- 239000004215 Carbon black (E152) Substances 0.000 description 12
- 238000001035 drying Methods 0.000 description 12
- 229910001868 water Inorganic materials 0.000 description 12
- 238000006243 chemical reaction Methods 0.000 description 11
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 10
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 10
- 239000004202 carbamide Substances 0.000 description 10
- 239000000243 solution Substances 0.000 description 10
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 9
- 239000008367 deionised water Substances 0.000 description 9
- 239000004071 soot Substances 0.000 description 9
- 238000011144 upstream manufacturing Methods 0.000 description 9
- 125000006701 (C1-C7) alkyl group Chemical group 0.000 description 8
- 239000003638 chemical reducing agent Substances 0.000 description 8
- 239000010949 copper Substances 0.000 description 8
- 229910021641 deionized water Inorganic materials 0.000 description 8
- 125000006273 (C1-C3) alkyl group Chemical group 0.000 description 7
- 229910052878 cordierite Inorganic materials 0.000 description 7
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 7
- 238000011068 loading method Methods 0.000 description 7
- 235000019391 nitrogen oxide Nutrition 0.000 description 7
- GQPLMRYTRLFLPF-UHFFFAOYSA-N nitrous oxide Inorganic materials [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 description 7
- DUFCMRCMPHIFTR-UHFFFAOYSA-N 5-(dimethylsulfamoyl)-2-methylfuran-3-carboxylic acid Chemical compound CN(C)S(=O)(=O)C1=CC(C(O)=O)=C(C)O1 DUFCMRCMPHIFTR-UHFFFAOYSA-N 0.000 description 6
- 229910002651 NO3 Inorganic materials 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 6
- 229910052593 corundum Inorganic materials 0.000 description 6
- 238000005470 impregnation Methods 0.000 description 6
- 229910001845 yogo sapphire Inorganic materials 0.000 description 6
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 5
- 229910052802 copper Inorganic materials 0.000 description 5
- 239000002808 molecular sieve Substances 0.000 description 5
- 229910052757 nitrogen Inorganic materials 0.000 description 5
- 229960005419 nitrogen Drugs 0.000 description 5
- 239000001301 oxygen Substances 0.000 description 5
- 229910052760 oxygen Inorganic materials 0.000 description 5
- 239000011148 porous material Substances 0.000 description 5
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 5
- 238000003756 stirring Methods 0.000 description 5
- 238000005406 washing Methods 0.000 description 5
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 4
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 description 4
- 235000010323 ascorbic acid Nutrition 0.000 description 4
- 229940001468 citrate Drugs 0.000 description 4
- 150000001860 citric acid derivatives Chemical class 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000005755 formation reaction Methods 0.000 description 4
- MVFCKEFYUDZOCX-UHFFFAOYSA-N iron(2+);dinitrate Chemical compound [Fe+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O MVFCKEFYUDZOCX-UHFFFAOYSA-N 0.000 description 4
- 150000002894 organic compounds Chemical class 0.000 description 4
- KRKNYBCHXYNGOX-UHFFFAOYSA-K Citrate Chemical compound [O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O KRKNYBCHXYNGOX-UHFFFAOYSA-K 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 230000004913 activation Effects 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- KDLHZDBZIXYQEI-UHFFFAOYSA-N palladium Substances [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 3
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Substances [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 3
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 2
- 150000000994 L-ascorbates Chemical class 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 2
- 150000001242 acetic acid derivatives Chemical class 0.000 description 2
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 229940072107 ascorbate Drugs 0.000 description 2
- 239000011668 ascorbic acid Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- VCJMYUPGQJHHFU-UHFFFAOYSA-N iron(3+);trinitrate Chemical compound [Fe+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O VCJMYUPGQJHHFU-UHFFFAOYSA-N 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000000523 multiple-quantum excitation in combination with magic angle spinning Methods 0.000 description 2
- 150000002823 nitrates Chemical class 0.000 description 2
- 229910052763 palladium Inorganic materials 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 231100000572 poisoning Toxicity 0.000 description 2
- 230000000607 poisoning effect Effects 0.000 description 2
- 229920000136 polysorbate Polymers 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000006722 reduction reaction Methods 0.000 description 2
- 229910052703 rhodium Inorganic materials 0.000 description 2
- 239000010948 rhodium Substances 0.000 description 2
- 238000007873 sieving Methods 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 2
- 238000003786 synthesis reaction Methods 0.000 description 2
- CBXCPBUEXACCNR-UHFFFAOYSA-N tetraethylammonium Chemical compound CC[N+](CC)(CC)CC CBXCPBUEXACCNR-UHFFFAOYSA-N 0.000 description 2
- RFBYLSCVRUTUSB-ZZMNMWMASA-L (2r)-2-[(1s)-1,2-dihydroxyethyl]-3-hydroxy-5-oxo-2h-furan-4-olate;iron(2+) Chemical compound [Fe+2].OC[C@H](O)[C@H]1OC(=O)C(O)=C1[O-].OC[C@H](O)[C@H]1OC(=O)C(O)=C1[O-] RFBYLSCVRUTUSB-ZZMNMWMASA-L 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 101100365087 Arabidopsis thaliana SCRA gene Proteins 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 238000005004 MAS NMR spectroscopy Methods 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 101150105073 SCR1 gene Proteins 0.000 description 1
- 101100134054 Saccharomyces cerevisiae (strain ATCC 204508 / S288c) NTG1 gene Proteins 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 235000019270 ammonium chloride Nutrition 0.000 description 1
- UNYSKUBLZGJSLV-UHFFFAOYSA-L calcium;1,3,5,2,4,6$l^{2}-trioxadisilaluminane 2,4-dioxide;dihydroxide;hexahydrate Chemical compound O.O.O.O.O.O.[OH-].[OH-].[Ca+2].O=[Si]1O[Al]O[Si](=O)O1.O=[Si]1O[Al]O[Si](=O)O1 UNYSKUBLZGJSLV-UHFFFAOYSA-L 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 229910052676 chabazite Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229940000425 combination drug Drugs 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000012065 filter cake Substances 0.000 description 1
- 239000000706 filtrate Substances 0.000 description 1
- 229940030980 inova Drugs 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 235000000011 iron ammonium citrate Nutrition 0.000 description 1
- 239000004313 iron ammonium citrate Substances 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000010979 pH adjustment Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000011541 reaction mixture Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 239000012047 saturated solution Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229940073455 tetraethylammonium hydroxide Drugs 0.000 description 1
- LRGJRHZIDJQFCL-UHFFFAOYSA-M tetraethylazanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)CC LRGJRHZIDJQFCL-UHFFFAOYSA-M 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/65—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38, as exemplified by patent documents US4046859, US4016245 and US4046859, respectively
- B01J29/66—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38, as exemplified by patent documents US4046859, US4016245 and US4046859, respectively containing iron group metals, noble metals or copper
- B01J29/68—Iron group metals or copper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
- B01D53/9418—Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
- B01J37/0027—Powdering
- B01J37/0036—Grinding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
- B01J37/0219—Coating the coating containing organic compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0236—Drying, e.g. preparing a suspension, adding a soluble salt and drying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/024—Multiple impregnation or coating
- B01J37/0246—Coatings comprising a zeolite
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B39/00—Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
- C01B39/02—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof; Direct preparation thereof; Preparation thereof starting from a reaction mixture containing a crystalline zeolite of another type, or from preformed reactants; After-treatment thereof
- C01B39/44—Ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/20—Reductants
- B01D2251/206—Ammonium compounds
- B01D2251/2067—Urea
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20715—Zirconium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20738—Iron
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/50—Zeolites
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
- B01J2229/10—After treatment, characterised by the effect to be obtained
- B01J2229/18—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself
- B01J2229/186—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself not in framework positions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
- B01J2229/10—After treatment, characterised by the effect to be obtained
- B01J2229/20—After treatment, characterised by the effect to be obtained to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
- B01J2229/30—After treatment, characterised by the means used
- B01J2229/42—Addition of matrix or binder particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2235/00—Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
- B01J2235/05—Nuclear magnetic resonance [NMR]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2370/00—Selection of materials for exhaust purification
- F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
- F01N2370/04—Zeolitic material
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
Definitions
- the present invention relates to a catalytic material for the treatment of an exhaust gas compris- ing NOx, preferably for the selective catalytic reduction of NOx. Further, the present invention relates to a process for preparing a catalytic material, a catalytic material obtained or obtainable by said process, an exhaust gas treatment system using the catalytic material of the present in- vention, a process for the treatment of an exhaust gas using the catalytic material of the present invention, and use of a catalytic material according to the present invention for the treatment of an exhaust gas, preferably for the selective catalytic reduction of NOx.
- the present invention pertains to the field of catalysts effective for selective catalytic reduction. Described are attributes of zeolitic materials having a framework structure having a maximum ring size of 10 T-atoms or less that provide best SCR performance when loaded with Fe. Fur- ther, a process for preparing a catalytic material is described herein allowing incorporation of comparatively high amounts of Fe into a zeolitic material.
- WO 2020/021054 A1 relates to a process for preparing a zeolitic material having framework type FER. It is disclosed therein that the prepared zeolitic material can be ion-exchanged with ions of one or more of Cu, Pd, Rh, Pt and Fe.
- WO 2021/198339 A1 relates to catalysts for the selective catalytic reduction of nitrogen oxide, processes for preparing said catalysts for the selective catalytic reduction of nitrogen oxide, use of a catalyst for the selective catalytic reduction of nitrogen oxide and an exhaust gas treatment system comprising said catalyst.
- the catalyst can comprise a zeolitic material having a frame- work structure type selected from the group consisting of MFI, MWW, AEL, HEU, FER, AFO, a mixture of two or more thereof and a mixed type of two or more thereof, wherein the zeolitic ma- terial can be ion-exchanged with Fe.
- WO 2015/128668 A1 relates to SCR-active molecular sieve based-catalysts produced by com- bining a molecular sieve with at least one ionic iron species and at least one organic compound to form a mixture, then calcining the mixture to remove the at least one organic compound. It is disclosed that this process improves the dispersion of the iron within the molecular sieve com- pared to an iron-containing molecular sieve that is not treated with an organic compound.
- the prepared Fe-containing ferrierite zeolites were tested in the selective catalytic reduction of nitro- gen oxides with NH3 or urea.
- BASF Corporation 220846WO01 - 2 - EP 2857084 A1 relates to a device for treatment of exhaust gas flowing in an exhaust line of an internal combustion engine, characterized in that it comprises a porous substrate coated and/or impregnated with catalytic composition(s) combining a chabazite zeolite in the H-form or im- pregnated copper and/or a ferrierite zeolite in the H-form or impregnated with one or more of Cu and Fe.
- DE 102011012799 A1 relates to a catalyst comprising a carrier body of a certain length and a catalytically active coating made of at least one material zone which may comprise a zeolite containing 1-10 wt.% of copper, iron and/or silver, based on the total weight of the zeolite, where the zeolite may comprise ferrierite (FER).
- EP 2409760 A1 relates to a gas-treatment device including such a composition comprising a ferrierite/iron-type zeolite.
- the substrate has an internal structure that is adapted for forming a particulate filter (1) and has a catalytic composition comprising ferrierite zeolite in the H-form and containing iron (0.3-2 mass%) deposited on the substrate.
- the cata- lytic composition is configured for performing chemical reaction such as reduction of nitrogen oxide.
- WO 2008/049557 A1 relates to a catalyst useful for decomposing and/or reduction of nitrous ox- ide, wherein the catalyst can comprise a ferrierite-type zeolite being Fe-exchanged.
- US 5041272 A relates to a method for removing nitrogen oxides from exhaust gases containing oxygen and moisture, which comprises bringing the exhaust gas into contact with hydrogenated zeolite catalysts or hydrogenated zeolite catalysts impregnated with one or more kinds of metals selected from the group consisting of copper, zinc, vanadium, chromium, manganese, iron, co- balt, nickel, rhodium, palladium, platinum, and molybdenum, in the presence of organic com- pounds.
- the zeolite may be of ferrierite type.
- US 2011/056187 A1 relates to a process for treating diesel engine exhaust gases comprising nitrogen oxides (NOx) and hydrocarbons (HC) by selective catalytic reduction of the nitrogen ox- ides with ammonia or a compound decomposable to ammonia as a reducing agent over an SCR catalyst based on a molecular sieve.
- NOx nitrogen oxides
- HC hydrocarbons
- P.Sarv et al. “Multinuclear MQMAS NMR Study of NH4/Na-Ferrierites”, J. Phys. Chem. B 1998, 102, 1372-1378, relates to (MQ)MAS NMR as a method to study quadrupolar nuclei, enabling separation of the chemical shift interaction from the quadrupolar interaction.
- the inventive catalytic material which is characterized by comprising a FER-type zeolitic material, especially shows an improved performance in selective catalytic reduction of NOx after aging and an improved re- sistance to hydrocarbon poisoning. Further, it was surprisingly found that use of one or more ammonium cations in the preparation of a catalytic material, in particular in combination with an adjustment of the pH of the respective aqueous reaction mixture, allows an improved incorpora- tion of Fe into a zeolitic material comprised in a catalytic material.
- the present invention relates to a catalytic material for the selective catalytic reduc- tion of NOx, the catalytic material comprising a zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has an FER-type framework structure, wherein the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from ⁇ 103.5 to ⁇ 108.5 ppm, wherein the integral of the first peak affords an area I 1 , wherein the integral of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm afford an area I total , wherein the ratio of the area I 1 of the first peak to the area I total of all peaks is equal to or greater than 0.20:1, wherein the catalytic material comprises Fe, wherein Fe is supported on the zeolitic material, and wherein the deconvoluted 29 Si MAS NMR of the ze
- the ratio of the area I 1 of the first peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or greater than 0.23:1, more preferably greater than 0.25:1. It is preferred that the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is in the range of 0.2:1 to 0.60:1, more preferably in the range of 0.23:1 to 0.50:1, more preferably in the range of 0.30:1 to 0.50:1.
