Method of manufacturing a transition metal catalyzed zeolite body
A method of manufacturing a catalyst body which includes: soaking at least part of a fired zeolite-based body in a transition metal oxide solution; removing the body from the transition metal oxide solution; exposing the body to a humidified atmosphere at one or more temperatures above 20° C.; then drying the body; and calcining the body.
1. A method of manufacturing a catalyst body, the method comprising:
hydrating a fired zeolite body having a total pore volume by exposing the fired zeolite body to an environment having a temperature of at least 50° C. and a relative humidity of 100%, including carrying out said hydrating until a water mass of 5% to 10% of the total pore volume is added to the fired zeolite body; then,
soaking at least part of the hydrated fired zeolite body in a transition metal oxide solution; then,
removing the body from the transition metal oxide solution; then,
exposing the body to a humidified atmosphere at one or more temperatures above 20° C.; then
drying the body; then
calcining the body.
2. The method of claim 1 wherein the catalyst body comprises between 0.5 and 5 wt % transition metal oxide after the calcining.
3. The method of claim 1 wherein, prior to the soaking step, the fired zeolite body is formed by extrusion and firing.
4. The method of claim 1 wherein the transition metal oxide solution comprises iron, copper, or a combination thereof.
5. The method of claim 1 wherein the transition metal oxide solution is an iron-containing solution.
6. The method of claim 1 wherein the transition metal oxide solution is an iron gluconate solution.
7. The method of claim 1 wherein substantially the entire fired zeolite body is immersed in the transition metal oxide solution.
8. The method of claim 1 wherein the hydrating is performed for at least 3 hours.
9. The method of claim 1 wherein the hydrating is performed for at least 4 hours.
10. The method of claim 1 further comprising, after the removing of the body, blowing the body with a gas stream.
11. The method of claim 10 wherein the gas stream blown at the body removes a portion of transition metal oxide solution from the body.
12. The method of claim 10 wherein the gas stream blown at the body removes a portion of transition metal oxide solution from an outside surface of the body.
13. The method of claim 1 wherein the drying of the body comprises exposing the body to an environment having a temperature of at least 100° C.
14. The method of claim 1 wherein the drying of the body comprises exposing the body to an environment having a temperature which is increased at 5° C./minute to 100° C. and held at one or more temperatures and for a time sufficient to achieve a water loading of less than 5 wt % in the body.
15. The method of claim 1 wherein the exposing of the body to the humidified atmosphere comprises placing the body in a closed container and heating the atmosphere within the container to at least 50° C. for at least 10 hours.
16. The method of claim 1 wherein the calcining comprises exposing the body to an environment of greater than 500° C. for more than 1 hour.
17. The method of claim 1 wherein the calcining comprises exposing the body to an environment of greater than 500° C. for more than 2 hours.
18. The method of claim 1 wherein the fired zeolite body comprises one or more of the group consisting of: silicoaluminophosphate having silicon to alumina ratio less than 50, zeolite beta, ZSM-5, mordenite, chabazite, and ferrierite.
19. The method of claim 1 wherein the fired zeolite body comprises a honeycomb structure.