Novel binderless zeolite-coated monolith reactor for environmental applications

A novel structured catalyst based on a binderless zeolite film was developed onto a cordierite monolith. The zeolitic film was obtained performing a binderless washcoating which was followed by a hydrothermal treatment, which resulted in a coating with hybrid physicochemical properties, having a porous washcoat-like microstructure with an intergrowth between the aggregates. This combination confers to the zeolite coating an open structure which is an advantage of washcoats and a high mechanical stability characteristic of the zeolite growths. It should be emphasized that these desired properties are obtained without the use of binders. The physico-chemical properties were investigated through MIP (mercury intrusion porosimetry), SEM (scanning electron microscopy), ultrasonic adherence tests, NO-TPD (temperature-programmed desorption of NO) and EPMA (electron probe microanalysis). The catalytic properties of the monolith were evaluated in the selective catalytic reduction of NO x at high spatial velocities, showing promising results.