Abstract: The present disclosure relates to a powder coated article for filtering particulate matter from exhaust gases. The powder coated article comprises a coated monolith article, and a powder coating on the coated monolith article. The coated monolith article is a monolith article coated with an on-wall washcoat, and the powder coating comprises an inorganic particle and a silicone resin in a ratio of between 50:1 to 1:9. The present disclosure also relates to a method forming said powder coated article.

Abstract: A powder spraying system comprises a source of dry powder (4), a spray nozzle (25), and a supply conduit (16) connecting the source of dry powder with the spray nozzle. The spray nozzle comprises a nozzle body (50) having a nozzle outlet (51), a first conduit (52) for dry powder, and a second conduit (53) for gas. The first conduit extends between a powder inlet (54) in communication with the supply conduit and a powder outlet (55). The second conduit extends between a gas inlet (56) and a gas outlet (57), the gas outlet being located in proximity to the powder outlet such that a gas flowing through the second conduit and out of the gas outlet produces a suction force at the powder outlet to promote flow of a dry powder through the first conduit and out of the powder outlet and the nozzle outlet. The powder outlet and the gas outlet are orientated to promote mixing of the gas with the dry powder. The first conduit (52) is a straight conduit between the powder inlet (54) and the powder outlet (55).

Abstract: Methods for treating a filter for filtering particulate matter from exhaust gas are disclosed in which a dry powder is sprayed towards an inlet face of the filter entrained in a primary flow of gas to pass through the inlet face to contact a porous structure of the filter. The back pressure of the filter is monitored during spraying of the dry powder and the spraying of the dry powder is stopped when the back pressure of the filter reaches a required value. The required value may equal an absolute back pressure, or a pre-determined target back pressure for the filter minus an offset pressure, or an estimated back pressure of the filter.

Abstract: A catalytic wall-flow monolith filter for use in an emission treatment system is disclosed. The filter comprises porous walls, a first face and a second face defining a longitudinal direction therebetween and first and second pluralities of channels extending in the longitudinal direction. The first plurality of channels provides a first plurality of inner surfaces and is open at the first face and closed at the second face; and the second plurality of channels provides a second plurality of inner surfaces and is open at the second face and closed at the first face. The filter comprises a first selective catalytic reduction (SCR) catalyst coated on the first plurality of inner surfaces of the porous walls to form a first SCR catalyst porous layer, a second SCR catalyst within the porous walls, and a third SCR catalyst coated on the second plurality of inner surfaces of the porous walls to form a third SCR catalyst porous layer.

Abstract: A catalytic wall-flow monolith filter for use in an emission treatment system is disclosed. The filter comprises porous walls, a first face and a second face defining a longitudinal direction therebetween and first and second pluralities of channels extending in the longitudinal direction. The first plurality of channels provides a first plurality of inner surfaces and is open at the first face and closed at the second face; and the second plurality of channels provides a second plurality of inner surfaces and is open at the second face and closed at the first face. The filter comprises a first selective catalytic reduction (SCR) catalyst coated on the first plurality of inner surfaces of the porous walls to form a first SCR catalyst porous layer, a second SCR catalyst within the porous walls, and a third SCR catalyst coated on the second plurality of inner surfaces of the porous walls to form a third SCR catalyst porous layer.

Abstract: A method of forming an inorganic oxide coating on a monolith article to produce a coated monolith article suitable for the treatment of an exhaust gas comprises spraying, as a dry particulate aerosol, inorganic particles and a silicone resin to form a coating layer. The present invention also provides an uncalcined porous monolith article for use in forming a monolith article for the treatment of an exhaust gas. The uncalcined monolith article comprises a dry particulate composition comprising inorganic particles and a silicone resin.

Abstract: A coated monolith article for the treatment of an exhaust gas is obtainable by the method comprising: providing a porous monolith article comprising a plurality of channels for passage of an exhaust gas, each channel having a gas-contacting surface; spraying onto the gas-contacting surface, as a dry particulate aerosol, inorganic particles and a silicone resin to form a coating layer; and calcining the coating layer to provide a coated monolith article.

Abstract: An uncalcined monolith article comprises a dry particulate composition comprising inorganic particles and a silicone resin. The uncalcined monolith article can be prepared by spraying, as a dry particulate aerosol, inorganic particles and a silicone resin on a monolith article to form a coating layer.

Abstract: The present disclosure relates to a powder coated article for filtering particulate matter from exhaust gases. The powder coated article comprises a coated monolith article, and a powder coating on the coated monolith article. The coated monolith article is a monolith article coated with an on-wall washcoat, and the powder coating comprises an inorganic particle and a silicone resin in a ratio of between 50:1 to 1:9. The present disclosure also relates to a method forming said powder coated article.

Abstract: A method of forming an inorganic oxide coating on a monolith article is disclosed. The coated monolith article is suitable for the treatment of an exhaust gas. The method comprises spraying, as a dry particulate aerosol, inorganic particles and a silicone resin to form a coating layer. The present invention also provides an uncalcined porous monolith article for use in forming a monolith article for the treatment of an exhaust gas. The uncalcined monolith article comprises a dry particulate composition comprising inorganic particles and a silicone resin.

