Abstract: A method of manufacturing a catalyst body which includes: combining one or more inorganic components with an inorganic binder, and optionally with an organic binder, to form a mixture, the one or more inorganic components comprising a primary phase material being zeolite, or CeO2—ZrO2, or a combination; forming the mixture into a shaped body; firing the shaped body to allow the inorganic binder to bind the one or more inorganic components; impregnating the shaped body with a source of a reducing or oxidizing element; and heating the impregnated shaped body to form a redox oxide from the source, the redox oxide being supported by the shaped body.

Abstract: Methods of making a filter apparatus includes the step of creating a filter stack by axially spacing the porous ceramic plates from one another with a plurality of compliant spacers. In another example, the method includes the step of firing the first filter stack to sinter bond the first plurality of porous ceramic plates together with a first spacing element. In another example, the plurality of plates comprise a composition including catalyst particles and a binder material and the plates are fired to form porous plates without sintering a substantial amount of the catalyst particles. Methods of fabricating a porous ceramic article also include providing a porous substrate with a first material composition including mullite and infiltrating the pores of the substrate with a second material composition including cordierite. The method further includes the step of firing the first composition and the second composition to form the porous ceramic article.

Abstract: A filter apparatus comprises a filter stack including a plurality of porous ceramic plates that are axially spaced from one another to define plurality of axially spaced apart radial flow areas. In one example, the filter stack is mounted within a housing. In further examples, the plurality of porous ceramic plates alternate between a first set of porous ceramic plates that are nested with a second set of porous ceramic plates. In still further examples, at least one of the sides of the porous ceramic plates defines a plurality of radial flutes arranged in a radial array.

Abstract: A method of making a nanoparticle catalyst composition including: a single heating of an aqueous salt solution comprising a Ce, a Zr, a rare earth dopant, and a transition metal oxide precursor to provide nanoparticles, the nanoparticles have a compositional gradient comprised of a CeZrREO2, where RE is a rare earth, and the outer portion of the nanoparticles has a Ce:Zr ratio different from the inner portion of the nanoparticles. Also disclosed is a nanoparticle-catalyst composition and articles containing the composition, as defined herein.

Abstract: A reactor for adsorbing CO2 from a fluid stream includes a reactor housing having a fluid inlet and a fluid outlet. The reactor also includes an inlet ceramic honeycomb structure and an outlet ceramic honeycomb structure positioned inside the reactor housing. The inlet and outlet ceramic honeycomb structures have a plurality of partition walls extending in an axial direction thereby forming a plurality of flow channels and comprises a material that forms bonds with CO2 to adsorb the CO2. The inlet ceramic honeycomb structure is capable of adsorbing an inlet quantity of CO2 and the outlet ceramic honeycomb structure is capable of adsorbing an outlet quantity of CO2. The inlet quantity of CO2 is greater than the outlet quantity of CO2.

Abstract: A batch composition for making a highly porous honeycomb ceramic catalytic filter article, including base inorganic components including a mixture of a nano-zeolite powder, and an inorganic filler, in amounts defined herein; and super additives including: a mixture of at least two pore formers; a binder; and a metal salt, in amounts defined herein. Also disclosed are extruded catalyst filter articles and methods for making the articles.

Abstract: Flow-through substrates, such as honeycombs, comprising certain zeolites. The flow-through substrates may be used, for example, in the removal of a heavy metal from a fluid such as a gas stream.

Abstract: Sorbent substrates for CO2 capture and methods for forming the same are disclosed. In one embodiment, a method for forming a sorbent substrate for CO2 capture may include forming a plurality of matrix rods from a sorbent material and forming a plurality of channel rods from a support material. The plurality of matrix rods may then be co-extruded with the plurality of channel rods to form a plurality of sorbent filaments comprising a matrix of the sorbent material in which channels of support material are positioned such that the channels extend in an axial direction of each of the plurality of sorbent filaments. The plurality of sorbent filaments may then be stacked to form a filament assembly in which the plurality of sorbent filaments are axially aligned. Thereafter, the plurality of sorbent filaments of the filament assembly may be bonded to one another to form the sorbent substrate.

Abstract: High volumetric-efficiency thermally integrated systems for capturing a target gas from a process gas stream include a monolithic body and a distribution system. The monolithic body includes a first plurality of channels and a second plurality of channels each having sorbent surfaces that reversibly adsorb the target gas. The channels are in thermal communication such that heat from an exothermic adsorption of target gas in one plurality of channels is used by an endothermic desorption of target gas from the other plurality of channels. Methods for separating a target gas from a process gas stream include switching the high volumetric-efficiency thermally integrated systems between a first state and a second state. In the first state, the first plurality of channels undergoes desorption while the second undergoes adsorption. In the second state, the second plurality of channels undergoes desorption while the first plurality undergoes adsorption.

