Synthesis of metal promoted zeolite catalyst
Provided are a novel synthesis technique for producing a metal promoted aluminosilicate zeolite having a small pore framework comprising the step of reacting a synthesis gel comprising at least one promoter metal containing zeolite, a structure directing agent and an optional additional silica source; and methods of using the same.
1. A method of synthesizing a metal promoted aluminosilicate zeolite catalyst having a small pore framework comprising the step of reacting a synthesis gel comprising at least one promoter metal containing zeolite, a structure directing agent (SDA) and an optional additional silica source at a temperature of at least about 100° C. until crystals of the small pore framework zeolite catalyst form;
wherein the zeolite catalyst crystals have a mean crystal size of about 0.1 μm to about 10 μm; and
wherein the promoter metal is copper.
2. The method of claim 1 , wherein the framework zeolite catalyst crystals are at least about 90% phase pure.
3. The method of claim 1 , wherein the framework zeolite crystals have a silica-to-alumina mole ratio (SAR) of at least about 15.
4. The method of claim 1 , wherein the framework is selected from the group consisting of AEI, AFX, CHA, EAB, ERI, KFI, LEV, LTA, RTH, and SFW.
5. The method of claim 1 , wherein the SDA comprises a cation selected from the group consisting of N,N-diethyl-cis 2,6-dimethylpiperidium, N,N-dimethyl-3,5-dimethylpiperidium, trimethyladamantylammonium, N,N,N-dimethylethylcyclohexylammonium, and 1,3-bis(1-adamantyl) imidazolium.
6. The method of claim 1 , wherein the at least one promoter metal containing zeolite is the only promoter metal and aluminum source to form the aluminosilicate zeolite catalyst.
7. The method of claim 1 , wherein the at least one promoter metal containing zeolite is the only silica source to form the aluminosilicate zeolite catalyst.
8. The method of claim 1 , wherein the promoter metal containing zeolite is promoter metal containing zeolite Y.
9. The method of claim 8 , wherein the promoter metal containing zeolite Y has an SAR of about 5 to about 60.
10. The method of claim 1 wherein the at least one promoter metal containing zeolite comprises two or more promoter metal containing zeolites.
11. The method of claim 1 , wherein the at least one promoter metal containing zeolite comprises two or more promoter metal containing zeolites Y.
12. The method of claim 1 , wherein the synthesis gel has one or more of the following compositional molar ratios:
SiO 2 /Al 2 O 3 of about 28 to about 105;
Na 2 O/Al 2 O 3 of about 7 to about 23;
MO/Al 2 O 3 of about 0.1 to about 5;
SDA 2 O/Al 2 O 3 of about 1.5 to about 9.5;
H 2 O/Al 2 O 3 of about 700 to about 2000; and
OH/SiO 2 of about 0.6 to about 0.65;
where MO is an oxide of the promoter metal.
13. The method of claim 1 , wherein the reacting step is performed at a temperature of about 120 to about 180° C. for about 2 to about 15 days.