Abstract: The disclosure relates to a method of forming a coated monolith article for the treatment of an exhaust gas. The method comprises the steps of: retaining a porous monolith article in a coating apparatus, the porous monolith article comprising a plurality of channels for the passage of an exhaust gas, each channel having a gas-contacting surface; depositing cementitious particles as a dry powder onto the gas-contacting surface of at least some of the channels; and reacting the cementitious particles with a liquid or gaseous reagent in situ within the porous monolith article to provide the coated monolith article.

Abstract: A vehicular exhaust filter comprising a porous substrate having an inlet face and an outlet face with the porous substrate comprising inlet channels extending from the inlet face and outlet channels extending from the outlet face is disclosed. The inlet channels and the outlet channels are separated by a plurality of filter walls having a porous structure. The vehicular exhaust filter is loaded with a refractory powder having a tapped density before loading of less than 0.10 g/cm3 and the vehicular exhaust filter has a mass loading of the refractory powder of less than 10 g/l.

Abstract: Methods for treating a filter (2) for filtering particulate matter from exhaust gas are disclosed in which a dry powder (4) is sprayed towards an inlet face of the filter (2) entrained in a primary flow of gas to pass through the inlet face to contact a porous structure of the filter. The back pressure of the filter (2) is monitored during spraying of the dry powder (4) and the spraying of the dry powder (4) is stopped when a back pressure of the filter (2) reaches a required value. The required value may equal an absolute back pressure, or a pre-determined target back pressure for the filter minus an offset pressure, or an estimated back pressure of the filter.

Abstract: A powder spraying system comprises a source of dry powder (4), a spray nozzle (25), and a supply conduit (16) connecting the source of dry powder with the spray nozzle. The spray nozzle comprises a nozzle body (50) having a nozzle outlet (51), a first conduit (52) for dry powder, and a second conduit (53) for gas. The first conduit extends between a powder inlet (54) in communication with the supply conduit and a powder outlet (55). The second conduit extends between a gas inlet (56) and a gas outlet (57), the gas outlet being located in proximity to the powder outlet such that a gas flowing through the second conduit and out of the gas outlet produces a suction force at the powder outlet to promote flow of a dry powder through the first conduit and out of the powder outlet and the nozzle outlet. The powder outlet and the gas outlet are orientated to promote mixing of the gas with the dry powder. The first conduit (52) is a straight conduit between the powder inlet (54) and the powder outlet (55).

Abstract: A vehicular exhaust filter comprising a porous substrate having an inlet face and an outlet face with the porous substrate comprising inlet channels extending from the inlet face and outlet channels extending from the outlet face is disclosed. The inlet channels and the outlet channels are separated by a plurality of filter walls having a porous structure. The vehicular exhaust filter is loaded with a refractory powder having a tapped density before loading of less than 0.10 g/cm3 and the vehicular exhaust filter has a mass loading of the refractory powder of less than 10 g/l.

Abstract: A vehicular exhaust filter (2) comprising a porous substrate having an inlet face and an outlet face with the porous substrate comprising inlet channels extending from the inlet face and outlet channels extending from the outlet face is disclosed. The inlet channels and the outlet channels are separated by a plurality of filter walls having a porous structure. The vehicular exhaust filter (2) is loaded with a refractory powder having a tapped density before loading of less than 0.10 g/cm3 and the vehicular exhaust filter has a mass loading of the refractory powder of less than 10 g/l.

Abstract: A method and apparatus (1) for treating a filter (2) for filtering particulate matter from exhaust gas and a treated filter (2) are described. A reservoir (3) containing a dry powder (4) is provided. A vacuum generator (6) establishes a primary gas flow through a porous structure of the filter (2) by applying a pressure reduction to an outlet face of the filter (2). A spray device (7) receives the dry powder (4) from a transport device (8) and sprays the dry powder (4) towards the inlet face of the filter (2). A controller (9) is configured to control operation of at least the vacuum generator (6) and the spray device (7). The dry powder (4) comprises or consists of a metal compound for forming by thermal decomposition a metal oxide.

Abstract: A vehicular exhaust filter (2) comprising a porous substrate having an inlet face and an outlet face with the porous substrate comprising inlet channels extending from the inlet face and outlet channels extending from the outlet face is disclosed. The inlet channels and the outlet channels are separated by a plurality of filter walls having a porous structure. The vehicular exhaust filter (2) is loaded with a refractory powder having a tapped density before loading of less than 0.10 g/cm3 and the vehicular exhaust filter has a mass loading of the refractory powder of less than 10 g/l.

Abstract: A method and apparatus (1) for treating a filter (2) for filtering particulate matter from exhaust gas. A reservoir (3) containing a dry powder (4) is provided. A vacuum generator (6) establishes a primary gas flow through a porous structure of the filter (2) by applying a pressure reduction to an outlet face of the filter (2). A spray device (7) receives the dry powder (4) from a transport device (8) and sprays the dry powder (4) towards the inlet face of the filter (2). A controller (9) is configured to control operation of at least the vacuum generator (6) and the spray device (7).

Abstract: A catalytic wall-flow monolith filter for use in an emission treatment system comprises a wall flow substrate having a first and a second face, and first and second pluralities of channels. The first plurality of channels is open at the first face and closed at the second face. The second plurality of channels is open at the second face and closed at the first face. The monolith filter comprises a porous substrate having a first zone extending from the first face towards the second face and a second zone extending from the second face towards the first face. Each of the zones are less that filter length. A first catalytic material is distributed throughout the first zone of the porous substrate, and a second catalytic material covers at least a portion of the surfaces in the second zone of the porous substrate and is not distributed throughout the porous substrate.