Conspectus
Copper-exchanged chabazite (Cu-CHA) zeolites are catalysts used
in diesel emissions control for the abatement of nitrogen oxides (NO
x
) via selective catalytic reduction (SCR)
reactions with ammonia as the reductant. The discovery of these materials
in the early 2010s enabled a step-change improvement in diesel emissions
aftertreatment technology. Key advantages of Cu-CHA zeolites over
prior materials include their effectiveness at the lower temperatures
characteristic of diesel exhaust, their durability under high-temperature
hydrothermal conditions, and their resistance to poisoning from residual
hydrocarbons present in exhaust. Fundamental catalysis research has
since uncovered mechanistic and kinetic features that underpin the
ability of Cu-CHA to selectively reduce NO
x
under strongly oxidizing conditions and to achieve improved NO
x
conversion relative to other zeolite frameworks,
particularly at low exhaust temperatures and with ammonia instead
of other reductants.
One critical mechanistic feature is the
NH3 solvation
of exchanged Cu ions at low temperatures (<523 K) to create cationic
Cu–amine coordination complexes that are ionically tethered
to anionic Al framework sites. This ionic tethering confers regulated
mobility that facilitates interconversion between mononuclear and
binuclear Cu complexes, which is necessary to propagate SCR through
a Cu2+/Cu+ redox cycle during catalytic turnover.
This dynamic catalytic mechanism, wherein single and dual metal sites
interconvert to mediate different half-reactions of the redox cycle,
combines features canonically associated with homogeneous and heterogeneous
reaction mechanisms.
In this Account, we describe how a unified
experimental and theoretical
interrogation of Cu-CHA catalysts in operando provided quantitative
evidence of regulated Cu ion mobility and its role in the SCR mechanism.
This approach relied on new synthetic methods to prepare model Cu-CHA
zeolites with varied active-site structures and spatial densities
in order to verify that the kinetic and mechanistic models describe
the catalytic behavior of a family of materials of diverse composition,
and on new computational approaches to capture the active-site structure
and dynamics under conditions representative of catalysis. Ex situ
interrogation revealed that the Cu structure depends on the conditions
for the zeolite synthesis, which influence the framework Al substitution
patterns, and that statistical and electronic structure models can
enumerate Cu site populations for a known Al distribution. This recognition
unifies seemingly disparate spectroscopic observations and inferences
regarding Cu ion structure and responses to different external conditions.
SCR rates depend strongly on the Cu spatial density and zeolite composition
in kinetic regimes where Cu+ oxidation with O2 becomes rate-limiting, as occurs at lower temperatures and under
fuel-rich conditions. Transient experiments, ab initio molecular dynamics
simulations, and statistical models relate these sensitivities to
the m...