Abstract: A thin-walled honeycomb body (100) having a plurality of repeating cell structures (110) formed of intersecting porous thick walls (112V, 112H) and thin walls (114V, 114H). Each repeating cell structure (110) is bounded on its periphery by the thick walls (112V, 122H) of a first transverse thickness (Tk) and the thin walls (114V, 114H) have a second transverse thickness (Tt) that subdivides each repeating cell structure (110) into between 7 and 36 individual cells (108). In the thin-walled honeycomb body (100), the first transverse thickness (Tk) of the thick walls (112V, 112H) is less than or equal to 0.127 mm (0.005 inch) and the second transverse thickness (Tt) of the thin walls (114V, 114H) is less than or equal to 0.0635 mm (0.0025 inch), and Tk>Tt. Honeycomb extrusion dies and methods of manufacturing the thin-walled honeycomb body (100) having thick walls (112V, 112H) and thin walls (114V, 114H) are provided.

Abstract: An extrusion system (100) includes at least one sensor (102, 104) to detect localized presence of oil (701) on an exterior surface (715) or skin of wet extrudate material (714 e.g., ceramic material having a honeycomb cross-sectional shape), and at least one infrared emitting device (106, 108) configured to impinge infrared emissions on at least a portion of the exterior surface responsive to one or more sensor signals. Localized impingement of infrared emissions may reduce presence of oil streaks (701) without undue differential drying of the extrudate skin (715), and avoid surface fissures that would otherwise result in fired ceramic bodies. Separately controllable infrared emitters (502), or at least one controllable infrared blocking or redirecting element (603), may be used to impinge infrared emissions on selected areas. A humidification section (120) arranged downstream of infrared emitters (106, 108) may be used to at least partially rehydrate the wet extrudate material, if necessary.

Abstract: Honeycomb bodies, honeycomb structures and extrusion dies, including a transition structural component. A honeycomb structure (100) includes a plurality of interconnected webs (106) defining a plurality of cell channels (108) in a honeycomb matrix (109) having a central axis (110) orthogonal to its transverse cross-section. Radial webs (116) diverge outwardly from the central axis (110). Radial webs (116) include a first radial web (150) and a second radial web (152). Tangential webs (120) are arranged concentrically with respect to the central axis (110), wherein at least one of the tangential webs (120) is a tangential transition web (142). At least one transition structural component (140) is located radially inward from the tangential transition web (124) and includes a first inclined web (144) having a first end (144A) coupled to the first radial web (150) and a second inclined web (146) having a first end (146A) coupled to the second radial web (152).

Abstract: A thin-walled honeycomb body (100) having a plurality of repeating cell structures (110) formed of intersecting porous thick walls (112V, 112H) and thin walls (114V, 114H). Each repeating cell structure (110) is bounded on its periphery by the thick walls (112V, 122H) of a first transverse thickness (Tk) and the thin walls (114V, 114H) have a second transverse thickness (Tt) that subdivides each repeating cell structure (110) into between 7 and 36 individual cells (108). In the thin-walled honeycomb body (100), the first transverse thickness (Tk) of the thick walls (112V, 112H) is less than or equal to 0.127 mm (0.005 inch) and the second transverse thickness (Tt) of the thin walls (114V, 114H) is less than or equal to 0.0635 mm (0.0025 inch), and Tk>Tt. Honeycomb extrusion dies and methods of manufacturing the thin-walled honeycomb body (100) having thick walls (112V, 112H) and thin walls (114V, 114H) are provided.

Abstract: Systems for and methods of drying a wet skin of a wet skinned ceramic ware are disclosed. The wet skinned ceramic ware includes a dry interior web with an outer surface. The wet skin is disposed on the outer surface of the dry interior web. The method includes generating an airstream and then directing the airstream through a first end of the wet-skinned ceramic ware only through an annular portion of the interior web that is adjacent the outer surface of the interior web. The flow of the airstream through the annular portion of the interior web causes moisture in the wet skin to migrate inwardly toward the interior web. The moisture is removed from the annular portion of the interior web when the airstream exits a second end of the ceramic ware, thereby drying the skin from the inside out of the wet-skinned ceramic ware.

Abstract: Honeycomb bodies, honeycomb structures and extrusion dies, including a transition structural component. A honeycomb structure (100) includes a plurality of interconnected webs (106) defining a plurality of cell channels (108) in a honeycomb matrix (109) having a central axis (110) orthogonal to its transverse cross-section. Radial webs (116) diverge outwardly from the central axis (110). Radial webs (116) include a first radial web (150) and a second radial web (152). Tangential webs (120) are arranged concentrically with respect to the central axis (110), wherein at least one of the tangential webs (120) is a tangential transition web (142). At least one transition structural component (140) is located radially inward from the tangential transition web (124) and includes a first inclined web (144) having a first end (144A) coupled to the first radial web (150) and a second inclined web (146) having a first end (146A) coupled to the second radial web (152).

Abstract: A substrate including a conversion catalyst for removing a volatile organic compound from ambient air. The substrate includes at least one porous wall. The conversion catalyst is within the pores of the at least one substrate porous wall.

Abstract: A substrate including a conversion catalyst for removing a volatile organic compound from ambient air. The substrate includes at least one porous wall. The conversion catalyst is within the pores of the at least one substrate porous wall.

