Abstract: Provided are methods for manufacturing a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, substantially free of platinum group metal components, and at least one catalytic layer.

Abstract: Provided is an exhaust article (catalyst) coated on a single substrate, such as a monolithic honeycomb having a plurality of channels along the axial length of the catalyst. Different washcoat compositions are deposited along the length the channel walls of the substrate beginning from either the inlet or outlet axial end of the substrate to form inlet and outlet catalyst layers, respectively. In the coating process, the channel walls are coated with catalyst washcoat compositions to lengths that are less than the substrates' axial length. The architecture of the resulting catalyst layers defines a plurality of zones along the length of the substrate. The properties of each zone of the catalyst can be optimized to address specific catalyst functions by manipulation of both the coating lengths and the catalyst washcoat compositions.

Abstract: Provided are methods for manufacturing a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, substantially free of platinum group metal components, and at least one catalytic layer.

Abstract: A layered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.

Abstract: Provided is a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, and at least one catalytic layer. Also provided are methods for preparing the catalyst and methods for monitoring the oxygen storage capacity of an exhaust article containing the catalyst.

Abstract: Provided are coated, multi-zoned catalyst substrates that trap and combust hydrocarbon and nitrogen oxides pollutants in a single monolith substrate. In some embodiments, the multi-zoned catalysts contain both radial and axial zones. The zones can be formed by deposition of segregated coating compositions (or washcoats) containing platinum group metals and pollutant adsorbent materials to form layers along the length and radius of the honeycomb substrate. The invention also relates to exhaust gas treating systems that incorporate the multi-zoned catalysts.

Abstract: Hydrogen sulfide formation is suppressed by a three-way conversion catalyst having an underlayer and a topcoat overlying the under layer. The under layer is prepared by dispersing a Group IIa metal oxide such as an oxide of magnesium, calcium, barium or strontium on a carrier such as a refractory metal oxide monolith. A topcoat overlying the undercoat is comprised of a three-way conversion catalyst material such as a platinum-group metal catalytic component, e.g., platinum, palladium, rhodium or mixtures thereof.

Abstract: The present invention relates to a layered catalyst composite of the type generally referred to as a three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides. The structure of the layered catalyst composite of the present invention is designed wherein there are three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising a high surface area refractory metal oxide; a second layer deposited on the first layer and comprising palladium and/or platinum deposited on a high surface area refractory metal oxide, and having substantially no oxygen storage components; and a third layer deposited on the second layer and comprising platinum and/or rhodium as well as an oxygen storage component, deposited on a high surface area refractory metal oxide.

Abstract: Provided are coated, multi-zoned catalyst substrates that trap and combust hydrocarbon and nitrogen oxides pollutants in a single monolith substrate. In some embodiments, the multi-zoned catalysts contain both radial and axial zones. The zones can be formed by deposition of segregated coating compositions (or washcoats) containing platinum group metals and pollutant adsorbent materials to form layers along the length and radius of the honeycomb substrate. The invention also relates to exhaust gas treating systems that incorporate the multi-zoned catalysts.

Abstract: Provided is an exhaust article (catalyst) coated on a single substrate, such as a monolithic honeycomb having a plurality of channels along the axial length of the catalyst. Different washcoat compositions are deposited along the length the channel walls of the substrate beginning from either the inlet or outlet axial end of the substrate to form inlet and outlet catalyst layers, respectively. In the coating process, the channel walls are coated with catalyst washcoat compositions to lengths that are less than the substrates' axial length. The architecture of the resulting catalyst layers defines a plurality of zones along the length of the substrate. The properties of each zone of the catalyst can be optimized to address specific catalyst functions by manipulation of both the coating lengths and the catalyst washcoat compositions.

Abstract: Hydrogen sulfide formation is suppressed by a three-way conversion catalyst having an underlayer and a topcoat overlying the under layer. The under layer is prepared by dispersing a Group IIa metal oxide such as an oxide of magnesium, calcium, barium or strontium on a carrier such as a refractory metal oxide monolith. A topcoat overlying the undercoat is comprised of a three-way conversion catalyst material such as a platinum-group metal catalytic component, e.g., platinum, palladium, rhodium or mixtures thereof.

Abstract: The present invention relates to a layered catalyst composite of the type generally referred to as a three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides. The structure of the layered catalyst composite of the present invention is designed wherein there are three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising a high surface area refractory metal oxide; a second layer deposited on the first layer and comprising palladium and/or platinum deposited on a high surface area refractory metal oxide, and having substantially no oxygen storage components; and a third layer deposited on the second layer and comprising platinum and/or rhodium as well as an oxygen storage component, deposited on a high surface area refractory metal oxide.