- the first peak (P1) has a maximum in the range of ⁇ 104.0 to ⁇ 108.0 ppm, more preferably in the range of ⁇ 104.5 to ⁇ 107.5 ppm, more preferably in the range of ⁇ 105.0 to ⁇ 107.0 ppm.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of ⁇ 97.5 to ⁇ 102.5 ppm, more preferably in the range of ⁇ 99.0 to ⁇ 101.0 ppm, wherein the integral of the second peak (P2) more preferably affords an area I2, wherein the ratio of the area I2 of the second peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of ⁇ 108.6 to ⁇ 112.5 ppm, more preferably in the range of ⁇ 110.0 to ⁇ 112.0 ppm, wherein the integral of the third peak (P3) more preferably af- fords an area I3, wherein the ratio of the area I3 of the third peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.55:1, more preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of ⁇ 112.6 to ⁇ 116.5 ppm, more preferably in the range of ⁇ 113.0 to ⁇ 115.0 ppm, wherein the integral of the fourth peak (P4) more preferably af- fords an area I4, wherein the ratio of the area I4 of the fourth peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1, more preferably equal to or smaller than 0.40:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of ⁇ 93.0 to ⁇ 97.0 ppm, more preferably in the range of ⁇ 94.0 to ⁇ 96.0 ppm, wherein the integral of the fifth peak (P5) more preferably affords an area I5, wherein the ratio of the area I5 of the fifth peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1.
- the zeolitic material has a molar ratio of SiO 2 to Al 2 O 3 of equal to or less than 50, more preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20.
- the catalytic material has an atomic ratio of Fe supported on the zeolitic ma- terial, calculated as element, to Al comprised in the framework structure of the zeolitic material, calculated as element, of equal to or greater than 0.20:1, preferably in the range of 0.20:1 to 0.50:1, more preferably in the range of 0.20:1 to 0.45:1, more preferably in the range of 0.20:1 to 0.40:1, more preferably in the range of 0.20:1 to 0.35:1.
- the catalytic material comprises Fe, calculated as Fe 2 O 3 , supported on the zeolitic material, calculated as sum of the weights of SiO 2 and X 2 O 3 comprised by the frame- work structure of the zeolitic material, in an amount of equal to or greater than 2.5 weight-%, more preferably in the range of 2.5 to 10.0 weight-%, more preferably in the range of 2.5 to 7.5 weight-%, more preferably in the range of 4.0 to 6.5 weight-%, more preferably in the range of 5.0 to 6.2 weight-%, more preferably in the range of 5.9 to 6.0 weight-%.
- the present invention relates to a process for producing a catalytic material, preferably for producing the catalytic material according to any one of the particular and preferred embodi- ments disclosed herein, the process comprising (i) providing an aqueous mixture comprising a zeolitic material, one or more sources of Fe, and one or more optionally substituted ammonium cations; (ii) subjecting the mixture obtained in (i) to ion-exchange conditions; wherein the zeolitic material comprises SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has a maximum ring size of 10 T-atoms or less, wherein the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from ⁇ 103.5 to ⁇ 108.5 ppm, wherein the integral of the first peak affords an area I 1 , wherein all peaks in the range of ⁇ 90.0 to ⁇
- supporting of Fe on a zeolitic material can be done via commonly known pro- Kres, especially via ion-exchange procedure, wherein the term "ion-exchange" according to the present invention generally refers to non-framework ionic elements and/or molecules con- tained in the zeolitic material.
- ion-exchange generally refers to non-framework ionic elements and/or molecules con- tained in the zeolitic material.
- any conceivable ion-exchange procedure with all pos- sible ionic elements and/or molecules can be conducted on the zeolitic material, with the excep- tion of organic structure directing agents specifically used in the synthesis of zeolitic materials.
- At least one cation and/or cationic element is employed which is preferably selected from the group consisting of H + , NH4 + , and Fe.
- a supporting, in par- ticular an ion-exchange can be conducted via impregnation, preferably via incipient wetness technique.
- Incipient wetness impregnation techniques also called capillary impregnation or dry impregnation are commonly used for the synthesis of heterogeneous materials, i.e., catalysts.
- the Fe can be supported on a zeolitic material as metal cluster and/or as metal ox- ide.
- the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or greater than 0.23:1, more preferably greater than 0.25:1. It is preferred that the ratio of the area I 1 of the first peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is in the range of 0.2:1 to 0.60:1, more preferably in the range of 0.23:1 to 0.50:1, more preferably in the range of 0.25:1 to 0.45:1.
- the first peak (P1) has a maximum in the range of ⁇ 104.0 to ⁇ 108.0 ppm, more preferably in the range of ⁇ 104.5 to ⁇ 107.0 ppm, more preferably in the range of ⁇ 105.0 to ⁇ 107.0 ppm.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of ⁇ 97.5 to ⁇ 102.5 ppm, more preferably in the range of ⁇ 99.0 to ⁇ 101.0 ppm, wherein the integral of the second peak (P2) preferably affords an area I 2 , wherein the ratio of the area I 2 of the second peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of ⁇ 108.6 to ⁇ 112.5 ppm, more preferably in the range of ⁇ 110.0 to ⁇ 112.0 ppm, wherein the integral of the third peak (P3) more preferably af- fords an area I 3 , wherein the ratio of the area I 3 of the third peak to the area I total of all peaks in BASF Corporation 220846WO01 - 7 - the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.55:1, more preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of ⁇ 112.6 to ⁇ 116.5 ppm, more preferably in the range of ⁇ 113.0 to ⁇ 115.0 ppm, wherein the integral of the fourth peak (P4) more preferably af- fords an area I 4 , wherein the ratio of the area I 4 of the fourth peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1, more preferably equal to or smaller than 0.40:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of ⁇ 93.0 to ⁇ 97.0 ppm, more preferably in the range of ⁇ 94.0 to ⁇ 96.0 ppm, wherein the integral of the fifth peak (P5) more preferably affords an area I 5 , wherein the ratio of the area I 5 of the fifth peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1.
- X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, more preferably selected from the group consisting of Al, B, and a mixture thereof, wherein X more preferably is Al.
- the zeolitic material has a molar ratio of SiO 2 to X 2 O 3 of equal to or less than 50, more preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20.
- the one or more optionally substituted ammonium cations are selected from the group consisting of NH 4 + , ((C 1 -C 10 )alkyl)NH 3 + , ((C 1 -C 10 )alkyl) 2 NH 2 + , ((C 1 -C 10 )alkyl) 3 NH + , ((C 1 - C 10 )alkyl) 4 N + , and mixtures of two or more thereof, more preferably from the group consisting of NH4 + , ((C1-C7)alkyl)NH3 + , ((C1-C7)alkyl)2NH2 + , ((C1-C7)alkyl)3NH + , ((C1-C7)alkyl)4N + , and mixtures of two or more thereof, more preferably from the group consisting of NH 4 + , ((C 1 -C 5 )alkyl)NH 3 + , ((C 1 -C 5 )alky
- the one or more sources of Fe are selected from the group consisting of Fe nitrates, Fe citrates, ammonium Fe citrates, Fe acetates, Fe sulfates, Fe ascorbates, and mix- tures of two or more thereof, more preferably from the group consisting of Fe(III) nitrate, Fe(III) BASF Corporation 220846WO01 - 8 - citrate, ammonium Fe(III) citrate, Fe(III) acetate, Fe(III) sulfate, Fe(III) ascorbate, and mixtures of two or more thereof, wherein the one or more sources of Fe more preferably are Fe(III) ni- trate.
- the mixture obtained in (i) has a weight ratio of water to the zeolitic material in the range of 4.0:1 to 10.0:1, more preferably in the range of 5.0:1 to 9.0:1, more preferably in the range of 6.0:1 to 8.0:1, more preferably in the range of 6.5:1 to 7.5:1.
- the pH of the mixture obtained in (i) has a pH in the range of 3.0 to 7.0, more preferably in the range of 3.5 to 6.5, more preferably in the range of 4.0 to 6.0, more preferably in the range of 4.5 to 5.5.
- the zeolitic material comprised in the mixture provided in (i) has an AEI-, AFT- , AFX-, CHA-, FER-, or MFI-type framework structure, more preferably a CHA-, FER-, or MFI- type framework structure, more preferably a CHA- or FER-type framework structure, more pref- erably a FER-type framework structure.
- the ion-exchange conditions comprise heating the mixture obtained in (i) to a temperature in the range of 30 to 100 °C, more preferably in the range of 35 to 80 °C, more preferably in the range of 40 to 70 °C, more preferably in the range of 45 to 65 °C.
- the ion-exchange conditions are applied in (ii) for a duration in the range of 0.1 to 48 h, more preferably in the range of 0.5 to 25 h, more preferably in the range of 1 to 5 h. It is preferred that the ion-exchange conditions comprise stirring the mixture obtained in (i). It is preferred that the process further comprises after (ii) (s) separating the catalytic material obtained in (ii), preferably by filtration. It is preferred that the process further comprises after (ii), more preferably after (s) as defined herein above, (w) washing the catalytic material obtained in (ii), more preferably after (s), with water, wherein washing is more preferably performed until the water has a conductivity of less than 200 ⁇ S.
- the process further comprises after (ii), more preferably after (s), more prefer- ably after (w) (d) drying the catalytic material obtained in (ii), (s), or (w) in a gas atmosphere having a tem- perature in the range of 70 to 135 °C, more preferably in the range of 80 to 120 °C, more prefer- ably in the range of 90 to 110 °C.
- the gas atmosphere ac- cording to (c) comprises one or more of nitrogen and oxygen, wherein the gas atmosphere more preferably comprises, more preferably consists of, air. It is preferred that the process further comprises after (ii), more preferably after (s), more prefer- ably after (w), more preferably after (d), more preferably after (c), (m) molding a mixture comprising the catalytic material obtained in (ii), (s), (w), (d), or (c), and an optionally hydrated binder, wherein the binder more preferably comprises one or more of Zr acetate, pseudoboehmite, alumina, silica-alumina, and a mixture of two or more thereof, wherein the mixture comprises the binder, calculated as oxide, in an amount in the range of 1 to 10 weight-%, more preferably in the range of 4 to 6 weight-%, based on the sum of the weights of SiO2 and X2O3 comprised in the framework structure
- the process further comprises (m) it is preferred that the process further comprises after (m) (md) drying the mixture obtained in (m) in a gas atmosphere having a temperature in the range of 500 to 650 °C, more preferably in the range of 560 to 620 °C, more preferably in the range of 580 to 600 °C.
- the process fur- ther comprises after (m), more preferably after (md) (mc) calcining the mixture obtained in (m) of (md) in a gas atmosphere having a temperature in the range of 500 to 650 °C, more preferably in the range of 560 to 620 °C, more preferably in the range of 580 to 600 °C, wherein calcining is more preferably performed for a duration in the range of 0.5 to 24 h, more preferably in the range of 1 to 5 h.
- the process fur- ther comprises after (m), more preferably after (md), more preferably after (mc) (mcr) crushing the mixture obtained in (m), (md), or (mc), wherein further preferred that the pro- cess further comprises (msi) sieving the mixture obtained in (m), (md), (mc), or (mcr) to particles, more preferably with a sieve having a mesh in the range of 250 to 500 ⁇ m.
- the present invention relates to a catalytic material obtained or obtainable by the process of any one of the particular and preferred embodiments disclosed herein.
- the present invention relates to an exhaust gas treatment system comprising a com- ponent comprising the catalytic material of any one of the particular and preferred embodiments disclosed herein, an internal combustion engine and an exhaust gas conduit in fluid communi- cation with the internal combustion engine, wherein the component comprising the catalytic ma- terial is present in the exhaust gas conduit.
- the component comprising the catalytic material comprises a substrate, wherein said catalytic material is disposed on said substrate.
- the internal combustion engine is a lean burn engine or a lean gasoline direct injection (GDI) engine, more preferably a diesel engine, more preferably a heavy duty diesel en- gine.
- GDI lean gasoline direct injection
- the exhaust gas treatment system further comprises a diesel oxidation cata- lyst (DOC), wherein the diesel oxidation catalyst is more preferably located upstream of the component comprising the catalytic material. It is preferred that the exhaust gas treatment system further comprises an optionally catalyzed soot filter, wherein the optionally catalyzed soot filter is located upstream or downstream of the component comprising the catalytic material. It is preferred that the exhaust gas treatment system further comprises an ammonia oxidation catalyst (AMOX), wherein the ammonia oxidation catalyst (AMOX) is located upstream or down- stream of the component comprising the catalytic material.
- AMOX ammonia oxidation catalyst
- the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas a SCR component, an ammonia oxidation catalyst (AMOX), a diesel oxidation catalyst (DOC), the component comprising the catalytic material, op- tionally a Cu-containing SCR component, and an ammonia oxidation catalyst (AMOX).
- AMOX ammonia oxidation catalyst
- DOC diesel oxidation catalyst
- AMOX ammonia oxidation catalyst
- the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas the component comprising the catalytic material, an ammonia oxidation catalyst (AMOX), a diesel oxidation catalyst (DOC), optionally a Cu-contain- ing SCR component, and an ammonia oxidation catalyst (AMOX).
- AMOX ammonia oxidation catalyst
- DOC diesel oxidation catalyst
- AMOX ammonia oxidation catalyst
- the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas a hydrocarbon injector, a diesel oxidation catalyst BASF Corporation 220846WO01 - 11 - (DOC), a catalyzed soot filter (CSF), an urea injector, the component comprising the catalytic material, and a combined selective catalytic reduction/ammonia oxidation catalyst.
- DOC diesel oxidation catalyst BASF Corporation 220846WO01 - 11 -
- CSF catalyzed soot filter
- urea injector the component comprising the catalytic material
- a combined selective catalytic reduction/ammonia oxidation catalyst a combined selective catalytic reduction/ammonia oxidation catalyst.
- the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas an urea injector, a close coupled selective catalytic re- duction (cc-SCR), a hydrocarbon injector, a diesel oxidation catalyst (DOC), a catalyzed soot filter (CSF), an urea injector, the component comprising the catalytic material, and a combined selective catalytic reduction/ammonia oxidation catalyst.
- the exhaust gas treatment system further comprises a reductant injector, wherein the reductant injector is more preferably located upstream of the component comprising the catalytic material, more preferably between the diesel oxidation catalyst (DOC) and the component comprising the catalytic material as defined for the first alternative for the exhaust gas treatment system herein above, or between the internal combustion engine and the component comprising the catalytic material as defined for the second alternative for the exhaust gas treatment system herein above.
- the reductant comprises, more preferably consists of, one or more of ammonia, a hydrocarbon, and urea.
- the present invention relates to a process for the treatment of an exhaust gas, pref- erably for the selective catalytic reduction of NOx comprised in an exhaust gas, the process comprising bringing the exhaust gas stream in contact with a catalytic material according to any one of the particular and preferred embodiments disclosed herein.
- the present invention relates to use of a catalytic material according to any one of the particular and preferred embodiments disclosed herein or of an exhaust gas treatment sys- tem according to any one of the particular and preferred embodiments disclosed herein for the treatment of an exhaust gas comprising NOx, preferably for the selective catalytic reduction (SCR) of NOx comprised in an exhaust gas.
