Synthesis-Structure-Catalysis Relations in CHA Zeolites Applied for Selective Catalytic Reduction of NOx with Ammonia

Microporous aluminosilicate zeolites are useful industrial catalysts. However, their hydrothermal synthesis is a multistep process with complicated and unclear reactions, limiting their rational functional design. Herein, we compare the formation pathway and the structural and catalytic properties of several CHA zeolites to obtain fundamental knowledge for intentionally controlling the catalytic function of zeolites. Three CHA zeolites were synthesized using different starting silica/alumina sources in the presence of tetraethylammonium hydroxide as an inexpensive organic structure-directing agent. FAU zeolite and an amorphous synthesis gel prepared using two different methods were used as starting materials. The obtained CHA zeolites were applied for exhaust gas purification (selective catalytic reduction of NOx with ammonia, NH3-SCR), and their structural characteristics and formation pathways were investigated using a combination of analytical methods. Stepwise gel preparation (SGP), which divides the compositional control of the amorphous synthesis gel, promotes the decomposition of the initial additive (zeolite seed), resulting in the formation of CHA zeolites with abundant micropores and paired Al sites. This structural feature obtained using the SGP method improves the catalytic durability of the NH3-SCR reaction. The present relationship, including different crystallization phenomena, structures, and catalytic abilities, provides useful insights into rational zeolite synthesis and its application.