Cu-exchanged 3D-printed geopolymer/ZSM-5 monolith for selective catalytic reduction of NOx

Cu-exchanged zeolites with MFI structure, such as ZSM-5, represent effective catalysts for SCR processes when the application requires a good thermal stability under a wide range of temperature as for the after-treatment of exhaust gas from diesel engine. The production of zeolite in a structured form, mandatorily required for mobile applications, is quite complex due to the poor adhesion of the material. In this paper 3D-printed geopolymers containing about 37 % ZSM-5 are proposed as potentially structured catalysts for SCR applications. The production of the monolith and the pre-treatment necessary to introduce copper as active exchanged cation are investigated. The effect of pre-treatments on the physical and morphological structure of both geopolymer and zeolite and on the nature of copper introduced in the subsequent step was studied using characterization techniques such as SEM, XRD, N2 physisorption and Temperature Programmed Reduction (TPR).