- SCR selective catalytic reduction
- the present invention is further illustrated by the following set of embodiments and combina- tions of embodiments resulting from the dependencies and back-references as indicated.
- par- ticular it is noted that in each instance where a range of embodiments is mentioned, for exam- ple in the context of a term such as "The catalytic material of any one of embodiments 1 to 4", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The cat- alytic material of any one of embodiments 1, 2, 3, and 4".
- a catalytic material for the selective catalytic reduction of NOx the catalytic material com- prising a zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has an FER-type framework structure, wherein the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from ⁇ 103.5 to ⁇ 108.5 ppm, wherein the integral of the first peak affords an area I 1 , wherein the integral of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm afford an area I total , wherein the ratio of the area I 1 of the first peak to the area Itotal
- a process for producing a catalytic material preferably for producing the catalytic material according to any one of embodiments 1 to 13, the process comprising (i) providing an aqueous mixture comprising a zeolitic material, one or more sources of Fe, and one or more optionally substituted ammonium cations; (ii) subjecting the mixture obtained in (i) to ion-exchange conditions; wherein the zeolitic material comprises SiO 2 and X 2 O 3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has a maximum ring size of 10 T-atoms or less, wherein the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from ⁇ 103.5 to ⁇ 108.5 ppm, wherein the integral of the first peak affords an area I 1 , wherein all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm have an area Itotal, wherein the ratio of
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of ⁇ 97.5 to ⁇ 102.5 ppm, preferably in the range of ⁇ 99.0 to ⁇ 101.0 ppm, wherein the integral of the second peak (P2) preferably affords an area I2, wherein the ratio of the area I 2 of the second peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 BASF Corporation 220846WO01 - 15 - ppm is equal to or smaller than 0.05:1, preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1. 19.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of ⁇ 108.6 to ⁇ 112.5 ppm, preferably in the range of ⁇ 110.0 to ⁇ 112.0 ppm, wherein the integral of the third peak (P3) preferably affords an area I 3 , wherein the ratio of the area I 3 of the third peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.55:1, preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of ⁇ 112.6 to ⁇ 116.5 ppm, preferably in the range of ⁇ 113.0 to ⁇ 115.0 ppm, wherein the integral of the fourth peak (P4) preferably affords an area I 4 , wherein the ratio of the area I4 of the fourth peak to the area Itotal of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.50:1, preferably equal to or smaller than 0.45:1, more preferably equal to or smaller than 0.40:1.
- the deconvoluted 29 Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of ⁇ 93.0 to ⁇ 97.0 ppm, preferably in the range of ⁇ 94.0 to ⁇ 96.0 ppm, wherein the integral of the fifth peak (P5) preferably affords an area I5, wherein the ratio of the area I5 of the fifth peak to the area I total of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm is equal to or smaller than 0.05:1, preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1. 22.
- the zeolitic material has a mo- lar ratio of SiO 2 to X 2 O 3 of equal to or less than 50, preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. 24.
- any one of embodiments 14 to 24, wherein the one or more sources of Fe are selected from the group consisting of Fe nitrates, Fe citrates, ammonium Fe citrates, Fe acetates, Fe sulfates, Fe ascorbates, and mixtures of two or more thereof, preferably from the group consisting of Fe(III) nitrate, Fe(III) citrate, ammonium Fe(III) citrate, Fe(III) acetate, Fe(III) sulfate, Fe(III) ascorbate, and mixtures of two or more thereof, wherein the one or more sources of Fe more preferably are Fe(III) nitrate. 26.
- the pH of the mixture obtained in (i) has a pH in the range of 3.0 to 7.0, preferably in the range of 3.5 to 6.5, more preferably in the range of 4.0 to 6.0, more preferably in the range of 4.5 to 5.5. 28.
- the zeolitic material comprised in the mixture provided in (i) has an AEI-, AFT-, AFX-, CHA-, FER-, or MFI-type frame- work structure, preferably a CHA-, FER-, or MFI-type framework structure, more prefera- bly a CHA- or FER-type framework structure, more preferably a FER-type framework structure. 29.
- any one of embodiments 14 to 28, wherein the ion-exchange conditions comprise heating the mixture obtained in (i) to a temperature in the range of 30 to 100 °C, preferably in the range of 35 to 80 °C, more preferably in the range of 40 to 70 °C, more preferably in the range of 45 to 65 °C. 30.
- the process of any one of embodiments 14 to 30, wherein the ion-exchange conditions comprise stirring the mixture obtained in (i).
- any one of embodiments 14 to 33 further comprising after (ii), preferably after (s), more preferably after (w) (d) drying the catalytic material obtained in (ii), (s), or (w) in a gas atmosphere having a temperature in the range of 70 to 135 °C, more preferably in the range of 80 to 120 °C, preferably in the range of 90 to 110 °C. 35.
- any one of embodiments 14 to 34 further comprising after (ii), preferably after (s), more preferably after (w), more preferably after (d), (c) calcining the catalytic material obtained in (ii), (s), (w), or (d) in a gas atmosphere having a temperature in the range of 400 to 600 °C, preferably in the range of 420 to 500 °C, more preferably in the range of 440 to 460 °C, wherein calcining is more preferably performed for a duration in the range of 0.5 to 24 h, preferably in the range of 1 to 5 h. 36.
- the gas atmosphere comprises one or more of nitrogen and oxygen, wherein the gas atmosphere more preferably comprises, more preferably consists of, air. 37.
- any one of embodiments 37 to 40 further comprising after (m), preferably after (md), more preferably after (mc) (mcr) crushing the mixture obtained in (m), (md), or (mc), and preferably further compris- ing (msi) sieving the mixture obtained in (m), (md), (mc), or (mcr) to particles, preferably with a sieve having a mesh in the range of 250 to 500 ⁇ m. 42.
- the exhaust gas treatment system of any one of embodiments 43 to 45 comprising in consecutive order in the direction of the exhaust gas the component comprising the cata- lytic material of any one of embodiments 1 to 13 and 42, an ammonia oxidation catalyst (AMOX), a diesel oxidation catalyst (DOC), optionally a Cu-containing SCR component, and an ammonia oxidation catalyst (AMOX). 51.
- AMOX ammonia oxidation catalyst
- DOC diesel oxidation catalyst
- AMOX ammonia oxidation catalyst
- the exhaust gas treatment system of any one of embodiments 43 to 45 comprising in consecutive order in the direction of the exhaust gas a hydrocarbon injector, a diesel oxi- dation catalyst (DOC), a catalyzed soot filter (CSF), an urea injector, the component com- prising the catalytic material of any one of embodiments 1 to 13 and 42, and a combined selective catalytic reduction/ammonia oxidation catalyst. 52.
- DOC diesel oxi- dation catalyst
- CSF catalyzed soot filter
- urea injector the component com- prising the catalytic material of any one of embodiments 1 to 13 and 42
- a combined selective catalytic reduction/ammonia oxidation catalyst 52.
- the exhaust gas treatment system of any one of embodiments 43 to 45 comprising in consecutive order in the direction of the exhaust gas an urea injector, a close coupled se- lective catalytic reduction (cc-SCR), a hydrocarbon injector, a diesel oxidation catalyst (DOC), a catalyzed soot filter (CSF), an urea injector, the component comprising the cata- lytic material of any one of embodiments 1 to 13 and 42, and a combined selective cata- lytic reduction/ammonia oxidation catalyst. 53.
- a process for the treatment of an exhaust gas, preferably for the selective catalytic reduc- tion of NOx comprised in an exhaust gas comprising bringing the exhaust gas stream in contact with a catalytic material according to any one of embodiments 1 to 13 and 42.
- a catalytic material according to any one of embodiments 1 to 13 and 42 or of an exhaust gas treatment system according to any one of embodiments 43 to 54 for the treat- ment of an exhaust gas comprising NOx, preferably for the selective catalytic reduction (SCR) of NOx comprised in an exhaust gas.
- SCR selective catalytic reduction
- the FER zeolitic materials of Examples 9-11 were analyzed in their H-form prior to ion-ex- change with Fe by 29 Si MAS NMR. To this effect, the FER zeolites were hydrated for 48 h. The results are shown in Table 3 and Figures 1-3. For each FER zeolite, four peaks were observed in the range of ⁇ 90.0 to ⁇ 130.0 ppm. The peak in the range of ⁇ 103.5 to ⁇ 108.5 ppm can be assigned to the Q4(1Al) sites in the FER zeolite.
- catalytic materials comprising a FER zeolite having a comparatively higher content of Q4(1Al) sites show a comparatively better SCR performance.
- BASF Corporation 220846WO01 - 22 - Table 3 Overview of catalytic materials according to Examples 9-11 and their properties.
- the mixture was stored for 20 h at 50 °C in an oven. Subsequently, the obtained material was dried and then calcined at 450 °C for 5 h. From the obtained impregnated zeolite a slurry was prepared and Zr-acetate was added (5 weight-% based on zeolite). The resulting mixture was dried under stirring and then calcined for 1 h at 550 °C. The obtained material was crushed and sieved (250 to 500 ⁇ m).
- Each FER zeolite was loaded with 5.9 to 6.0 weight-% Fe, calculated as Fe 2 O 3 , and based on the sum of the weights of Fe, calculated as Fe 2 O 3 , and SiO 2 and Al 2 O 3 comprised in the framework structure of the FER zeolite.
- a peak in the range of from ⁇ 103.5.0 to ⁇ 108.5.0 ppm indicates presence of Q 4 (1Al) sites.
- catalytic materials which particularly comprise a zeolitic material having a specific Al distribution, thus, especially showing in the deconvoluted 29 Si MAS NMR a first peak (P1) having a maximum in said range, while further having a specific integral ratio of the first peak to the integral of all peaks in the range of ⁇ 90.0 to ⁇ 130.0 ppm.
- P1 first peak
- the peak in- tegrals do not correlate with the silica to alumina ratios, such that they describe specific Al distri- butions in the zeolitic frameworks which are independent of their respective silica to alumina ra- tios.
- Example 13 Catalytic testing The prepared catalytic materials comprising Fe-FER zeolites were tested with respect to their SCR performance in a fresh state (as-prepared), after aging for 50 h at 650 °C in air comprising 10 % steam, and after aging for 16 h at 820 °C in air comprising 10 % steam. The following testing conditions were applied: Standard SCR feed having a gas hourly space velocity (GHSV) of 80000 h -1 , and comprising 500 ppm NO, 500 ppm NH 3 , 5 % H 2 O, 10% O 2 , balance N 2 .
- GHSV gas hourly space velocity
- Fast SCR feed having a gas hourly space velocity (GHSV) of 80000 h -1 , and comprising 250 ppm NO, 250 ppm NO2, 500 ppm NH3, 5 % H2O, 10 % O2, balance N2.
- GHSV gas hourly space velocity
- Fast SCR run: T 575, 550, 450, 350, 250, 225, 200, 175°C
- the resulting data for the testing of aged catalytic materials according to Examples 1-8 is shown in Figures 4 and 5.
- the catalytic materials in accordance with the present invention showed a very good SCR performance after aging for 50 h at 650 °C in air comprising 10 % steam, and a good performance after aging for 16 h at 820 °C in air com- prising 10 % steam.
- the standard SCR performance for the catalytic materials according to Examples 9-11 was measured after 650 °C/50 h aging and 820 °C/16 h aging.
- the performance data shown in Fig- ure 6 demonstrate that the catalytic material comprising a FER zeolite having SAR 15.7 shows the highest SCR activity as compared to the rest of the samples.
- Example 14 Comparative catalytic testing Two types of Fe-zeolites are commonly used currently – Fe-CHA and Fe-BEA. It is widely known that it is difficult to incorporate Fe into the pores of CHA zeolite. An activation with steam or reducing atmosphere is required to incorporate Fe into the pores of CHA zeolites, which sig- nificantly adds to the cost of the final Fe-zeolite catalyst. While BEA has the advantage that there is no activation step required to incorporate Fe and make the active catalyst, it is known that BEA can be deactivated by hydrocarbons present in the gas feed. Consequently, Fe-CHA is used in applications that require tolerance to hydrocarbons in place of Fe-BEA.
- FER zeolite provides the advantage of not requiring activation by steam and is at the same time tolerant to hydrocarbons. This is all the more surprising since FER zeolites belong to the group of medium pore zeolites, which particularly comprise pores with 10 membered rings, which are typically considered as not showing as much steric hindrance as observed for small pore zeolites. Additionally, FER zeolites also show tolerance to humidity treatment.
- BASF Corporation 220846WO01 - 24 - 89.9 parts by weight of the ammonium-form of FER, 5.1 parts by weight of Iron nitrate calcu- lated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were mixed into deionized water to form a slurry. pH of the slurry is adjusted to 3.3 with TEAOH solution. The slurry was milled to a particle size of D90 between 4 ⁇ m to 10 ⁇ m, as measured with a Sym- patec particle size analyzer.
- the slurry was milled to a particle size of D90 be- tween 4 ⁇ m to 10 ⁇ m, as measured with a Sympatec particle size analyzer.
- the slurry was coated onto a flow-through cordierite monolith substrate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C.
- the washcoat loading was 2.5 g/in 3 .
- pH of the slurry is adjusted to 3.3 with TEAOH solution.
- the slurry was milled to a particle size of D90 between 4 ⁇ m to 10 ⁇ m, as measured with a Sympatec par- ticle size analyzer.
- the slurry was coated onto a flow-through cordierite monolith substrate hav- ing a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and cal- cination at 590 °C.
- the washcoat loading was 2.5 g/in 3 .
- deionized water 82 parts by weight of deionized water is combined with 12.8 parts by weight of ammonium-form FER zeolite and 5.2 parts by weight of Ferric nitrate solution (9.5 weight-% aqueous solution, calculated as Fe 2 O 3 ).
- This solution is heated to 60 °C under stirring and then the pH is adjusted to 5.0-5.15 by the use of tetraethylammonium hydroxide (35 weight-% aqueous solution) as a base. After pH adjustment, the solution is stirred for 1 hour at 60 °C before cutting off the heat. The cooled solution is filtered and washed with deionized water until the conductivity of the fil- trate is lower than 200 ⁇ S.
- the filtercake is then dried overnight at 90 °C to obtain Fe/FER with 5.5% Fe 2 O 3 .
- 95 parts by weight of Fe/FER containing 5.5% of Fe 2 O 3 and 5.0 parts by weight of zirconium ac- etate calculated as ZrO 2 were mixed into deionized water to form a slurry.
