Templated catalyst composition and associated method

Abstract

A composition includes a templated metal oxide, at least 3 weight percent of silver, and at least one catalytic metal. A method of making and a method of using are included.

1 . A composition, comprising:
 a templated metal oxide substrate material having a plurality of pores; and   a catalyst material comprising a catalyst metal and silver; and the silver is present in an amount of at least about three weight percent based on a total weight of the substrate material.   
     
     
         2 . The composition as defined in  claim 1 , wherein the templated metal oxide is alumina or silica-alumina. 
     
     
         3 . The composition as defined in  claim 1 , wherein the templated metal oxide has periodically arranged templated pores, wherein the average diameter of the pores is in a range of from about 2 nanometers to about 100 nanometers and the pores have a periodicity in a range of from about 50 Angstrom to about 130 Angstrom. 
     
     
         4 . The composition as defined in  claim 1 , wherein the templated metal oxide has a surface area greater than about 0.5 meter 2 /gram; wherein the templated metal oxide is present in an amount greater than about 50 mole percent of the composition; or wherein the silver is present in an amount of less than or equal to ten weight percent of a total weight of the substrate material. 
     
     
         5 . The composition as defined in  claim 1 , wherein the catalyst metal comprises one or more material selected from group consisting of zirconium, iron, gallium, indium, tungsten, zinc, platinum, and rhodium. 
     
     
         6 . The composition as defined in  claim 5 , wherein the catalyst metal is zirconium. 
     
     
         7 . The composition as defined in  claim 5 , wherein the catalyst metal comprises iron. 
     
     
         8 . The composition as defined in  claim 5 , wherein the catalyst metal comprises gallium, indium, or both gallium and indium. 
     
     
         9 . The composition as defined in  claim 8 , wherein the catalyst metal comprises both gallium and indium, and they are present in a ratio such that gallium is present more than 2:1 relative to indium. 
     
     
         10 . The composition as defined in  claim 5 , wherein the catalyst metal is tungsten. 
     
     
         11 . The composition as defined in  claim 5 , wherein the catalyst metal is zinc. 
     
     
         12 . The composition as defined in  claim 5 , wherein the catalyst metal is platinum. 
     
     
         13 . The composition as defined in  claim 5 , wherein the catalyst metal is rhodium. 
     
     
         14 . The composition as defined in  claim 5 , wherein the catalyst metal comprises an oxide. 
     
     
         15 . The composition as defined in  claim 1 , wherein the catalyst metal is present in an amount in a range of from about 0.1 weight percent to about 3 weight percent, based on the total weight of the composition. 
     
     
         16 . The composition as defined in  claim 1 , wherein the composition is free of alkaline earth metal. 
     
     
         17 . The composition as defined in  claim 1 , wherein the composition is capable of reducing NOx in reactive proximity therewith without absorbing the NOx on a catalyst material surface. 
     
     
         18 . The composition as defined in  claim 1 , wherein the composition has capability of reducing nitrogen oxide greater than 40 percent by volume at a temperature of about 325 degrees Celsius. 
     
     
         19 . A method, comprising:
 introducing a gas stream in a chamber that includes the composition as defined in  claim 1 ; and   reducing nitrogen oxide present in the gas stream at a temperature that is greater than about 275 degrees Celsius.   
     
     
         20 . The method as defined in  claim 19 , wherein the reducing nitrogen oxide comprises maintaining a temperature in the chamber that is greater than about 275 degrees Celsius and that is less than about 325 degrees Celsius. 
     
     
         21 . A method, comprising:
 reacting a metal alkoxide, a silver composition, a catalyst metal composition and a templating agent to form a reaction product;   hydrolyzing the reaction product to form a hydrolyzed reaction product;   condensing the hydrolysed reaction product to form a templated substrate; and   controlling the reacting, hydrolysing and condensing step to control the silver loading of the templated substrate.   
     
     
         22 . The method as defined in  claim 21 , controlling the silver loading so that the silver is present in an amount of at least about three weight percent based on a total weight of the material that is the templated substrate. 
     
     
         23 . The method as defined in  claim 21 , wherein the condensing step includes calcinating. 
     
     
         24 . The method as defined in  claim 21 , wherein the hydrolyzing step comprises hydrolyzing the reaction product over a period that is greater than about 1 hour.