Abstract: Systems and methods for rapid drying of ceramic greenwares having a high graphite content are disclosed. The methods include employing microwave drying to bring the dryness of the ceramic greenware to a first select dryness and then employing close-coupled hot-air drying to bring the dryness to the final target dryness. The judicious use of close-coupled hot-air drying reduces end defects due to unevenness in the microwave drying process while also substantially speeding up the drying process. Various configurations for and combinations of microwave drying and close-coupled hot-air drying are disclosed.

Abstract: Systems for and methods of drying a wet skin of a wet skinned ceramic ware are disclosed. The wet skinned ceramic ware includes a dry interior web with an outer surface. The wet skin is disposed on the outer surface of the dry interior web. The method includes generating an airstream and then directing the airstream through a first end of the wet-skinned ceramic ware only through an annular portion of the interior web that is adjacent the outer surface of the interior web. The flow of the airstream through the annular portion of the interior web causes moisture in the wet skin to migrate inwardly toward the interior web. The moisture is removed from the annular portion of the interior web when the airstream exits a second end of the ceramic ware, thereby drying the skin from the inside out of the wet-skinned ceramic ware.

Abstract: A method and system to dry crack-free and high strength skin including an inorganic binder of an average particle size (D50) in a range between 10 nm and 700 nm on a porous ceramic body. The method includes supporting the honeycomb body on an end face such that axial channels and outer periphery are substantially vertical. A gas is flowed past the honeycomb body substantially parallel to the axial channel direction, substantially equally around the outer periphery of the skin, to uniformly dry the skin to form a partially dried skin under mild conditions. Then the partially dried skin may be dried more severely resulting in rapidly dried crack-free and high strength skin.

Abstract: Disclosed is a ceramic honeycomb structure comprising a honeycomb body and a multilayered outer layer formed of a thick core layer applied and rapidly dried and a thin clad layer dried more gently to form a crack free dual skin layer. The core layer may have properties that are closer to those of the ceramic honeycomb body in service than the clad layer that may provide a tough outer shell to withstand handling and assembly.

Abstract: Systems and methods for drying skinned ceramic wares (10) using recycled microwave radiation are disclosed. The method includes irradiating wet skinned ceramic wares (10W) in a first applicator section (124W) with microwave radiation (212), wherein said irradiating (212) gives rise to reflected microwave radiation (212R). The method also includes capturing a portion of the reflected microwave radiation (212R) and irradiating a plurality of semi-dry skinned ceramic wares (105) in a second applicator section (124S) with the reflected microwave radiation (212R). Systems for carrying out the method are also disclosed.

Abstract: A method and system to dry crack-free and high strength skin including an inorganic binder of an average particle size (D50) in a range between 10 nm and 700 nm on a porous ceramic body. The method includes supporting the honeycomb body on an end face such that axial channels and outer periphery are substantially vertical. A gas is flowed past the honeycomb body substantially parallel to the axial channel direction, substantially equally around the outer periphery of the skin, to uniformly dry the skin to form a partially dried skin under mild conditions. Then the partially dried skin may be dried more severely resulting in rapidly dried crack-free and high strength skin.

Abstract: Cyclonic separation devices and fluid stream separating apparatuses incorporating cyclonic separation devices are described. A cyclonic separation device may include an exterior housing having an exterior cylindrical portion and an exterior conical portion extending from the exterior cylindrical portion and an interior housing having an interior cylindrical portion and an interior conical portion extending from the interior cylindrical portion. The interior housing is positioned relative to the exterior housing to form a circulating chamber. The cyclonic separation device also includes a fluid inlet coupled to the exterior housing, where the fluid inlet positioned to inject a fluid stream into the circulating chamber at an orientation generally tangential to the cylindrical portions of the exterior housing and the interior housing. The cyclonic separation device further includes a low-density outlet coupled to at least one of the exterior conical portion or the interior conical portion.

Abstract: A method of determining an optimal geometry for monoliths useful for capturing CO2 is described. Monoliths having the determined desired geometry are also described.

Abstract: Systems and methods for efficient microwave drying of extruded honeycomb structures are disclosed. The methods include conveying first and second sets of honeycomb structures in opposite directions through multiple applicator cavities. Each honeycomb structure has a moisture content MC, and the honeycomb structures within each cavity define an average moisture content MCA between 40% and 60% therein. The methods include irradiating the first and second sets of honeycomb structures within the cavities with microwave radiation having an amount of input microwave power PI that results in an amount of reflected microwave power PR from the honeycomb structures, where PR<(0.2)PI. This allows for a relatively high microwave power to be maintained in each cavity. Batch microwave drying methods are also disclosed.

Abstract: A method and system to dry crack-free and high strength skin including an inorganic binder of an average particle size (D50) in a range between 10 nm and 700 nm on a porous ceramic body. The method includes supporting the honeycomb body on an end face such that axial channels and outer periphery are substantially vertical. A gas is flowed past the honeycomb body substantially parallel to the axial channel direction, substantially equally around the outer periphery of the skin, to uniformly dry the skin to form a partially dried skin under mild conditions. Then the partially dried skin may be dried more severely resulting in rapidly dried crack-free and high strength skin.

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: Disclosed is a ceramic honeycomb structure comprising a honeycomb body and a multilayered outer layer formed of a thick core layer applied and rapidly dried and a thin clad layer dried more gently to form a crack free dual skin layer. The core layer may have properties that are closer to those of the ceramic honeycomb body in service than the clad layer that may provide a tough outer shell to withstand handling and assembly.