- the slurry was milled to a particle size of D90 between 4 ⁇ m to 10 ⁇ m, as measured with a Sympatec particle size an- alyzer.
- the slurry was coated onto a flow-through cordierite monolith substrate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C.
- Example 22 Catalytic testing The NOx conversion and N2O formation was tested using a flow reactor under pseudo-steady state conditions with a gas stream of 1000 ppmv NOx (NO 2 /NOx ratio 0.5), 1050 ppmv NH 3 , 10 vol% O 2 , 7 vol% H 2 O, 8 vol% CO 2 and balanced N 2 , at a space velocity of 60,000 h -1 .
- SCR cata- lysts were hydrothermally aged in 10% O2, 10% H2O and balanced N2 at 650 °C for 100 h, or degreened in 10% O2, 10% H2O and balanced N2 at 550 °C for 4 h.
- All inventive examples 15 to 21 show improved NOx conversion over the state of art Fe/CHA SCR as shown in Figures 8-11.
- BASF Corporation 220846WO01 - 26 - It is shown in Figure 12 that the inventive SCR catalyst maintains high NOx conversion at low temperature such as 200 °C with extended testing time. On the contrary, low temperature NOx conversion of the state of art Fe/CHA decreases with extended testing time, likely due to for- mation of NH 4 NO 3 that partially blocks active sites.
- the inventive SCR catalyst according to Example 17 was tested after aging with respect to its HC resistance.
- the testing conditions were as follows: 200 ppm NO, Ammonia/NOx ratio 1.05, 1000 ppm HC (C1 basis, 2:1 C 3 H 6 :C 3 H 8 ), 10 % O 2 , 7 % H 2 O, 80 k/h SV, 300 °C. The results are shown in Figure 13.
- the catalytic materials according to the present invention which are particularly characterized in showing in the deconvoluted 29 Si MAS NMR of the zeolitic material a first peak (P1) having a maximum in the range of from ⁇ 103.5 to ⁇ 108.5 ppm, wherein the integral of the first peak affords a specific area I 1 relative to the area I total of all peaks, achieve a favorable SCR activity, especially after hydrothermal aging.
- Figure 4 shows the results for the catalytic testing of aged catalytic materials according to Ex- amples 1-8.
- FIG. 7 shows the results for comparative catalytic testing of a state-of-the-art Fe-BEA, a state-of-the-art Fe-CHA, and catalytic materials in accordance with Examples 2 and 7 in the fresh state as well as after aging.
- the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %.
- Figure 8 shows the results for the catalytic testing of the catalytic materials according to Ex- amples 15, 17, 19-20, and a state-of-the-art Fe-CHA.
- the tempera- ture is shown in °C and on the ordinate
- the NOx conversion is shown in %.
- Figure 9 shows the results for the catalytic testing of the catalytic materials according to Ex- amples 15, 17, 19-20, and a state-of-the-art Fe-CHA.
- the tempera- ture is shown in °C and on the ordinate, the N 2 O formation is shown ppm.
- Figure 10 shows the results for the catalytic testing of the catalytic materials according to Ex- amples 18, 21, and a state-of-the-art Fe-CHA.
- the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %.
- Figure 11 shows the results for the catalytic testing of the catalytic materials according to Ex- amples 18, 21, and a state-of-the-art Fe-CHA. On the abscissa, the temperature is shown in °C and on the ordinate, the N2O formation is shown ppm.
- Figure 12 shows the outlet NOx concentration in a catalytic test at 200 °C for the catalytic ma- terial according to example 15 and a state-of-the-art Fe-CHA. On the abscissa, the time is shown in seconds and on the ordinate, the NOx concentration is shown in ppm.
- Figure 13 shows the results of the hydrocarbon tolerance test for the catalytic material accord- ing to Example 17 after aging.
- Figure 14 shows two exemplary exhaust gas treatment systems, wherein both exemplary sys- tems include in consecutive order in the direction of exhaust gas flow a hydrocarbon injector, a diesel oxidation catalyst (DOC), a catalyzed soot filter (CSF), an urea in- jector, a component comprising the catalytic material in accordance with the present invention (SCR1), and a combined selective catalytic reduction/ammonia oxidation catalyst.
- the exemplary system in the lower part additionally comprises a close cou- pled selective catalytic reduction (cc-SCR) catalyst upstream of the hydrocarbon in- jector.
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Abstract
The present invention relates to an iron-containing catalytic material for the selective catalytic reduction of NOx in exhaust gas from an internal combustion engine. The catalytic material comprises a zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein X is a trivalent element such as aluminium, wherein the zeolitic material has an FER-type framework structure, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a specific first peak (Pl) corresponding to Q4(1AI) sites and having a maximum in the range of from -103.5 to -108.5 ppm with a certain minimum integral relative to three other peaks in the range of -90.0 to -130.0 ppm. The catalytic material also comprises Fe supported on the zeolitic material. Further, the present invention relates to a process for producing a catalytic material, an exhaust gas treatment system comprising a catalytic material in accordance with the present invention as well as to use thereof and a process for the treatment of an exhaust gas including said catalytic material.
Description
BASF Corporation 220846WO01 Fe-containing catalytic materials for the treatment of an exhaust gas TECHNICAL FIELD The present invention relates to a catalytic material for the treatment of an exhaust gas compris- ing NOx, preferably for the selective catalytic reduction of NOx. Further, the present invention relates to a process for preparing a catalytic material, a catalytic material obtained or obtainable by said process, an exhaust gas treatment system using the catalytic material of the present in- vention, a process for the treatment of an exhaust gas using the catalytic material of the present invention, and use of a catalytic material according to the present invention for the treatment of an exhaust gas, preferably for the selective catalytic reduction of NOx. INTRODUCTION The present invention pertains to the field of catalysts effective for selective catalytic reduction. Described are attributes of zeolitic materials having a framework structure having a maximum ring size of 10 T-atoms or less that provide best SCR performance when loaded with Fe. Fur- ther, a process for preparing a catalytic material is described herein allowing incorporation of comparatively high amounts of Fe into a zeolitic material. WO 2020/021054 A1 relates to a process for preparing a zeolitic material having framework type FER. It is disclosed therein that the prepared zeolitic material can be ion-exchanged with ions of one or more of Cu, Pd, Rh, Pt and Fe. WO 2021/198339 A1 relates to catalysts for the selective catalytic reduction of nitrogen oxide, processes for preparing said catalysts for the selective catalytic reduction of nitrogen oxide, use of a catalyst for the selective catalytic reduction of nitrogen oxide and an exhaust gas treatment system comprising said catalyst. The catalyst can comprise a zeolitic material having a frame- work structure type selected from the group consisting of MFI, MWW, AEL, HEU, FER, AFO, a mixture of two or more thereof and a mixed type of two or more thereof, wherein the zeolitic ma- terial can be ion-exchanged with Fe. WO 2015/128668 A1 relates to SCR-active molecular sieve based-catalysts produced by com- bining a molecular sieve with at least one ionic iron species and at least one organic compound to form a mixture, then calcining the mixture to remove the at least one organic compound. It is disclosed that this process improves the dispersion of the iron within the molecular sieve com- pared to an iron-containing molecular sieve that is not treated with an organic compound. The prepared Fe-containing ferrierite zeolites were tested in the selective catalytic reduction of nitro- gen oxides with NH3 or urea.
BASF Corporation 220846WO01 - 2 - EP 2857084 A1 relates to a device for treatment of exhaust gas flowing in an exhaust line of an internal combustion engine, characterized in that it comprises a porous substrate coated and/or impregnated with catalytic composition(s) combining a chabazite zeolite in the H-form or im- pregnated copper and/or a ferrierite zeolite in the H-form or impregnated with one or more of Cu and Fe. DE 102011012799 A1 relates to a catalyst comprising a carrier body of a certain length and a catalytically active coating made of at least one material zone which may comprise a zeolite containing 1-10 wt.% of copper, iron and/or silver, based on the total weight of the zeolite, where the zeolite may comprise ferrierite (FER). EP 2409760 A1 relates to a gas-treatment device including such a composition comprising a ferrierite/iron-type zeolite. It is disclosed that the substrate has an internal structure that is adapted for forming a particulate filter (1) and has a catalytic composition comprising ferrierite zeolite in the H-form and containing iron (0.3-2 mass%) deposited on the substrate. The cata- lytic composition is configured for performing chemical reaction such as reduction of nitrogen oxide. WO 2008/049557 A1 relates to a catalyst useful for decomposing and/or reduction of nitrous ox- ide, wherein the catalyst can comprise a ferrierite-type zeolite being Fe-exchanged. US 5041272 A relates to a method for removing nitrogen oxides from exhaust gases containing oxygen and moisture, which comprises bringing the exhaust gas into contact with hydrogenated zeolite catalysts or hydrogenated zeolite catalysts impregnated with one or more kinds of metals selected from the group consisting of copper, zinc, vanadium, chromium, manganese, iron, co- balt, nickel, rhodium, palladium, platinum, and molybdenum, in the presence of organic com- pounds. The zeolite may be of ferrierite type. US 2011/056187 A1 relates to a process for treating diesel engine exhaust gases comprising nitrogen oxides (NOx) and hydrocarbons (HC) by selective catalytic reduction of the nitrogen ox- ides with ammonia or a compound decomposable to ammonia as a reducing agent over an SCR catalyst based on a molecular sieve. P.Sarv et al., “Multinuclear MQMAS NMR Study of NH4/Na-Ferrierites”, J. Phys. Chem. B 1998, 102, 1372-1378, relates to (MQ)MAS NMR as a method to study quadrupolar nuclei, enabling separation of the chemical shift interaction from the quadrupolar interaction. Illustrated are 29Si MAS NMR spectra of a NH4-ferrierites with a peak distribution in the range of from −90.0 to − 120.0 ppm. Accordingly, it was an object of the present invention to provide a catalytic material showing an improved performance in selective catalytic reduction (SCR), in particular in selective catalytic reduction of NOx. Especially, it was an object to provide a catalytic material showing an im- proved performance in selective catalytic reduction of NOx after aging. Further, it was an object
BASF Corporation 220846WO01 - 3 - of the present invention to provide a catalytic material showing an improved resistance to hydro- carbon poisoning. Additionally, it was an object of the present invention to provide a process for the preparation of a catalytic material, in particular allowing an improved ion-exchange, in partic- ular with Fe, of a zeolitic material comprised in the catalytic material. Yet further, it was an ob- ject of the present invention to provide an exhaust gas treatment system comprising the cata- lytic material in accordance with the present invention. Exemplary designs for exhaust gas treat- ment systems in accordance with the present invention are shown in Figure 14. DETAILED DESCRIPTION Thus, it has surprisingly been found that a catalytic material can be provided showing a very good SCR performance, in particular after aging of the catalytic material. The inventive catalytic material, which is characterized by comprising a FER-type zeolitic material, especially shows an improved performance in selective catalytic reduction of NOx after aging and an improved re- sistance to hydrocarbon poisoning. Further, it was surprisingly found that use of one or more ammonium cations in the preparation of a catalytic material, in particular in combination with an adjustment of the pH of the respective aqueous reaction mixture, allows an improved incorpora- tion of Fe into a zeolitic material comprised in a catalytic material. Therefore, the present invention relates to a catalytic material for the selective catalytic reduc- tion of NOx, the catalytic material comprising a zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has an FER-type framework structure, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from −103.5 to −108.5 ppm, wherein the integral of the first peak affords an area I1, wherein the integral of all peaks in the range of −90.0 to −130.0 ppm afford an area Itotal, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks is equal to or greater than 0.20:1, wherein the catalytic material comprises Fe, wherein Fe is supported on the zeolitic material, and wherein the deconvoluted 29Si MAS NMR of the zeolitic material is preferably determined ac- cording to Reference Example 1. There is no particular restriction according to the present invention as to the state in which the zeolitic material is subjected to the 29Si MAS NMR experiment. It is however preferred that the values given in the present application relative to the 29Si MAS NMR spectrum are obtained from the zeolitic material which has not been subject to any post-synthetic treatment and is therefore an untreated zeolitic material as-crystallized. According to the present invention it is, however, further preferred that the values given in the present application relative to the 29Si MAS NMR spectrum are directly obtained from the zeolitic material as-crystallized wherein after isolation, washing and drying thereof, the material has only been subject to calcination, wherein
BASF Corporation 220846WO01 - 4 - preferably calcination has been conducted according to any of the particular and preferred em- bodiments as defined in the present application, wherein more preferably calcination has been conducted at 550 °C for a duration of 5 h under air. It is preferred that the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or greater than 0.23:1, more preferably greater than 0.25:1. It is preferred that the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is in the range of 0.2:1 to 0.60:1, more preferably in the range of 0.23:1 to 0.50:1, more preferably in the range of 0.30:1 to 0.50:1. It is preferred that the first peak (P1) has a maximum in the range of −104.0 to −108.0 ppm, more preferably in the range of −104.5 to −107.5 ppm, more preferably in the range of −105.0 to −107.0 ppm. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of −97.5 to −102.5 ppm, more preferably in the range of −99.0 to −101.0 ppm, wherein the integral of the second peak (P2) more preferably affords an area I2, wherein the ratio of the area I2 of the second peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of −108.6 to −112.5 ppm, more preferably in the range of −110.0 to −112.0 ppm, wherein the integral of the third peak (P3) more preferably af- fords an area I3, wherein the ratio of the area I3 of the third peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.55:1, more preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of −112.6 to −116.5 ppm, more preferably in the range of −113.0 to −115.0 ppm, wherein the integral of the fourth peak (P4) more preferably af- fords an area I4, wherein the ratio of the area I4 of the fourth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1, more preferably equal to or smaller than 0.40:1. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of −93.0 to −97.0 ppm, more preferably in the range of −94.0 to −96.0 ppm, wherein the integral of the fifth peak (P5) more preferably affords an area I5, wherein the ratio of the area I5 of the fifth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1.