Abstract: Zeolite-based honeycomb bodies and methods of manufacturing same. Zeolite-based honeycomb bodies especially suited for engine exhaust treatment applications include a primary phase comprising a zeolite having a SiO2 to Al2O3 molar ratio in the range from 5 to 300. The zeolite-based composites are porous with an open porosity of at least 25% and a median pore diameter of at least 1 micron. The zeolite-based honeycomb bodies can be manufactured by an extrusion method.

Abstract: An article comprising a plurality of intersecting walls having outer surfaces that define a plurality of cells extending from one end to a second end, wherein the walls forming each cell in a first subset of cells are covered by a barrier layer to form a plurality of heat exchange flow channels, and wherein the walls forming each cell in a second subset of cells different from the first subset of cells, comprise a CO2 sorbent and form reaction flow channels. Heat exchange flow channels allow quick and uniform heating and cooling of the sorbent body. The article may be useful, for example, for removing CO2 from a gas stream.

Abstract: A method of making a nanoparticle catalyst composition including: a single heating of an aqueous salt solution comprising a Ce, a Zr, a rare earth dopant, and a transition metal oxide precursor to provide nanoparticles, the nanoparticles have a compositional gradient comprised of a CeZrREO2, where RE is a rare earth, and the outer portion of the nanoparticles has a Ce:Zr ratio different from the inner portion of the nanoparticles. Also disclosed is a nanoparticle-catalyst composition and articles containing the composition, as defined herein.

Abstract: A flow-through substrate having a treated activated carbon surface, useful, for example, in the removal of a toxic metal from a fluid.

Abstract: A filter apparatus comprises a filter stack including a plurality of porous ceramic plates that are axially spaced from one another to define plurality of axially spaced apart radial flow areas. In one example, the filter stack is mounted within a housing. In further examples, the plurality of porous ceramic plates alternate between a first set of porous ceramic plates that are nested with a second set of porous ceramic plates. In still further examples, at least one of the sides of the porous ceramic plates defines a plurality of radial flutes arranged in a radial array.

Abstract: Methods of making a filter apparatus includes the step of creating a filter stack by axially spacing the porous ceramic plates from one another with a plurality of compliant spacers. In another example, the method includes the step of firing the first filter stack to sinter bond the first plurality of porous ceramic plates together with a first spacing element. In another example, the plurality of plates comprise a composition including catalyst particles and a binder material and the plates are fired to form porous plates without sintering a substantial amount of the catalyst particles. Methods of fabricating a porous ceramic article also include providing a porous substrate with a first material composition including mullite and infiltrating the pores of the substrate with a second material composition including cordierite. The method further includes the step of firing the first composition and the second composition to form the porous ceramic article.

Abstract: Extruded honeycomb catalyst bodies and methods of manufacturing same. The catalyst body includes a first oxide selected from the group consisting of tungsten oxides, vanadium oxides, and combinations thereof, a second oxide selected from the group consisting of cerium oxides, lanthanum oxides, zirconium oxides, and combinations thereof, and a zeolite.

Abstract: A method for strengthening an extruded catalyst honeycomb filter body, including: contacting an extruded catalyst honeycomb filter body and a siliceous formulation including at least one siliceous source comprising a silicone emulsion, a silica sol, or a combination thereof; drying the contacted filter body; and firing the dried contacted filter body to provide the filter body. Also disclosed are zeolite-based honeycomb filter articles, including a matrix of walls of: a primary phase material homogeneously distributed throughout the walls, as defined herein.

Abstract: Flow-through substrates, such as honeycombs, comprising certain zeolites. The flow-through substrates may be used, for example, in the removal of a heavy metal from a fluid such as a gas stream.

Abstract: The invention describes a high porosity ceramic article and method of manufacturing the same and intermediate dried honeycomb green body articles. The article may have a total porosity of at least about fifty-five percent, above sixty percent, or even above sixty-five percent. The method of manufacture includes mixing a ceramic-forming powder, an organic pore former, water, and a crosslinker. Drying causes a condensation reaction between the pore former and the crosslinker thereby forming a network within the green body that strengthens the green body and reduces cracking. The pore former may include starch or an activated cellulose compounds. Secondary pore forming agents, such as graphite may also be included.

Abstract: A method of manufacturing a catalyst body which includes: soaking at least part of a fired zeolite-based body in a transition metal oxide solution; removing the body from the transition metal oxide solution; exposing the body to a humidified atmosphere at one or more temperatures above 20° C.; then drying the body; and calcining the body.