Investigating hydrothermal stability and influence of water on the activity of Cu-CHA catalysts for NH3-SCR

Licentiate thesis, 2024

Selective catalytic reduction of nitrogen oxides (NOx) with NH3 as a reducing agent (NH3- SCR) is a leading technology for diesel exhaust emission control. Cu-exchanged zeolites with the chabazite structure (Cu-CHA) have emerged as the preferred catalysts thanks to its high activity and hydrothermal stability. Hydrothermal stability is related to dealumination, i.e. removal of aluminum from the zeolite framework to form extraframework
aluminum, at high temperatures in the presence of water vapor. Copperexchanged chabazite (Cu-CHA) zeolites have higher hydrothermal stability compared to H-chabazite (H-CHA).

To understand the delayed dealumination of Cu-CHA catalysts, we have investigated the reaction paths for dealumination in H-CHA and Cu-CHA using density functional theory (DFT) calculations combined with microkinetic modeling. We find that Cu-CHA and H-CHA follow similar four-step hydrolysis processes, yet the dealumination of Cu-CHA has higher energy barriers, suggesting stabilization of the CHA structure by Cu ions. Furthermore, the preferred reaction product upon complete dealumination of Cu-CHA is a copper-aluminate like species bound to the zeolite framework. The microkinetic analysis quantifies the increased stability of Cu-CHA as compared to H-CHA.

In addition to the high-temperature dealumination, we investigated the role of water on low-temperature SCR by experimentally measuring the activity and reaction order of water. The reaction order of water is found to be increasingly negative with increasing water pressure. DFT calculations reveal that water blocks the active Cu-sites and a DFT-based microkinetic model reproduces the measured change of reaction order with water pressure.