BASF Corporation 220846WO01 - 5 - It is preferred that X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, more preferably selected from the group consisting of Al, B, and a mixture thereof, wherein X more preferably is Al. It is preferred that the zeolitic material has a molar ratio of SiO2 to X2O3 of equal to or less than 50, more preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. In the case where X is Al, it is preferred that the zeolitic material has a molar ratio of SiO2 to Al2O3 of equal to or less than 50, more preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. Furthermore and independently thereof, it is preferred according to a first alternative for the cat- alytic material, that the catalytic material has an atomic ratio of Fe supported on the zeolitic ma- terial, calculated as element, to Al comprised in the framework structure of the zeolitic material, calculated as element, of equal to or greater than 0.20:1, preferably in the range of 0.20:1 to 0.50:1, more preferably in the range of 0.20:1 to 0.45:1, more preferably in the range of 0.20:1 to 0.40:1, more preferably in the range of 0.20:1 to 0.35:1. Furthermore and independently thereof, it is preferred according to a second alternative for the catalytic material, that the catalytic material comprises Fe, calculated as Fe2O3, supported on the zeolitic material, calculated as sum of the weights of SiO2 and X2O3 comprised by the frame- work structure of the zeolitic material, in an amount of equal to or greater than 2.5 weight-%, more preferably in the range of 2.5 to 10.0 weight-%, more preferably in the range of 2.5 to 7.5 weight-%, more preferably in the range of 4.0 to 6.5 weight-%, more preferably in the range of 5.0 to 6.2 weight-%, more preferably in the range of 5.9 to 6.0 weight-%. Further, the present invention relates to a process for producing a catalytic material, preferably for producing the catalytic material according to any one of the particular and preferred embodi- ments disclosed herein, the process comprising (i) providing an aqueous mixture comprising a zeolitic material, one or more sources of Fe, and one or more optionally substituted ammonium cations; (ii) subjecting the mixture obtained in (i) to ion-exchange conditions; wherein the zeolitic material comprises SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has a maximum ring size of 10 T-atoms or less, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from −103.5 to −108.5 ppm, wherein the integral of the first peak affords an area I1, wherein all peaks in the range of −90.0 to −130.0 ppm
BASF Corporation 220846WO01 - 6 - have an area Itotal, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks is equal to or greater than 0.20:1, and Fe supported on the zeolitic material, wherein the deconvoluted 29Si MAS NMR of the zeolitic material is preferably determined according to Reference Example 1. In particular, supporting of Fe on a zeolitic material can be done via commonly known pro- cesses, especially via ion-exchange procedure, wherein the term "ion-exchange" according to the present invention generally refers to non-framework ionic elements and/or molecules con- tained in the zeolitic material. In general, any conceivable ion-exchange procedure with all pos- sible ionic elements and/or molecules can be conducted on the zeolitic material, with the excep- tion of organic structure directing agents specifically used in the synthesis of zeolitic materials. Preferably, as ionic elements at least one cation and/or cationic element is employed which is preferably selected from the group consisting of H+, NH4+, and Fe. Further, a supporting, in par- ticular an ion-exchange, can be conducted via impregnation, preferably via incipient wetness technique. Incipient wetness impregnation techniques, also called capillary impregnation or dry impregnation are commonly used for the synthesis of heterogeneous materials, i.e., catalysts. As a result, the Fe can be supported on a zeolitic material as metal cluster and/or as metal ox- ide. It is preferred that the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or greater than 0.23:1, more preferably greater than 0.25:1. It is preferred that the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is in the range of 0.2:1 to 0.60:1, more preferably in the range of 0.23:1 to 0.50:1, more preferably in the range of 0.25:1 to 0.45:1. It is preferred that the first peak (P1) has a maximum in the range of −104.0 to −108.0 ppm, more preferably in the range of −104.5 to −107.0 ppm, more preferably in the range of −105.0 to −107.0 ppm. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of −97.5 to −102.5 ppm, more preferably in the range of −99.0 to −101.0 ppm, wherein the integral of the second peak (P2) preferably affords an area I2, wherein the ratio of the area I2 of the second peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of −108.6 to −112.5 ppm, more preferably in the range of −110.0 to −112.0 ppm, wherein the integral of the third peak (P3) more preferably af- fords an area I3, wherein the ratio of the area I3 of the third peak to the area Itotal of all peaks in
BASF Corporation 220846WO01 - 7 - the range of −90.0 to −130.0 ppm is equal to or smaller than 0.55:1, more preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of −112.6 to −116.5 ppm, more preferably in the range of −113.0 to −115.0 ppm, wherein the integral of the fourth peak (P4) more preferably af- fords an area I4, wherein the ratio of the area I4 of the fourth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1, more preferably equal to or smaller than 0.40:1. It is preferred that the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of −93.0 to −97.0 ppm, more preferably in the range of −94.0 to −96.0 ppm, wherein the integral of the fifth peak (P5) more preferably affords an area I5, wherein the ratio of the area I5 of the fifth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, more preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1. It is preferred that X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, more preferably selected from the group consisting of Al, B, and a mixture thereof, wherein X more preferably is Al. It is preferred that the zeolitic material has a molar ratio of SiO2 to X2O3 of equal to or less than 50, more preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. It is preferred that the one or more optionally substituted ammonium cations are selected from the group consisting of NH4 +, ((C1-C10)alkyl)NH3 +, ((C1-C10)alkyl)2NH2 +, ((C1-C10)alkyl)3NH+, ((C1- C10)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4+, ((C1-C7)alkyl)NH3+, ((C1-C7)alkyl)2NH2+, ((C1-C7)alkyl)3NH+, ((C1-C7)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4 +, ((C1-C5)alkyl)NH3 +, ((C1-C5)alkyl)2NH2 +, ((C1-C5)alkyl)3NH+, ((C1-C5)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4 +, ((C1-C3)alkyl)NH3 +, ((C1-C3)alkyl)2NH2 +, ((C1- C3)alkyl)3NH+, ((C1-C3)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4 +, ((C2-C3)alkyl)NH3 +, ((C2-C3)alkyl)2NH2 +, ((C2-C3)alkyl)3NH+, ((C2-C3)al- kyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4 +, (C2alkyl)NH3+, (C2alkyl)2NH2+, (C2alkyl)3NH+, (C2alkyl)4N+, and mixtures of two or more thereof, wherein the one or more optionally substituted ammonium cations are more preferably one or more of NH4 + and tetraethylammonium. It is preferred that the one or more sources of Fe are selected from the group consisting of Fe nitrates, Fe citrates, ammonium Fe citrates, Fe acetates, Fe sulfates, Fe ascorbates, and mix- tures of two or more thereof, more preferably from the group consisting of Fe(III) nitrate, Fe(III)
BASF Corporation 220846WO01 - 8 - citrate, ammonium Fe(III) citrate, Fe(III) acetate, Fe(III) sulfate, Fe(III) ascorbate, and mixtures of two or more thereof, wherein the one or more sources of Fe more preferably are Fe(III) ni- trate. It is preferred that the mixture obtained in (i) has a weight ratio of water to the zeolitic material in the range of 4.0:1 to 10.0:1, more preferably in the range of 5.0:1 to 9.0:1, more preferably in the range of 6.0:1 to 8.0:1, more preferably in the range of 6.5:1 to 7.5:1. It is preferred that the pH of the mixture obtained in (i) has a pH in the range of 3.0 to 7.0, more preferably in the range of 3.5 to 6.5, more preferably in the range of 4.0 to 6.0, more preferably in the range of 4.5 to 5.5. It is preferred that the zeolitic material comprised in the mixture provided in (i) has an AEI-, AFT- , AFX-, CHA-, FER-, or MFI-type framework structure, more preferably a CHA-, FER-, or MFI- type framework structure, more preferably a CHA- or FER-type framework structure, more pref- erably a FER-type framework structure. It is preferred that the ion-exchange conditions comprise heating the mixture obtained in (i) to a temperature in the range of 30 to 100 °C, more preferably in the range of 35 to 80 °C, more preferably in the range of 40 to 70 °C, more preferably in the range of 45 to 65 °C. It is preferred that the ion-exchange conditions are applied in (ii) for a duration in the range of 0.1 to 48 h, more preferably in the range of 0.5 to 25 h, more preferably in the range of 1 to 5 h. It is preferred that the ion-exchange conditions comprise stirring the mixture obtained in (i). It is preferred that the process further comprises after (ii) (s) separating the catalytic material obtained in (ii), preferably by filtration. It is preferred that the process further comprises after (ii), more preferably after (s) as defined herein above, (w) washing the catalytic material obtained in (ii), more preferably after (s), with water, wherein washing is more preferably performed until the water has a conductivity of less than 200 µS. It is preferred that the process further comprises after (ii), more preferably after (s), more prefer- ably after (w) (d) drying the catalytic material obtained in (ii), (s), or (w) in a gas atmosphere having a tem- perature in the range of 70 to 135 °C, more preferably in the range of 80 to 120 °C, more prefer- ably in the range of 90 to 110 °C. It is preferred that the process further comprises after (ii), more preferably after (s), more prefer- ably after (w), more preferably after (d),
BASF Corporation 220846WO01 - 9 - (c) calcining the catalytic material obtained in (ii), (s), (w), or (d) in a gas atmosphere having a temperature in the range of 400 to 600 °C, more preferably in the range of 420 to 500 °C, more preferably in the range of 440 to 460 °C, wherein calcining is more preferably performed for a duration in the range of 0.5 to 24 h, more preferably in the range of 1 to 5 h. In the case where the process further comprises (c), it is preferred that the gas atmosphere ac- cording to (c) comprises one or more of nitrogen and oxygen, wherein the gas atmosphere more preferably comprises, more preferably consists of, air. It is preferred that the process further comprises after (ii), more preferably after (s), more prefer- ably after (w), more preferably after (d), more preferably after (c), (m) molding a mixture comprising the catalytic material obtained in (ii), (s), (w), (d), or (c), and an optionally hydrated binder, wherein the binder more preferably comprises one or more of Zr acetate, pseudoboehmite, alumina, silica-alumina, and a mixture of two or more thereof, wherein the mixture comprises the binder, calculated as oxide, in an amount in the range of 1 to 10 weight-%, more preferably in the range of 4 to 6 weight-%, based on the sum of the weights of SiO2 and X2O3 comprised in the framework structure of the zeolitic material. In the case where the process further comprises (m), it is preferred that the process further comprises after (m) (md) drying the mixture obtained in (m) in a gas atmosphere having a temperature in the range of 500 to 650 °C, more preferably in the range of 560 to 620 °C, more preferably in the range of 580 to 600 °C. Further in the case where the process further comprises (m), it is preferred that the process fur- ther comprises after (m), more preferably after (md) (mc) calcining the mixture obtained in (m) of (md) in a gas atmosphere having a temperature in the range of 500 to 650 °C, more preferably in the range of 560 to 620 °C, more preferably in the range of 580 to 600 °C, wherein calcining is more preferably performed for a duration in the range of 0.5 to 24 h, more preferably in the range of 1 to 5 h. In the case where the process further comprises (md) or (mc), it is preferred that the gas atmos- phere in one or more of (md) and (mc), more preferably in (md) and (mc) comprises one or more of nitrogen and oxygen, wherein the gas atmosphere more preferably comprises, more preferably consists of, air. Further in the case where the process further comprises (m), it is preferred that the process fur- ther comprises after (m), more preferably after (md), more preferably after (mc) (mcr) crushing the mixture obtained in (m), (md), or (mc), wherein further preferred that the pro- cess further comprises (msi) sieving the mixture obtained in (m), (md), (mc), or (mcr) to particles, more preferably with a sieve having a mesh in the range of 250 to 500 µm.