Abstract: Provided is a base metal undercoat containing catalyst and an exhaust article containing the catalyst. The catalyst contains a base metal undercoat with an oxygen storage component, and at least one catalytic layer. Also provided are methods for preparing the catalyst and methods for monitoring the oxygen storage capacity of an exhaust article containing the catalyst.

Abstract: A stable, close-coupled catalyst, an article comprising the close-coupled catalyst and a related method of operation. The close-coupled catalyst comprises a catalyst support and a palladium catalytic component. Preferably and optionally, there are stabilizers including alkaline metal oxide, and rare earth metal components selected from the neodymium and lanthanum components. The close-coupled catalyst composition includes substantially no additional oxygen storage component such as praseodymium or cerium compounds. There is preferably a catalyst such as a three-way catalyst downstream of the close-coupled catalyst. The downstream catalyst preferably includes an oxygen storage component such as cerium oxide or praseodymium oxide.

Abstract: A stable, close-coupled catalyst, an article comprising the close-coupled catalyst and a related method of operation. The close-coupled catalyst comprises a catalyst support and a palladium catalytic component. Preferably and optionally, there are stabilizers including alkaline metal oxide, and rare earth metal components selected from the neodymium and lanthanum components. The close-coupled catalyst composition includes substantially no additional oxygen storage component such as praseodymium or cerium compounds. There is preferably a catalyst such as a three-way catalyst downstream of the close-coupled catalyst. The downstream catalyst preferably includes an oxygen storage component such as cerium oxide or praseodymium oxide.

Abstract: A novel catalytic material is prepared by dispersing a catalytically active species, e.g., one or more platinum group metals, on a support phase that contains a high porosity, meso-pores high surface area (HPMPHSA) material. The HPMPHSA material has a porosity, measured in milliliters per gram of material, that is typically at least about 30 percent greater than that of a corresponding conventional material, preferably at least 50 percent greater. In a particular embodiment, the support phase of the catalytic material contains a HPMPHSA alumina having a porosity of about 0.9 ml/g, whereas a conventional alumina typically has a porosity of about 0.45 ml/g. The surface area is above 90, preferably above 100, more preferably equal or above 150 to 160 m.sup.2 /g. The support phase may be wholly composed of the HPMPHSA material or it may be composed of a mixture of the HPMPHSA material and a conventional material. Such a mixture preferably contains at least about 20 percent HPMPHSA material, by weight, e.g.

Abstract: The present invention relates to an exhaust gas treatment catalytic article having an upstream catalytic zone and at least one downstream catalytic zone. The upstream catalytic zone has an upstream composition which has a first upstream support, and at least one first upstream palladium component. The upstream zone can have one or more layers. The downstream catalytic zone has a first downstream layer which has a first downstream support and a first downstream precious metal component. A second downstream layer has a second downstream support and a second downstream precious metal component.

Abstract: A stable, close-coupled catalyst, an article comprising the close-coupled catalyst and a related method of operation. The close-coupled catalyst comprises a catalyst support and a palladium catalytic component. Preferably and optionally, there are stabilizers including alkaline metal oxide, and rare earth metal components selected from the neodymium and lanthanum components. The close-coupled catalyst composition includes substantially no additional oxygen storage component such as praseodymium or cerium compounds. There is preferably a catalyst such as a three-way catalyst downstream of the close-coupled catalyst. The downstream catalyst preferably includes an oxygen storage component such as cerium oxide or praseodymium oxide.

Abstract: In an exhaust gas system comprising a hydrocarbon trap (28) and a downstream catalyst zone (30), a heat exchange catalyst member (10) is incorporated into the system to provide heat exchange between the exhaust gas and air that is pumped through the heat exchange catalyst member (10). The heated air is injected into the exhaust gas stream to facilitate the oxidation of hydrocarbons in the downstream catalyst zone. The heat exchange catalyst member (10) defines two separate flow paths therethrough, one of the flow paths containing a catalyst zone for the exhaust gas. In an alternative embodiment, the injected air is heated by a heat exchange trap (28') or by a separate heating element (62).

Abstract: A catalyst composition suitable for three-way conversion of internal combustion engine, e.g., automobile gasoline engine, exhaust gases includes a catalytic material disposed in on a carrier. The catalytic material contains a co-formed (e.g., co-precipitated) rare earth oxide-zirconia support on which a first rhodium catalytic component is dispersed, and an alumina support having a platinum catalytic component dispersed thereon. The catalytic material may also include a second rhodium catalytic component dispersed on the alumina support bearing the platinum or a second alumina support. The catalytic material may be disposed as a catalytic coating directly on the carrier or upon an optional undercoat which is disposed on the carrier and which includes alumina and optionally, ceria and/or, iron oxide.