BASF Corporation 220846WO01 - 10 - Yet further, the present invention relates to a catalytic material obtained or obtainable by the process of any one of the particular and preferred embodiments disclosed herein. Yet further, the present invention relates to an exhaust gas treatment system comprising a com- ponent comprising the catalytic material of any one of the particular and preferred embodiments disclosed herein, an internal combustion engine and an exhaust gas conduit in fluid communi- cation with the internal combustion engine, wherein the component comprising the catalytic ma- terial is present in the exhaust gas conduit. It is preferred that the component comprising the catalytic material comprises a substrate, wherein said catalytic material is disposed on said substrate. It is preferred that the internal combustion engine is a lean burn engine or a lean gasoline direct injection (GDI) engine, more preferably a diesel engine, more preferably a heavy duty diesel en- gine. It is preferred that the exhaust gas treatment system further comprises a diesel oxidation cata- lyst (DOC), wherein the diesel oxidation catalyst is more preferably located upstream of the component comprising the catalytic material. It is preferred that the exhaust gas treatment system further comprises an optionally catalyzed soot filter, wherein the optionally catalyzed soot filter is located upstream or downstream of the component comprising the catalytic material. It is preferred that the exhaust gas treatment system further comprises an ammonia oxidation catalyst (AMOX), wherein the ammonia oxidation catalyst (AMOX) is located upstream or down- stream of the component comprising the catalytic material. Furthermore and independently thereof, it is preferred according to a first alternative for the ex- haust gas treatment system that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas a SCR component, an ammonia oxidation catalyst (AMOX), a diesel oxidation catalyst (DOC), the component comprising the catalytic material, op- tionally a Cu-containing SCR component, and an ammonia oxidation catalyst (AMOX). Furthermore and independently thereof, it is preferred according to a second alternative for the exhaust gas treatment system that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas the component comprising the catalytic material, an ammonia oxidation catalyst (AMOX), a diesel oxidation catalyst (DOC), optionally a Cu-contain- ing SCR component, and an ammonia oxidation catalyst (AMOX). Furthermore and independently thereof, it is preferred according to a third alternative for the ex- haust gas treatment system that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas a hydrocarbon injector, a diesel oxidation catalyst
BASF Corporation 220846WO01 - 11 - (DOC), a catalyzed soot filter (CSF), an urea injector, the component comprising the catalytic material, and a combined selective catalytic reduction/ammonia oxidation catalyst. Furthermore and independently thereof, it is preferred according to a fourth alternative for the exhaust gas treatment system that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas an urea injector, a close coupled selective catalytic re- duction (cc-SCR), a hydrocarbon injector, a diesel oxidation catalyst (DOC), a catalyzed soot filter (CSF), an urea injector, the component comprising the catalytic material, and a combined selective catalytic reduction/ammonia oxidation catalyst. It is preferred that the exhaust gas treatment system further comprises a reductant injector, wherein the reductant injector is more preferably located upstream of the component comprising the catalytic material, more preferably between the diesel oxidation catalyst (DOC) and the component comprising the catalytic material as defined for the first alternative for the exhaust gas treatment system herein above, or between the internal combustion engine and the component comprising the catalytic material as defined for the second alternative for the exhaust gas treatment system herein above. In the case where the exhaust gas treatment system further comprises a reductant injector, it is preferred that the reductant comprises, more preferably consists of, one or more of ammonia, a hydrocarbon, and urea. Yet further, the present invention relates to a process for the treatment of an exhaust gas, pref- erably for the selective catalytic reduction of NOx comprised in an exhaust gas, the process comprising bringing the exhaust gas stream in contact with a catalytic material according to any one of the particular and preferred embodiments disclosed herein. Yet further, the present invention relates to use of a catalytic material according to any one of the particular and preferred embodiments disclosed herein or of an exhaust gas treatment sys- tem according to any one of the particular and preferred embodiments disclosed herein for the treatment of an exhaust gas comprising NOx, preferably for the selective catalytic reduction (SCR) of NOx comprised in an exhaust gas. The present invention is further illustrated by the following set of embodiments and combina- tions of embodiments resulting from the dependencies and back-references as indicated. In par- ticular, it is noted that in each instance where a range of embodiments is mentioned, for exam- ple in the context of a term such as "The catalytic material of any one of embodiments 1 to 4", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The cat- alytic material of any one of embodiments 1, 2, 3, and 4". Further, it is explicitly noted that the following set of embodiments is not the set of claims determining the extent of protection, but
BASF Corporation 220846WO01 - 12 - represents a suitably structured part of the description directed to general and preferred aspects of the present invention. 1. A catalytic material for the selective catalytic reduction of NOx, the catalytic material com- prising a zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has an FER-type framework structure, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from −103.5 to −108.5 ppm, wherein the integral of the first peak affords an area I1, wherein the integral of all peaks in the range of −90.0 to −130.0 ppm afford an area Itotal, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks is equal to or greater than 0.20:1, wherein the catalytic material comprises Fe, wherein Fe is supported on the zeolitic mate- rial, and wherein the deconvoluted 29Si MAS NMR of the zeolitic material is preferably determined according to Reference Example 1. 2. The catalytic material of embodiment 1, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or greater than 0.23:1, preferably greater than 0.25:1. 3. The catalytic material of embodiment 1 or 2, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is in the range of 0.2:1 to 0.60:1, preferably in the range of 0.23:1 to 0.50:1, more preferably in the range of 0.30:1 to 0.50:1. 4. The catalytic material of any one of embodiments 1 to 3, wherein the first peak (P1) has a maximum in the range of −104.0 to −108.0 ppm, preferably in the range of −104.5 to − 107.5 ppm, more preferably in the range of −105.0 to −107.0 ppm. 5. The catalytic material of any one of embodiments 1 to 4, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of −97.5 to −102.5 ppm, preferably in the range of −99.0 to −101.0 ppm, wherein the integral of the second peak (P2) preferably affords an area I2, wherein the ratio of the area I2 of the second peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1. 6. The catalytic material of any one of embodiments 1 to 5, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of −108.6 to −112.5 ppm, preferably in the range of −110.0 to −112.0 ppm, wherein the integral of the third peak (P3) preferably affords an area I3, wherein the ratio of the
BASF Corporation 220846WO01 - 13 - area I3 of the third peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.55:1, preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1. 7. The catalytic material of any one of embodiments 1 to 6, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of −112.6 to −116.5 ppm, preferably in the range of −113.0 to −115.0 ppm, wherein the integral of the fourth peak (P4) preferably affords an area I4, wherein the ratio of the area I4 of the fourth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.50:1, preferably equal to or smaller than 0.45:1, more prefera- bly equal to or smaller than 0.40:1. 8. The catalytic material of any one of embodiments 1 to 7, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of −93.0 to −97.0 ppm, preferably in the range of −94.0 to −96.0 ppm, wherein the integral of the fifth peak (P5) preferably affords an area I5, wherein the ratio of the area I5 of the fifth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1. 9. The catalytic material of any one of embodiments 1 to 8, wherein X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, preferably selected from the group consisting of Al, B, and a mixture thereof, wherein X more preferably is Al. 10. The catalytic material of any one of embodiments 1 to 9, wherein the zeolitic material has a molar ratio of SiO2 to X2O3 of equal to or less than 50, preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. 11. The catalytic material of any one of embodiments 1 to 9, wherein X is Al and wherein the zeolitic material has a molar ratio of SiO2 to Al2O3 of equal to or less than 50, preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. 12. The catalytic material of any one of embodiments 1 to 11, having an atomic ratio of Fe supported on the zeolitic material, calculated as element, to Al comprised in the frame- work structure of the zeolitic material, calculated as element, of equal to or greater than 0.20:1, preferably in the range of 0.20:1 to 0.50:1, more preferably in the range of 0.20:1 to 0.45:1, more preferably in the range of 0.20:1 to 0.40:1, more preferably in the range of 0.20:1 to 0.35:1.
BASF Corporation 220846WO01 - 14 - 13. The catalytic material of any one of embodiments 1 to 11, comprising Fe, calculated as Fe2O3, supported on the zeolitic material, calculated as sum of the weights of SiO2 and X2O3 comprised by the framework structure of the zeolitic material, in an amount of equal to or greater than 2.5 weight-%, preferably in the range of 2.5 to 10.0 weight-%, more preferably in the range of 2.5 to 7.5 weight-%, more preferably in the range of 4.0 to 6.5 weight-%, more preferably in the range of 5.0 to 6.2 weight-%, more preferably in the range of 5.9 to 6.0 weight-%. 14. A process for producing a catalytic material, preferably for producing the catalytic material according to any one of embodiments 1 to 13, the process comprising (i) providing an aqueous mixture comprising a zeolitic material, one or more sources of Fe, and one or more optionally substituted ammonium cations; (ii) subjecting the mixture obtained in (i) to ion-exchange conditions; wherein the zeolitic material comprises SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has a maximum ring size of 10 T-atoms or less, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from −103.5 to −108.5 ppm, wherein the integral of the first peak affords an area I1, wherein all peaks in the range of −90.0 to −130.0 ppm have an area Itotal, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks is equal to or greater than 0.20:1, and Fe supported on the zeolitic material, wherein the deconvoluted 29Si MAS NMR of the zeolitic material is preferably determined according to Reference Example 1. 15. The process of embodiment 14, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or greater than 0.23:1, preferably greater than 0.25:1. 16. The process of embodiment 14 or 15, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is in the range of 0.2:1 to 0.60:1, preferably in the range of 0.23:1 to 0.50:1, more preferably in the range of 0.25:1 to 0.45:1. 17. The process of any one of embodiments 14 to 16, wherein the first peak (P1) has a maxi- mum in the range of −104.0 to −108.0 ppm, preferably in the range of −104.5 to −107.0 ppm, more preferably in the range of −105.0 to −107.0 ppm. 18. The process of any one of embodiments 14 to 17, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of −97.5 to −102.5 ppm, preferably in the range of −99.0 to −101.0 ppm, wherein the integral of the second peak (P2) preferably affords an area I2, wherein the ratio of the area I2 of the second peak to the area Itotal of all peaks in the range of −90.0 to −130.0
BASF Corporation 220846WO01 - 15 - ppm is equal to or smaller than 0.05:1, preferably equal to or smaller than 0.04:1, more preferably equal to or smaller than 0.03:1. 19. The process of any one of embodiments 14 to 18, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a third peak (P3) having a maximum in the range of −108.6 to −112.5 ppm, preferably in the range of −110.0 to −112.0 ppm, wherein the integral of the third peak (P3) preferably affords an area I3, wherein the ratio of the area I3 of the third peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.55:1, preferably equal to or smaller than 0.50:1, more preferably equal to or smaller than 0.45:1. 20. The process of any one of embodiments 14 to 19, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of −112.6 to −116.5 ppm, preferably in the range of −113.0 to −115.0 ppm, wherein the integral of the fourth peak (P4) preferably affords an area I4, wherein the ratio of the area I4 of the fourth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.50:1, preferably equal to or smaller than 0.45:1, more preferably equal to or smaller than 0.40:1. 21. The process of any one of embodiments 14 to 20, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of −93.0 to −97.0 ppm, preferably in the range of −94.0 to −96.0 ppm, wherein the integral of the fifth peak (P5) preferably affords an area I5, wherein the ratio of the area I5 of the fifth peak to the area Itotal of all peaks in the range of −90.0 to −130.0 ppm is equal to or smaller than 0.05:1, preferably equal to or smaller than 0.3:1, more preferably equal to or smaller than 0.02:1. 22. The process of any one of embodiments 14 to 21, wherein X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof, preferably selected from the group consisting of Al, B, and a mixture thereof, wherein X more preferably is Al. 23. The process of any one of embodiments 14 to 22, wherein the zeolitic material has a mo- lar ratio of SiO2 to X2O3 of equal to or less than 50, preferably of equal to or less than 40, more preferably of equal to or less than 30, more preferably in the range of from 1 to 30, more preferably in the range of from 5 to 25, more preferably in the range of from 10 to 20. 24. The process of any one of embodiments 14 to 23, wherein the one or more optionally sub- stituted ammonium cations are selected from the group consisting of NH4 +, ((C1-C10)al- kyl)NH3+, ((C1-C10)alkyl)2NH2+, ((C1-C10)alkyl)3NH+, ((C1-C10)alkyl)4N+, and mixtures of two or more thereof, preferably from the group consisting of NH4+, ((C1-C7)alkyl)NH3+, ((C1- C7)alkyl)2NH2 +, ((C1-C7)alkyl)3NH+, ((C1-C7)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4 +, ((C1-C5)alkyl)NH3 +, ((C1-C5)alkyl)2NH2 +,
BASF Corporation 220846WO01 - 16 - ((C1-C5)alkyl)3NH+, ((C1-C5)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4+, ((C1-C3)alkyl)NH3+, ((C1-C3)alkyl)2NH2+, ((C1-C3)al- kyl)3NH+, ((C1-C3)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consisting of NH4 +, ((C2-C3)alkyl)NH3 +, ((C2-C3)alkyl)2NH2 +, ((C2-C3)alkyl)3NH+, ((C2- C3)alkyl)4N+, and mixtures of two or more thereof, more preferably from the group consist- ing of NH4+, (C2alkyl)NH3+, (C2alkyl)2NH2+, (C2alkyl)3NH+, (C2alkyl)4N+, and mixtures of two or more thereof, wherein the one or more optionally substituted ammonium cations are more preferably one or more of NH4 + and tetraethylammonium. 25. The process of any one of embodiments 14 to 24, wherein the one or more sources of Fe are selected from the group consisting of Fe nitrates, Fe citrates, ammonium Fe citrates, Fe acetates, Fe sulfates, Fe ascorbates, and mixtures of two or more thereof, preferably from the group consisting of Fe(III) nitrate, Fe(III) citrate, ammonium Fe(III) citrate, Fe(III) acetate, Fe(III) sulfate, Fe(III) ascorbate, and mixtures of two or more thereof, wherein the one or more sources of Fe more preferably are Fe(III) nitrate. 26. The process of any one of embodiments 14 to 25, wherein the mixture obtained in (i) has a weight ratio of water to the zeolitic material in the range of 4.0:1 to 10.0:1, preferably in the range of 5.0:1 to 9.0:1, more preferably in the range of 6.0:1 to 8.0:1, more preferably in the range of 6.5:1 to 7.5:1. 27. The process of any one of embodiments 14 to 26, preferably of embodiment 26, wherein the pH of the mixture obtained in (i) has a pH in the range of 3.0 to 7.0, preferably in the range of 3.5 to 6.5, more preferably in the range of 4.0 to 6.0, more preferably in the range of 4.5 to 5.5. 28. The process of any one of embodiments 14 to 27, wherein the zeolitic material comprised in the mixture provided in (i) has an AEI-, AFT-, AFX-, CHA-, FER-, or MFI-type frame- work structure, preferably a CHA-, FER-, or MFI-type framework structure, more prefera- bly a CHA- or FER-type framework structure, more preferably a FER-type framework structure. 29. The process of any one of embodiments 14 to 28, wherein the ion-exchange conditions comprise heating the mixture obtained in (i) to a temperature in the range of 30 to 100 °C, preferably in the range of 35 to 80 °C, more preferably in the range of 40 to 70 °C, more preferably in the range of 45 to 65 °C. 30. The process of any one of embodiments 14 to 29, wherein the ion-exchange conditions are applied in (ii) for a duration in the range of 0.1 to 48 h, preferably in the range of 0.5 to 25 h, more preferably in the range of 1 to 5 h. 31. The process of any one of embodiments 14 to 30, wherein the ion-exchange conditions comprise stirring the mixture obtained in (i).
BASF Corporation 220846WO01 - 17 - 32. The process of any one of embodiments 14 to 31, further comprising after (ii) (s) separating the catalytic material obtained in (ii), preferably by filtration. 33. The process of any one of embodiments 14 to 32, further comprising after (ii), preferably after (s) as defined in embodiment 32, (w) washing the catalytic material obtained in (ii), preferably after (s), with water, wherein washing is preferably performed until the water has a conductivity of less than 200 µS. 34. The process of any one of embodiments 14 to 33, further comprising after (ii), preferably after (s), more preferably after (w) (d) drying the catalytic material obtained in (ii), (s), or (w) in a gas atmosphere having a temperature in the range of 70 to 135 °C, more preferably in the range of 80 to 120 °C, preferably in the range of 90 to 110 °C. 35. The process of any one of embodiments 14 to 34, further comprising after (ii), preferably after (s), more preferably after (w), more preferably after (d), (c) calcining the catalytic material obtained in (ii), (s), (w), or (d) in a gas atmosphere having a temperature in the range of 400 to 600 °C, preferably in the range of 420 to 500 °C, more preferably in the range of 440 to 460 °C, wherein calcining is more preferably performed for a duration in the range of 0.5 to 24 h, preferably in the range of 1 to 5 h. 36. The process of embodiment 34 or 35, wherein the gas atmosphere comprises one or more of nitrogen and oxygen, wherein the gas atmosphere more preferably comprises, more preferably consists of, air. 37. The process of any one of embodiments 14 to 36, further comprising after (ii), preferably after (s), more preferably after (w), more preferably after (d), more preferably after (c), (m) molding a mixture comprising the catalytic material obtained in (ii), (s), (w), (d), or (c), and an optionally hydrated binder, wherein the binder preferably comprises one or more of Zr acetate, pseudoboehmite, alumina, silica-alumina, and a mixture of two or more thereof, wherein the mixture comprises the binder, calculated as oxide, in an amount in the range of 1 to 10 weight-%, preferably in the range of 4 to 6 weight-%, based on the sum of the weights of SiO2 and X2O3 comprised in the framework structure of the zeolitic material. 38. The process of embodiment 37, further comprising after (m) (md) drying the mixture obtained in (m) in a gas atmosphere having a temperature in the range of 500 to 650 °C, preferably in the range of 560 to 620 °C, more preferably in the range of 580 to 600 °C.
BASF Corporation 220846WO01 - 18 - 39. The process of embodiment 37 or 38, further comprising after (m), preferably after (md) (mc) calcining the mixture obtained in (m) in a gas atmosphere having a temperature in the range of 500 to 650 °C, preferably in the range of 560 to 620 °C, more preferably in the range of 580 to 600 °C, wherein calcining is more preferably performed for a duration in the range of 0.5 to 24 h, preferably in the range of 1 to 5 h. 40. The process of embodiment 38 or 39, wherein the gas atmosphere comprises one or more of nitrogen and oxygen, wherein the gas atmosphere more preferably comprises, more preferably consists of, air. 41. The process of any one of embodiments 37 to 40, further comprising after (m), preferably after (md), more preferably after (mc) (mcr) crushing the mixture obtained in (m), (md), or (mc), and preferably further compris- ing (msi) sieving the mixture obtained in (m), (md), (mc), or (mcr) to particles, preferably with a sieve having a mesh in the range of 250 to 500 µm. 42. A catalytic material obtained or obtainable by the process of any one of embodiments 14 to 41. 43. An exhaust gas treatment system comprising a component comprising the catalytic mate- rial of any one of embodiments 1 to 13 and 42, an internal combustion engine and an ex- haust gas conduit in fluid communication with the internal combustion engine, wherein the component comprising the catalytic material is present in the exhaust gas conduit. 44. The exhaust gas treatment system of embodiment 43, wherein the component comprising the catalytic material of any one of embodiments 1 to 13 and 42 comprises a substrate, wherein said catalytic material is disposed on said substrate. 45. The exhaust gas treatment system of embodiment 43 or 44, wherein the internal combus- tion engine is a lean burn engine or a lean gasoline direct injection (GDI) engine, more preferably a diesel engine, more preferably a heavy duty diesel engine. 46. The exhaust gas treatment system of any one of embodiments 43 to 45, further compris- ing a diesel oxidation catalyst (DOC), wherein the diesel oxidation catalyst is preferably located upstream of the component comprising the catalytic material of any one of embod- iments 1 to 13 and 42. 47. The exhaust gas treatment system of any one of embodiments 43 to 46, further compris- ing an optionally catalyzed soot filter, wherein the optionally catalyzed soot filter is located upstream or downstream of the component comprising the catalytic material of any one of embodiments 1 to 13 and 42.
BASF Corporation 220846WO01 - 19 - 48. The exhaust gas treatment system of any one of embodiments 43 to 47, further compris- ing an ammonia oxidation catalyst (AMOX), wherein the ammonia oxidation catalyst (AMOX) is located upstream or downstream of the component comprising the catalytic material of any one of embodiments 1 to 13 and 42. 49. The exhaust gas treatment system of any one of embodiments 43 to 45, comprising in consecutive order in the direction of the exhaust gas a SCR component, an ammonia oxi- dation catalyst (AMOX), a diesel oxidation catalyst (DOC), the component comprising the catalytic material of any one of embodiments 1 to 13 and 42, optionally a Cu-containing SCR component, and an ammonia oxidation catalyst (AMOX). 50. The exhaust gas treatment system of any one of embodiments 43 to 45, comprising in consecutive order in the direction of the exhaust gas the component comprising the cata- lytic material of any one of embodiments 1 to 13 and 42, an ammonia oxidation catalyst (AMOX), a diesel oxidation catalyst (DOC), optionally a Cu-containing SCR component, and an ammonia oxidation catalyst (AMOX). 51. The exhaust gas treatment system of any one of embodiments 43 to 45, comprising in consecutive order in the direction of the exhaust gas a hydrocarbon injector, a diesel oxi- dation catalyst (DOC), a catalyzed soot filter (CSF), an urea injector, the component com- prising the catalytic material of any one of embodiments 1 to 13 and 42, and a combined selective catalytic reduction/ammonia oxidation catalyst. 52. The exhaust gas treatment system of any one of embodiments 43 to 45, comprising in consecutive order in the direction of the exhaust gas an urea injector, a close coupled se- lective catalytic reduction (cc-SCR), a hydrocarbon injector, a diesel oxidation catalyst (DOC), a catalyzed soot filter (CSF), an urea injector, the component comprising the cata- lytic material of any one of embodiments 1 to 13 and 42, and a combined selective cata- lytic reduction/ammonia oxidation catalyst. 53. The exhaust gas treatment system of any one of embodiments 43 to 52, further compris- ing a reductant injector, wherein the reductant injector is preferably located upstream of the component comprising the catalytic material of any one of embodiments 1 to 13 and 42, preferably between the diesel oxidation catalyst (DOC) and the component comprising the catalytic material of any one of embodiments 1 to 13 and 42 as defined in embodiment 49, or between the internal combustion engine and the component comprising the catalytic material of any one of embodiments 1 to 13 and 42 as defined in embodiment 50. 54. The exhaust gas treatment system of embodiment 53, wherein the reductant comprises, more preferably consists of, one or more of ammonia, a hydrocarbon, and urea.
BASF Corporation 220846WO01 - 20 - 55. A process for the treatment of an exhaust gas, preferably for the selective catalytic reduc- tion of NOx comprised in an exhaust gas, the process comprising bringing the exhaust gas stream in contact with a catalytic material according to any one of embodiments 1 to 13 and 42. 56. Use of a catalytic material according to any one of embodiments 1 to 13 and 42 or of an exhaust gas treatment system according to any one of embodiments 43 to 54 for the treat- ment of an exhaust gas comprising NOx, preferably for the selective catalytic reduction (SCR) of NOx comprised in an exhaust gas. The present invention is further illustrated by the following reference examples, examples, and comparative examples. EXAMPLES Reference Example 1: 29Si MAS NMR 29Si MAS NMR measurements were run on a Varian Unity Inova 400 MHz spectrometer, using a 7.5 mm rotor spun at 3.5 kHz. Spectra were obtained using a 90 second recycle delay with 128 scans, and a 6.5 µs pi/2 pulse. Prior to measurement, samples were hydrated for at least 48 hours in a vessel containing a saturated solution of Ammonium Chloride to maintain a relative humidity of >80 %. Spectra were fit and peaks deconvoluted with ACD Labs Spectrus software using mixed Gaussian/Lorentzian functions and peak position variability of <100 Hz. Expected peak assignments are Q4(0Al) at -114 ppm and -111 ppm, Q4(1Al) at -106 ppm, and a potential overlap of Q3(0Al) and Q4(2Al) at -99 ppm. Examples 1-8: Preparation of catalytic materials Four FER zeolite samples were obtained as powders from Zeolyst and Tosoh. These samples were loaded with Fe (atomic ratio Fe/Al = 0.25 or 0.40), aged and then evaluated for SCR. For the impregnation, a zeolite was loaded with Fe nitrate solution using incipient wetness im- pregnation. The mixture was stored for 20 h at 50 °C in an oven. Subsequently, the obtained material was dried and then calcined at 450 °C for 5 h. From the obtained impregnated zeolite a slurry was prepared and Zr-acetate was added (5 weight-% based on zeolite). The resulting mixture was dried under stirring and then calcined for 1 h at 550 °C. The obtained material was crushed and sieved (250 to 500 µm). An overview on the characteristics of the prepared cata- lytic materials is given in Table 1 below. Table 1: Overview of the prepared catalytic materials according to Examples 1-8.
BASF Corporation 220846WO01 - 21 - # SiO2:Al2O3 Supplier Atomic ratio molar ratio Fe:Al Ex.1 18 Zeolyst 0.25:1 Ex.2 18 Zeolyst 0.40:1 Ex.3 20 Zeolyst 0.25:1 Ex.4 20 Zeolyst 0.40:1 Ex.5 25 Zeolyst 0.25:1 Ex.6 25 Zeolyst 0.40:1 Ex.7 18 Tosoh 0.25:1 Ex.8 18 Tosoh 0.40:1 For the FER zeolite used for Examples 7 and 8, five peaks were observed in the range of −90.0 to −130.0 ppm. The details of said peaks are shown in table 2 below. In particular, two individual peaks in the range of −93.0 to −101.0 ppm were observed with respect to Q3(0Al) and Q4(2Al) sites, in accordance with the expected peak assignments detailed in Reference Example 1 above with respect to the 29Si MAS NMR. Table 2: Overview of zeolitic materials for Examples 7 and 8 and their properties. Percentage of total peak area of 29Si MAS NMR spectrum SiO2:Al2O3 peak in the peak in the peak in the peak in the peak in the molar ratio range of range of range of range of range of −93.0 to −97.5 to −103.5 to −108.6 to −112.6 to −97.0 ppm −102.5 ppm −108.5 ppm −112.5 ppm −116.5 ppm Ex.7+8 18 1.45 % 1.44 % 27.62 % 43.08 % 26.40 % Examples 9-12: Preparation of catalytic materials Four FER zeolites in the H-form (silica-to-alumina ratio of 15.7, 17.5, 19.7, and 13.3 for Exam- ples 9, 10, 11, and 12, respectively) were obtained from China Catalyst Holding Co., Ltd.. These materials were loaded with Fe (5.9-6.0 weight-% Fe2O3). The FER zeolitic materials of Examples 9-11 were analyzed in their H-form prior to ion-ex- change with Fe by 29Si MAS NMR. To this effect, the FER zeolites were hydrated for 48 h. The results are shown in Table 3 and Figures 1-3. For each FER zeolite, four peaks were observed in the range of −90.0 to −130.0 ppm. The peak in the range of −103.5 to −108.5 ppm can be assigned to the Q4(1Al) sites in the FER zeolite. In connection with the results shown in Figure 6 for the SCR testing, it can be seen that catalytic materials comprising a FER zeolite having a comparatively higher content of Q4(1Al) sites show a comparatively better SCR performance.
BASF Corporation 220846WO01 - 22 - Table 3: Overview of catalytic materials according to Examples 9-11 and their properties. Percentage of total peak area of 29Si MAS NMR spectrum SiO2:Al2O3 peak in the peak in the peak in the peak in the molar ratio range of −97.5 range of −103.5 range of −108.6 range of −112.6 to −102.5 ppm to −108.5 ppm to −112.5 ppm to −116.5 ppm Ex.9 15.7 2.0 % 40.0 % 20.1 % 37.9 % Ex.10 17.5 2.8 % 29.0 % 23.5 % 44.7 % Ex.11 19.7 2.7 % 25.6 % 32.2 % 39.5 % For the impregnation, a zeolite was loaded with Fe nitrate solution using incipient wetness im- pregnation. The mixture was stored for 20 h at 50 °C in an oven. Subsequently, the obtained material was dried and then calcined at 450 °C for 5 h. From the obtained impregnated zeolite a slurry was prepared and Zr-acetate was added (5 weight-% based on zeolite). The resulting mixture was dried under stirring and then calcined for 1 h at 550 °C. The obtained material was crushed and sieved (250 to 500 µm). Each FER zeolite was loaded with 5.9 to 6.0 weight-% Fe, calculated as Fe2O3, and based on the sum of the weights of Fe, calculated as Fe2O3, and SiO2 and Al2O3 comprised in the framework structure of the FER zeolite. As noted in Reference Ex- ample 1 with respect to the determination of the 29Si MAS NMR spectra for zeolites, a peak in the range of from −103.5.0 to −108.5.0 ppm indicates presence of Q4(1Al) sites. In accordance with the present invention, catalytic materials are claimed, which particularly comprise a zeolitic material having a specific Al distribution, thus, especially showing in the deconvoluted 29Si MAS NMR a first peak (P1) having a maximum in said range, while further having a specific integral ratio of the first peak to the integral of all peaks in the range of −90.0 to −130.0 ppm. In this re- spect, as may be taken from the results displayed in Tables 2 and 3, it is noted that the peak in- tegrals do not correlate with the silica to alumina ratios, such that they describe specific Al distri- butions in the zeolitic frameworks which are independent of their respective silica to alumina ra- tios. Example 13: Catalytic testing The prepared catalytic materials comprising Fe-FER zeolites were tested with respect to their SCR performance in a fresh state (as-prepared), after aging for 50 h at 650 °C in air comprising 10 % steam, and after aging for 16 h at 820 °C in air comprising 10 % steam. The following testing conditions were applied: Standard SCR feed having a gas hourly space velocity (GHSV) of 80000 h-1, and comprising 500 ppm NO, 500 ppm NH3, 5 % H2O, 10% O2, balance N2. Fast SCR feed having a gas hourly space velocity (GHSV) of 80000 h-1, and comprising 250 ppm NO, 250 ppm NO2, 500 ppm NH3, 5 % H2O, 10 % O2, balance N2.
BASF Corporation 220846WO01 - 23 - • First run for degreening (Std. SCR feed): T = 200, 400, 575°C • Standard SCR run: T = 175, 200, 225, 250, 350, 450, 550, 575°C • Fast SCR run: T = 575, 550, 450, 350, 250, 225, 200, 175°C The resulting data for the testing of aged catalytic materials according to Examples 1-8 is shown in Figures 4 and 5. As it can be gathered from the results, the catalytic materials in accordance with the present invention showed a very good SCR performance after aging for 50 h at 650 °C in air comprising 10 % steam, and a good performance after aging for 16 h at 820 °C in air com- prising 10 % steam. The standard SCR performance for the catalytic materials according to Examples 9-11 was measured after 650 °C/50 h aging and 820 °C/16 h aging. The performance data shown in Fig- ure 6 demonstrate that the catalytic material comprising a FER zeolite having SAR 15.7 shows the highest SCR activity as compared to the rest of the samples. Example 14: Comparative catalytic testing Two types of Fe-zeolites are commonly used currently – Fe-CHA and Fe-BEA. It is widely known that it is difficult to incorporate Fe into the pores of CHA zeolite. An activation with steam or reducing atmosphere is required to incorporate Fe into the pores of CHA zeolites, which sig- nificantly adds to the cost of the final Fe-zeolite catalyst. While BEA has the advantage that there is no activation step required to incorporate Fe and make the active catalyst, it is known that BEA can be deactivated by hydrocarbons present in the gas feed. Consequently, Fe-CHA is used in applications that require tolerance to hydrocarbons in place of Fe-BEA. In contrast thereto, FER zeolite provides the advantage of not requiring activation by steam and is at the same time tolerant to hydrocarbons. This is all the more surprising since FER zeolites belong to the group of medium pore zeolites, which particularly comprise pores with 10 membered rings, which are typically considered as not showing as much steric hindrance as observed for small pore zeolites. Additionally, FER zeolites also show tolerance to humidity treatment. A comparative catalytic testing was carried out, wherein a state-of-the-art Fe-BEA, a state-of- the-art Fe-CHA, and catalytic materials in accordance with Examples 2 and 7 were tested in the fresh state as well as after aging for 50 h at 650 °C in air comprising 10 % steam. The results for the catalytic testing are shown in Figure 7. As it can be gathered from the re- sults, the catalytic materials according to the present invention show a very good performance, in particular at low temperatures. At high temperatures, especially the catalytic materials in the fresh state show a very good performance. Example 15: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 18, Fe2O3% = 5.4%).
BASF Corporation 220846WO01 - 24 - 89.9 parts by weight of the ammonium-form of FER, 5.1 parts by weight of Iron nitrate calcu- lated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were mixed into deionized water to form a slurry. pH of the slurry is adjusted to 3.3 with TEAOH solution. The slurry was milled to a particle size of D90 between 4 μm to 10 μm, as measured with a Sym- patec particle size analyzer. The slurry was coated onto a flow-through cordierite monolith sub- strate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C. The washcoat loading was 2.5 g/in3. Example 16: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 18, Fe2O3% = 2.5%). 92.6 parts by weight of the ammonium-form of FER, 2.4 parts by weight of Iron nitrate calcu- lated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were mixed into deionized water to form a slurry. pH of the slurry is adjusted to 3.3 with TEAOH solution. The slurry was milled to a particle size of D90 between 4 μm to 10 μm, as measured with a Sym- patec particle size analyzer. The slurry was coated onto a flow-through cordierite monolith sub- strate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C. The washcoat loading was 2.5 g/in3. Example 17: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 17, Fe2O3% = 5.4%). 89.9 parts by weight of the ammonium-form of FER, 5.1 parts by weight of Iron nitrate calcu- lated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were mixed into deionized water to form a slurry. pH of the slurry is adjusted to 3.3 with NH4OH solution. The slurry was milled to a particle size of D90 between 4 μm to 10 μm, as measured with a Sym- patec particle size analyzer. The slurry was coated onto a flow-through cordierite monolith sub- strate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C. The washcoat loading was 3.0 g/in3. Example 18: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 17, Fe2O3% = 5.4%). 89.9 parts by weight of the ammonium-form of FER, 5.1 parts by weight of Iron ammonium cit- rate calculated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were mixed into deionized water to form a slurry. The slurry was milled to a particle size of D90 be- tween 4 μm to 10 μm, as measured with a Sympatec particle size analyzer. The slurry was coated onto a flow-through cordierite monolith substrate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C. The washcoat loading was 2.5 g/in3. Example 19: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 17, Fe2O3% = 5.4%). 89.9 parts by weight of the ammonium-form of FER, 5.1 parts by weight of Iron(II) ascorbate so- lution calculated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were
BASF Corporation 220846WO01 - 25 - mixed into deionized water to form a slurry. The slurry was milled to a particle size of D90 be- tween 4 μm to 10 μm, as measured with a Sympatec particle size analyzer. The slurry was coated onto a flow-through cordierite monolith substrate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C. The washcoat loading was 2.5 g/in3. Example 20: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 16, Fe2O3% = 5.4%). 89.9 parts by weight of the hydrogen-form of FER, 5.1 parts by weight of Iron nitrate calculated as Fe2O3 and 5.0 parts by weight of zirconium acetate calculated as ZrO2 were mixed into de- ionized water to form a slurry. pH of the slurry is adjusted to 3.3 with TEAOH solution. The slurry was milled to a particle size of D90 between 4 μm to 10 μm, as measured with a Sympatec par- ticle size analyzer. The slurry was coated onto a flow-through cordierite monolith substrate hav- ing a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and cal- cination at 590 °C. The washcoat loading was 2.5 g/in3. Example 21: Preparation of a Catalytic Article Comprising Fe/FER (SAR = 17, Fe2O3% = 5.5%). 82 parts by weight of deionized water is combined with 12.8 parts by weight of ammonium-form FER zeolite and 5.2 parts by weight of Ferric nitrate solution (9.5 weight-% aqueous solution, calculated as Fe2O3). This solution is heated to 60 °C under stirring and then the pH is adjusted to 5.0-5.15 by the use of tetraethylammonium hydroxide (35 weight-% aqueous solution) as a base. After pH adjustment, the solution is stirred for 1 hour at 60 °C before cutting off the heat. The cooled solution is filtered and washed with deionized water until the conductivity of the fil- trate is lower than 200 µS. The filtercake is then dried overnight at 90 °C to obtain Fe/FER with 5.5% Fe2O3. 95 parts by weight of Fe/FER containing 5.5% of Fe2O3 and 5.0 parts by weight of zirconium ac- etate calculated as ZrO2 were mixed into deionized water to form a slurry. The slurry was milled to a particle size of D90 between 4 μm to 10 μm, as measured with a Sympatec particle size an- alyzer. The slurry was coated onto a flow-through cordierite monolith substrate having a cell density of 600 cpsi and a wall thickness of 3 mil, followed by drying at 130 °C and calcination at 590 °C. The washcoat loading was 2.5 g/in3. Example 22: Catalytic testing The NOx conversion and N2O formation was tested using a flow reactor under pseudo-steady state conditions with a gas stream of 1000 ppmv NOx (NO2/NOx ratio 0.5), 1050 ppmv NH3, 10 vol% O2, 7 vol% H2O, 8 vol% CO2 and balanced N2, at a space velocity of 60,000 h-1. SCR cata- lysts were hydrothermally aged in 10% O2, 10% H2O and balanced N2 at 650 °C for 100 h, or degreened in 10% O2, 10% H2O and balanced N2 at 550 °C for 4 h. All inventive examples 15 to 21 show improved NOx conversion over the state of art Fe/CHA SCR as shown in Figures 8-11.
BASF Corporation 220846WO01 - 26 - It is shown in Figure 12 that the inventive SCR catalyst maintains high NOx conversion at low temperature such as 200 °C with extended testing time. On the contrary, low temperature NOx conversion of the state of art Fe/CHA decreases with extended testing time, likely due to for- mation of NH4NO3 that partially blocks active sites. The inventive SCR catalyst according to Example 17 was tested after aging with respect to its HC resistance. The testing conditions were as follows: 200 ppm NO, Ammonia/NOx ratio 1.05, 1000 ppm HC (C1 basis, 2:1 C3H6:C3H8), 10 % O2, 7 % H2O, 80 k/h SV, 300 °C. The results are shown in Figure 13. As it can be gathered from the results for catalytic testing, the catalytic materials according to the present invention, which are particularly characterized in showing in the deconvoluted 29Si MAS NMR of the zeolitic material a first peak (P1) having a maximum in the range of from − 103.5 to −108.5 ppm, wherein the integral of the first peak affords a specific area I1 relative to the area Itotal of all peaks, achieve a favorable SCR activity, especially after hydrothermal aging. BRIEF DESCRIPTION OF FIGURES Figure 1: shows the deconvoluted 29Si MAS NMR spectrum of the zeolitic material (SAR = 19.7) used for the preparation of the catalytic material according to Example 11. On the abscissa, the shift is noted in ppm. Figure 2: shows the deconvoluted 29Si MAS NMR spectrum of the zeolitic material (SAR = 15.7) used for the preparation of the catalytic material according to Example 9. On the abscissa, the shift is noted in ppm. Figure 3: shows the deconvoluted 29Si MAS NMR spectrum of the zeolitic material (SAR = 17.5) used for the preparation of the catalytic material according to Example 10. On the abscissa, the shift is noted in ppm. Figure 4: shows the results for the catalytic testing of aged catalytic materials according to Ex- amples 1-8. On the abscissa, the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %. Figure 5: shows the results for the catalytic testing of aged catalytic materials according to Ex- amples 1-8. On the abscissa, the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %. Figure 6: shows the standard SCR performance for the catalytic materials according to Exam- ples 9-12 after aging. On the abscissa, the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %.
BASF Corporation 220846WO01 - 27 - Figure 7: shows the results for comparative catalytic testing of a state-of-the-art Fe-BEA, a state-of-the-art Fe-CHA, and catalytic materials in accordance with Examples 2 and 7 in the fresh state as well as after aging. On the abscissa, the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %. Figure 8: shows the results for the catalytic testing of the catalytic materials according to Ex- amples 15, 17, 19-20, and a state-of-the-art Fe-CHA. On the abscissa, the tempera- ture is shown in °C and on the ordinate, the NOx conversion is shown in %. Figure 9: shows the results for the catalytic testing of the catalytic materials according to Ex- amples 15, 17, 19-20, and a state-of-the-art Fe-CHA. On the abscissa, the tempera- ture is shown in °C and on the ordinate, the N2O formation is shown ppm. Figure 10: shows the results for the catalytic testing of the catalytic materials according to Ex- amples 18, 21, and a state-of-the-art Fe-CHA. On the abscissa, the temperature is shown in °C and on the ordinate, the NOx conversion is shown in %. Figure 11: shows the results for the catalytic testing of the catalytic materials according to Ex- amples 18, 21, and a state-of-the-art Fe-CHA. On the abscissa, the temperature is shown in °C and on the ordinate, the N2O formation is shown ppm. Figure 12: shows the outlet NOx concentration in a catalytic test at 200 °C for the catalytic ma- terial according to example 15 and a state-of-the-art Fe-CHA. On the abscissa, the time is shown in seconds and on the ordinate, the NOx concentration is shown in ppm. Figure 13: shows the results of the hydrocarbon tolerance test for the catalytic material accord- ing to Example 17 after aging. On the abscissa, the time is shown in seconds and on the ordinate, the hydrocarbon concentration is shown in ppm. Figure 14: shows two exemplary exhaust gas treatment systems, wherein both exemplary sys- tems include in consecutive order in the direction of exhaust gas flow a hydrocarbon injector, a diesel oxidation catalyst (DOC), a catalyzed soot filter (CSF), an urea in- jector, a component comprising the catalytic material in accordance with the present invention (SCR1), and a combined selective catalytic reduction/ammonia oxidation catalyst. The exemplary system in the lower part additionally comprises a close cou- pled selective catalytic reduction (cc-SCR) catalyst upstream of the hydrocarbon in- jector. CITED LITERATURE: - WO 2020/021054 A1 - WO 2021/198339 A1
BASF Corporation 220846WO01 - 28 - - WO 2015/128668 A1 - EP 2857084 A1 - DE 102011012799 A1 - EP 2409760 A1 - WO 2008/049557 A1 - US 5041272 A - US 2011/056187 A1 - P.Sarv et al., “Multinuclear MQMAS NMR Study of NH4/Na-Ferrierites”, J. Phys. Chem. B 1998, 102, 1372-1378
Claims
BASF Corporation 220846WO01 - 29 - Claims 1. A catalytic material for the selective catalytic reduction of NOx, the catalytic material com- prising a zeolitic material comprising SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has an FER-type framework structure, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from −103.5 to −108.5 ppm, wherein the integral of the first peak affords an area I1, wherein the integral of all peaks in the range of −90.0 to −130.0 ppm afford an area Itotal, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks is equal to or greater than 0.20:1, wherein the catalytic material comprises Fe, wherein Fe is supported on the zeolitic mate- rial. 2. The catalytic material of claim 1, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a second peak (P2) having a maximum in the range of −97.5 to − 102.5 ppm. 3. The catalytic material of claim 1 or 2, wherein the deconvoluted 29Si MAS NMR of the zeo- litic material comprises a third peak (P3) having a maximum in the range of −108.6 to − 112.5 ppm. 4. The catalytic material of any one of claims 1 to 3, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fourth peak (P4) having a maximum in the range of −112.6 to −116.5 ppm. 5. The catalytic material of any one of claims 1 to 4, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a fifth peak (P5) having a maximum in the range of −93.0 to −97.0 ppm. 6. The catalytic material of any one of claims 1 to 5, wherein X is selected from the group consisting of Al, B, In, Ga, and mixtures of two or more thereof. 7. The catalytic material of any one of claims 1 to 6, wherein the zeolitic material has a molar ratio of SiO2 to X2O3 of equal to or less than 50. 8. The catalytic material of any one of claims 1 to 7, having an atomic ratio of Fe supported on the zeolitic material, calculated as element, to Al comprised in the framework structure of the zeolitic material, calculated as element, of equal to or greater than 0.20:1. 9. The catalytic material of any one of claims 1 to 8, comprising Fe, calculated as Fe2O3, supported on the zeolitic material, calculated as sum of the weights of SiO2 and X2O3
BASF Corporation 220846WO01 - 30 - comprised by the framework structure of the zeolitic material, in an amount of from 4.0 to 6.5 weight-%. 10. A process for producing a catalytic material, preferably for producing the catalytic material according to any one of claims 1 to 9, the process comprising (i) providing an aqueous mixture comprising a zeolitic material, one or more sources of Fe, and one or more optionally substituted ammonium cations; (ii) subjecting the mixture obtained in (i) to ion-exchange conditions; wherein the zeolitic material comprises SiO2 and X2O3 in its framework structure, wherein X is a trivalent element, wherein the zeolitic material has a maximum ring size of 10 T-atoms or less, wherein the deconvoluted 29Si MAS NMR of the zeolitic material comprises a first peak (P1) having a maximum in the range of from −103.5 to −108.5 ppm, wherein the integral of the first peak affords an area I1, wherein all peaks in the range of −90.0 to −130.0 ppm have an area Itotal, wherein the ratio of the area I1 of the first peak to the area Itotal of all peaks is equal to or greater than 0.20:1, and Fe supported on the zeolitic material. 11. The process of claim 10, wherein the one or more optionally substituted ammonium cati- ons are selected from the group consisting of NH4 +, ((C1-C10)alkyl)NH3 +, ((C1-C10)al- kyl)2NH2+, ((C1-C10)alkyl)3NH+, ((C1-C10)alkyl)4N+, and mixtures of two or more thereof. 12. A catalytic material obtained or obtainable by the process of claim 10 or 11. 13. An exhaust gas treatment system comprising a component comprising the catalytic mate- rial of any one of claims 1 to 9 and 12, an internal combustion engine and an exhaust gas conduit in fluid communication with the internal combustion engine, wherein the compo- nent comprising the catalytic material is present in the exhaust gas conduit. 14. A process for the treatment of an exhaust gas, the process comprising bringing the ex- haust gas stream in contact with a catalytic material according to any one of claims 1 to 9 and 12. 15. Use of a catalytic material according to any one of claims 1 to 9 and 12 or of an exhaust gas treatment system according to claim 14 for the treatment of an exhaust gas compris- ing NOx.
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